2004 Hybrid build #2

Discussion for swapping a KDX motor in a MX frame...
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Tedh98
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2004 Hybrid build #2

Post by Tedh98 »

I've been working on #2 for a while and have some time to post some pictures.

I found a easier way to cut the swingarm. In my first build I used a number of different pieces of wood to prop and secure the swingarm in place so it wouldn't move on the table saw.

The easier approach is to build a sled that holds the rear wheel bolt and keeps the swingarm in place. This is the completed sled.
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Next is the swingarm and bolt mounted in the sled.
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And here it all is on the table saw. I initially leave the bolt loose. Once it is on the sled, I adjusted the swingarm for proper position. Then I tightened the rear wheel bolt to keep it in alignment.
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I think it took me about 20 minutes to get the sled together and then each cut took a couple of minutes to position and make the cut.
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I put together this very high tech sandblasting cabinet. It did a really good job of keeping most of the media in the box. I wore a respirator to be on the safe side, but I didn't use eye protection and didn't get anything in my eyes. I bought the replaceable sandblasting cabinet 'windows' and duct taped them in place so I could see what I was doing.
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Here is the frame primed. I'm painting it now, I'll have some more pictures in a few days.
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Post by dfeckel »

Wow. Looking good!

What is it about building a hybrid that makes you want to build another soon after? I'm not even done with the first, and I'm already considering another...
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Post by Tedh98 »

Frame is all painted.
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Here are the rear headstay brackets I made to work with the oversize tank I'll be using.
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Post by Indawoods »

What blade are you using in your tablesaw? Does it buck at all?
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Post by Tedh98 »

>|<>QBB<
Indawoods wrote:What blade are you using in your tablesaw? Does it buck at all?
This time I used a 40 tooth. No bucking. On my first swingarm I used a blade with a higher tooth count and didn't notice a difference between the effort to make the cut or the final cut quality.

I've routed a bunch of aluminum and I'll have bucking or chatter if I try to cut too much in one pass.
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Post by Tedh98 »

My 18" spokes came in. So I'm starting with this . . . .
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It took me a while to get the tire off the rim, but I eventually got to the point where the hub and rim were apart.
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1/2 the spokes on
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All the spokes with just 1 thread showing.
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I need to figure out the easiest truing stand to build and then order a new rim lock and rear tire.

The paint should be cured enough in a couple of days where I can start putting the bike together.
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Post by scheckaet »

you can use the bike as a truing stand, worked great for me
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Post by Tedh98 »

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scheckaet wrote:you can use the bike as a truing stand, worked great for me
I would if the bike were together. I guess I could try to clamp the swingarm to the workbench.
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Post by dfeckel »

A pair of jackstands works well, too. Tape a pair of dowel rods or straws or something as referances for side-to-side and up and down variations.
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Post by Tedh98 »

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dfeckel wrote:A pair of jackstands works well, too. Tape a pair of dowel rods or straws or something as referances for side-to-side and up and down variations.
I like that approach. I can put that up on the workbench and due the truing standing up. Thanks!
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Post by Tedh98 »

I couldn't get the jackstands to work, I kept moving the wheel left or right when I was tightening the spokes.

So I got out my other frame, bolted the swingarm in place and then put the wheel on. Worked out well, didn't take too long to true up the wheel. I used my small torque wrench with an allen head bit to get the spokes torqued equally.

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Post by Tedh98 »

I made some progress today. Put new bearings in the swingarm. Started the bearings in a vice . . .
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Seated them with a socket . . .
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The new teflon bearing on the left is supposed to be more durable to mud and sand than the roller bearing on the right. I guess time will tell.
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Front end installed, motor and swingarm bolted on. . .

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More pictures to follow.
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Post by Tedh98 »

A few things came in over the last few days to finish up the rear wheel.
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As usual, not enough grease.
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Finally, no milk crates!
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Post by dfeckel »

Lookin' good! I like the dark-colored frame.
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Post by scheckaet »

where did you get that teflon bearing?
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Post by Tedh98 »

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scheckaet wrote:where did you get that teflon bearing?
It came with the swingarm bearing kit. It was All Balls.
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Post by Tedh98 »

Ran into a little clearance problem with the IMS tank and the water outlet on the top of the head.
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I made this adapter plate to rotate the water outlet out of the way.
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Bottom view of the plate and water outlet bolted together.
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Top view with my hand cut gasket.
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I originally had to put a splice into the factory KX hose (left) to rotate the end 90 degrees to fit onto the head. With the water outlet rotated, I was able to cut the curved end off (right), no splice was needed.
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All bolted up.
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Plenty of room now.
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Post by Jupiter2 »

A work of art. Very nice.
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Post by bulabula09 »

Dang!! very nice handy work!! that looks awesome!
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Post by Tedh98 »

Thanks for the positive comments guys. It is pretty neat what you can do with a router.

I tightened the last bolt earlier today. I need to wait till the rtv dries on the exhaust pipe before I can fire it up. I'm not real happy with the fit of the IMS tank, but I got it for $30 on eBay so I can't complain. I'm going to be on the lookout for a Clarke tank to see if that fits better.

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I already like the 18" rear just based on looks, I'm sure I like it better once I go riding.
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I changed were I put the electrical components from my 1st hybrid. I put the CDI above the left radiator.
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A saw a late model KX 250 that had the coil mounted behind the right radiator. I copied that approach so I'd have more room to get to the spark plug. Kind of hard to see the coil in this picture, but it is back there.
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Between the pipe and coil with my 1st bike, there wasn't much room to get at the spark plug, now there is a little more room with that out of the way.
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I also upgraded with the vforce and air striker carb.
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Hopefully I'll get to do a little test ride tomorrow before going riding this weekend.
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