Rmz200dx hybrid build

Discussion for swapping a KDX motor in a MX frame...
Ffryno13
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Rmz200dx hybrid build

Post by Ffryno13 »

Well I started on my journey for a kdx hybrid. I bought a running and riding 04 RMZ250 from a guy at work for super cheap sold the motor and started parting out the rest of the useless stuff.

The motor made my money back on buying the bike so I'm already in the black. The rmz already had mozarrchi suspension which I think I will have lowered an inch oversized brakes and excel wheels which I'll swap the rear to an 18 with a trials tire and tubliss system.

Now I'm on the hunt for kdx200 e or h series at this point. I plan on having the porting done by frp and RB designs is just down the road from me so they will get the carb and head. With a boysen power valve and gnarly pipe I should be good to go for some great technical trails here in the PNW.
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Re: Rmz200dx hybrid build

Post by Ffryno13 »

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Last edited by Ffryno13 on 09:39 am Jan 21 2016, edited 2 times in total.
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Re: Rmz200dx hybrid build

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Tyl3r
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Re: Rmz200dx hybrid build

Post by Tyl3r »

Nice, I'm interested to see how your swingarm/motor fitment goes as well as air box and pipe fitment. Keep us updated with how it goes! I'm having fun building mine right now, its an 04 220 in 05 KX125 roller.

I would recommend going with the H series motor, rather than an E; parts will be much easier to locate. I see threads pop up all of the time for people looking for e series KIPS parts that have been discontinued by Kawi. I opted to buy a complete, good running shape KDX. That way I can steal parts off of it while I'm building if I need it, and I can sell all of the unused stuff to make more money back. But hey, that's just me, I'm sure some would disagree.

Just an FYI, when you are in photobucket and are looking at a photo, there are 4 links for sharing the photo on the right side of the screen. If you copy the 4th link, titled "IMG" and paste it in a post, your photo will show up like this:
Image
04/05 KX220 Hybrid all decked out
18 KTM 500 EXC-F Dual Sport/Sumo toy
24 KTM 300XC-W Cheater bike
Ffryno13
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Re: Rmz200dx hybrid build

Post by Ffryno13 »

Thanks for the photo info. My original plan was to use a air cooled motor but they are pretty rare around here and parts availability is low too.

Do you know what an H series motor weighs?
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Re: Rmz200dx hybrid build

Post by Ffryno13 »

Well I got a line on a basket case 01 that needs a rebuild the guy only wants 400$ for it and he already has most of the rebuild pieces. I'm going to pick it up on Saturday night.

I'm getting excited!
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Tyl3r
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Re: Rmz200dx hybrid build

Post by Tyl3r »

Ffryno13 wrote:Well I got a line on a basket case 01 that needs a rebuild the guy only wants 400$ for it and he already has most of the rebuild pieces. I'm going to pick it up on Saturday night.

I'm getting excited!
Score! Does it just need a top end? Or is the bottom end in bad shape as well?
04/05 KX220 Hybrid all decked out
18 KTM 500 EXC-F Dual Sport/Sumo toy
24 KTM 300XC-W Cheater bike
Ffryno13
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Re: Rmz200dx hybrid build

Post by Ffryno13 »

From what he told me it's just a top end but I'll probably do a full rebuild so I know it's good.

Did you build an engine jig to support your frame while you do you fab work? Out do you not have to cut the frame for the kx swap.
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Tedh98
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Re: Rmz200dx hybrid build

Post by Tedh98 »

Ffryno13 wrote:Out do you not have to cut the frame for the kx swap.
Just the mounts need to be cut out. The front onea definitely need to be re-done. Some have gotten away with elongating the stock lower mounts.
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Re: Rmz200dx hybrid build

Post by Tyl3r »

Ffryno13 wrote:Did you build an engine jig to support your frame while you do you fab work? Out do you not have to cut the frame for the kx swap.
Once you get the swingarm bolt through the motor and frame, the motor will pivot up and down. With the whole thing sitting on a bench, its not that hard to move around. I don't really see the need for an engine jig for the fab work.
Tedh98 wrote:Just the mounts need to be cut out. The front onea definitely need to be re-done. Some have gotten away with elongating the stock lower mounts.
I have read that others have done that as well. I tried dropping my KDX motor in the KX chassis when the motor mounts were still in tact. The KDX motor was too wide to fit between the mounts, so I don't know if people have bent out the mounts so that they work? Or if earlier year KX motors were wider than the 05. I just said screw it and hacked em out.
04/05 KX220 Hybrid all decked out
18 KTM 500 EXC-F Dual Sport/Sumo toy
24 KTM 300XC-W Cheater bike
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Re: Rmz200dx hybrid build

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Re: Rmz200dx hybrid build

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Re: Rmz200dx hybrid build

Post by Ffryno13 »

So here's the donor 01. I think I made a pretty good score. It has an fmf gnarly and turbine core 2, I think an acerbis head light. It came with 2 18" complete wheels one with a paddle which will go to my cr250. I'm hoping that I can use one of the rims and lace it up on my rmz hub.

3rd gear is toasted but he already bought the new one the cylinder has some bad scoring in it but it looks like it's sleeved so it might just be a bore and new piston.

If you guys need any kdx parts let me know. Plastic is in decent shape, the stock seat looks great
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Re: Rmz200dx hybrid build

Post by Ffryno13 »

Well, update on the build. The cases are completely worthless, the main shaft needle bearing destroyed it self and took out the race with it. The right case looks like someone tried to drive the bearing from the wrong end and broke part of the bearing stop.

If any one has a usable set of 01 cases let me know
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Re: Rmz200dx hybrid build

Post by Tedh98 »

Ffryno13 wrote:If any one has a usable set of 01 cases let me know

Sorry to hear that. You dont need to limit yourself to 2001. Anything from 1995+ from a 200 or 220 will work for you.
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Re: Rmz200dx hybrid build

Post by Ffryno13 »

Thanks I ordered some on eBay this morning for 125$ shipped. I really hope these work out...

On side note I stopped by RB Designs and talked to Ron hoping that he would be able to help me out with the bad cases. Really great guy to talk to. But now I'll have to wait until I get some more money together before I do the mods.

I guess the silver lining here is that I now have a set of cases to use as a jig for my frame mounts. Yay!... Kinda :neutral:
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Re: Rmz200dx hybrid build

Post by Ffryno13 »

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The issue with the original cases
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Rmz200dx hybrid build

Post by Ffryno13 »

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Main shaft end will welded needle bearing on it
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Re: Rmz200dx hybrid build

Post by Ffryno13 »

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Some goodies
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Re: Rmz200dx hybrid build

Post by Ffryno13 »

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For some reason the pipe looks like it's for a 125 to me... Anyone?
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