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I haven't raced for a long time, but you can make it as expensive as you want, or you can spend a reasonable amount and have loads of fun.
When picking a class your weight (combined with the kart) must be taken into account so you don't end up in the situation where there's no class where you can be competitive (even club day competitive!) An example would be if your mate is a big guy, a 'J' won't be suitable as they don't run "National Super Heavy". J's need to be driven smoothly where a S's have that little bit more power that means you can chuck it around a bit more and get a way with it.
New or 2nd Hand? Probably 2nd hand as they'll save a fair amount and be able to sell it again for minimal loss if they don't like it. Many gung-ho newbies never managed to return for a 2nd meeting! It was common practice to buy a 2nd hand Chassis and a new motor.
Ohh, answers for your questions...
1. Not if he's a big guy
2. National a fair chunk cheaper. Engine need less maintenance (rebuilds/pistons/etc), Tyres generally last longer.
3. No idea... too long out of it. Don't forget suit, suitable footwear, neckbrace (?), gloves, legal helmet, tools (couple special ones needed), something to cart it to the track (trailer,etc).
4. Depends... run your club meetings at local track, you're probably looking at $1000-$2000, maybe $1500-$2500 these days, something like that. An engine rebuild, a piston or two, entry fees, some petrol, oil, a few spark plugs, carby kit and a few sets of tyres. Start going to meetings around the state and by the time you add in food, fuel and accomodation that's when you start spending $$$.
5. Go down to the track and watch the classe(s) you've narrowed your interest down to. Make sure it's run (not enough turn up they won't run it) See the club is run efficiently, genraly things like that. Once you get on the track, learn to drive. Until your within 0.5sec of a good time, more time will be found in driving technique than endlessly fiddling with kart setup (that's not to say you don't want to get it pretty right)
Check out the Rotax catergories too. Bit faster, apparently less maintenance and an electrical starter so you don't have to push start it! (some Clubman derived classes are starting to use these too I think)
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