Hybrid is Done.....Almost

Discussion for swapping a KDX motor in a MX frame...
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Rjcapt
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Hybrid is Done.....Almost

Post by Rjcapt »

Just wrapped up my build this week. Runs and rides great. Can't wait to get it dirty.....

http://m1221.photobucket.com/albumview/ ... g.html?o=6

.......and build a kickstand. Can't believe I forgot the kickstand....

Pete
kawabunga
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Location: Beavercreek, OR

Post by kawabunga »

All I see is a black bike.
Any details you wanna share?
reviving old war-horse.
dfeckel
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Post by dfeckel »

Looks nice!
David Eckel
Rjcapt
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Post by Rjcapt »

Thanks. Yes it's black and white, never was a fan of green....

It was a little more work than some listed here because I used the parts I had on hand:

1997 kdx200 engine:
RB carb and head mods
Millennium plated cylinder
New weisco piston (yeah I know after all my talk about using the stock piston, I went with a weisco. Mainly because new rings were going to run $40 and I got the piston with rings for $90....go figure)

2001 KX125 frame and swing arm
Swing arm modified as usual (on my tablesaw....worked very well btw)
Bushings cut on my lathe
Engine case drilled and reamed like everyone else, but I used an inch reamer that I think was 0.005" larger than 17mm but $20 cheaper...
Reused forward head stay and welded new lower and forward mounts
Added 3/4" to a FMF Gnarly woods pipe and cut and shortened rear stinger for easier routing to silencer
Used the KX125 silencer housing, but put the KDX pipe and internals in it
Modified silencer inlet pipe to mate to pipe
Relaced the KDX rim to the KX hub in the rear to get an 18" wheel

Now the truly entertaining part was putting the 97 KX plastics, gas tank, seat, airbox and subframe on the 2001 frame....

They don't fit.... I had to make new mounts for the radiator shrouds, cut the lower legs off the subframe and reweld at a different angle, move the brackets for the number plates and silencer.

I reused the kx airbox but remade the front of the box to accept the kdx boot and aircleaner.

I stole the tubes from the kdx petcock and mated them to the kx petcock giving me a reserve.

Used the kdx wiring harness after removing the lighting wires and plugged in the kx coil

Other than that it was a piece of cake.....

Pete
kawabunga
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Joined: 12:13 am Oct 14 2011
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Location: Beavercreek, OR

Post by kawabunga »

:supz:
reviving old war-horse.
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