My Kdx-Kx Hybrid
Posted: 04:44 pm Nov 15 2011
Here is my hdybrid story:
I bought a 2004 Kdx 220 motor a year ago that had the piston grenaded. I had to replace one side of the crankcase and replace the crank bearings. I sent the cylinder to Langcourt and the head to Ron for his magic touch. I then found a super clean 2002 KX125 and traded a CRF150 for it. I'm in Cally so '02 is the best year to use. I pretty much followed the cookbook for hybrids and did all of the work myself.
A few of the things I found along the way that might help others:
1. The new Bill's pipe I bought had too short of headpipe to work. I was able to make some slight bends to an FMF desert pipe to make it clear the frame, radiator and meet up with the silencer. I used some fat bars for my bending leverage tool. I swapped the pipe mounting brackets top & bottom and made an extension bracket for the top mount.
2. I bought a Turbinecore SST silencer for a KX250 and made a couple of brackets and a bend to the inlet pipe to move it forward enough and meet the chamber pipe.
3. I did not cut off the existing motor mounts. I removed the inside half of the lower mount on each side and elongated the mount bolt hole with a dremel to line up with the engine bolt hole. I then made a plate to reinforce it and riveted it in place on the outside of the existing mount. Similarly I made a plate for the top mount and bolted and riveted it to the existing mount.
4. I used a petcock from an '87 KDX. It has a reserve and the outlet pivots.
5. I used the front fender, number plate and triple clamps from a 2004 KX250f for a newer look. I used the '02 stem with the clamps.
6. Rear wheel is the 18" KDX wheel using the KX spacers.
7. Kick lever is also from the '87 KDX, although I may go with a KX250 kicker later.
8. I am running the KX125's TMX 38 carb. I had to lean it out a lot on the pilot jet, but I am very happy with how it runs.
9. I'm using the KX's air box with no mods.
10. I'm using the KX's coil with the KDX wiring and CDI. I removed the voltage regulator since I don't have lighting. CDI is mounted in the airbox.
11. I re-used the KX's water hoses.
12. New kickstand is bolted to the swingarm.
13. I used a GPR steering stabilizer from my KX500. I had to ream out the frame mount to fit the KX steering head.
It is a blast to ride. I still need to soften the front forks a little, but that will happen soon.
I bought a 2004 Kdx 220 motor a year ago that had the piston grenaded. I had to replace one side of the crankcase and replace the crank bearings. I sent the cylinder to Langcourt and the head to Ron for his magic touch. I then found a super clean 2002 KX125 and traded a CRF150 for it. I'm in Cally so '02 is the best year to use. I pretty much followed the cookbook for hybrids and did all of the work myself.
A few of the things I found along the way that might help others:
1. The new Bill's pipe I bought had too short of headpipe to work. I was able to make some slight bends to an FMF desert pipe to make it clear the frame, radiator and meet up with the silencer. I used some fat bars for my bending leverage tool. I swapped the pipe mounting brackets top & bottom and made an extension bracket for the top mount.
2. I bought a Turbinecore SST silencer for a KX250 and made a couple of brackets and a bend to the inlet pipe to move it forward enough and meet the chamber pipe.
3. I did not cut off the existing motor mounts. I removed the inside half of the lower mount on each side and elongated the mount bolt hole with a dremel to line up with the engine bolt hole. I then made a plate to reinforce it and riveted it in place on the outside of the existing mount. Similarly I made a plate for the top mount and bolted and riveted it to the existing mount.
4. I used a petcock from an '87 KDX. It has a reserve and the outlet pivots.
5. I used the front fender, number plate and triple clamps from a 2004 KX250f for a newer look. I used the '02 stem with the clamps.
6. Rear wheel is the 18" KDX wheel using the KX spacers.
7. Kick lever is also from the '87 KDX, although I may go with a KX250 kicker later.
8. I am running the KX125's TMX 38 carb. I had to lean it out a lot on the pilot jet, but I am very happy with how it runs.
9. I'm using the KX's air box with no mods.
10. I'm using the KX's coil with the KDX wiring and CDI. I removed the voltage regulator since I don't have lighting. CDI is mounted in the airbox.
11. I re-used the KX's water hoses.
12. New kickstand is bolted to the swingarm.
13. I used a GPR steering stabilizer from my KX500. I had to ream out the frame mount to fit the KX steering head.
It is a blast to ride. I still need to soften the front forks a little, but that will happen soon.