99' KX / 03' KDX Hybrid build......

HRDROKN · Post by **HRDROKN** » 05:35 pm Sep 17 2010

Back on the project....

Finished up the frame with the addition of the case saver hoops off the KDX frame and now she's sitting at the powder coaters for a nice coat of silver....

HRDROKN · Post by **HRDROKN** » 05:49 pm Sep 17 2010

So with the frame gone.... it's time to get some other things ready. I decided that I would go to a 18" rear and settled on some black Excel's with ProWheel stainless spokes on stock hubs.

HRDROKN · Post by **HRDROKN** » 04:35 pm Sep 24 2010

Picked up the frame from the powder coater today and was able to get a little assembly done before work. The down side (besides work) was that in my rush to get the frame to powder (before taking off to Disneyland), I completely forgot about the sub-frame.

David_L6 · Post by **David_L6** » 05:02 am Sep 25 2010

Looks good so far. Maybe you can find a paint for the sub-frame that matches the color of the frame close enough.

HRDROKN · Post by **HRDROKN** » 05:55 pm Sep 25 2010

David_L6 wrote:Looks good so far. Maybe you can find a paint for the sub-frame that matches the color of the frame close enough.

That's a doable option... the other things that have been sugested are a brushed aluminum finish or polished?

HRDROKN · Post by **HRDROKN** » 06:06 pm Sep 25 2010

I was able to get all the swingarm, linkage and shock bearings/seals replaced today along with getting the motor in place...

HRDROKN · Post by **HRDROKN** » 11:08 pm Sep 30 2010

I got a little more work done...

Front wheel laced up...

Tedh98 · Post by **Tedh98** » 06:56 am Oct 02 2010

HRDROKN - do you know which type of seal savers you've got on your forks? I haven't seen ones like that which completely cover the lower fork tube on an inverted fork.

I've seen the short saver and then the longer one, but their website shows the longer one covering/protecting the upper fork tube.

Does any of that material get in the way of the rotor as it bunches up as the forks are compressed?

Thanks

HRDROKN · Post by **HRDROKN** » 06:17 pm Oct 02 2010

Tedh98 wrote:HRDROKN - do you know which type of seal savers you've got on your forks? I haven't seen ones like that which completely cover the lower fork tube on an inverted fork.

I've seen the short saver and then the longer one, but their website shows the longer one covering/protecting the upper fork tube.

Does any of that material get in the way of the rotor as it bunches up as the forks are compressed?

Thanks

They are the long ones... think I bought them from Rockymountain for the KX application. Ran them on my KTM for more than six years without a seal failure or bunching up. Run a tie top and bottom works great! I also kept a nice coating of WD40 on the inside after every ride.

Post by **scheckaet** » 08:37 pm Oct 02 2010

rockymountain has them

HRDROKN · Post by **HRDROKN** » 10:49 am Oct 04 2010

Looks like I will have plenty of petcock/fuel line clearance, but would still like to add one with a reserve. So I will have to do a little research on that...

I will have to make a slight adjustment on the tank to clear the water neck as the bolt just touches the tank...

HRDROKN · Post by **HRDROKN** » 10:52 am Oct 04 2010

What oversize tanks, if any are the best bet for a fit? Would like to have at least 3.0 gals of capacity...

Post by **scheckaet** » 01:25 pm Oct 04 2010

fuel petcock: (thanks frankenshwim

)
431410 FUEL COCK ASSY 1 (2GU-24500-02-00) X $17.10 $26.77 $17.10

HRDROKN · Post by **HRDROKN** » 05:32 pm Oct 04 2010

scheckaet wrote:fuel petcock: (thanks frankenshwim )
431410 FUEL COCK ASSY 1 (2GU-24500-02-00) X $17.10 $26.77 $17.10

I think that is the one with the outlet on the side? If so that puts the outlet into my carb slide... need to keep the outlet stright down preferably.

HRDROKN · Post by **HRDROKN** » 05:33 pm Oct 04 2010

Here's what we can do!

This is the stock KX fuel valve and notice that I have already drilled a pilot hole...

This is the main pickup tube from the KDX fuel valve...

And I removed 1" as the stock KX tank holds less total fuel...

Drilled out the fuel valve for a light press fit. The preexisting part of the hole was a little large for the tube, but this is perfect to add some fuel proof cold set epoxy to hold the tube in when I dump the bike over...

I will have to order some new filters.... before I get her all back together!

HRDROKN · Post by **HRDROKN** » 05:34 pm Oct 04 2010

So now lets get the tank end of things going....

HRDROKN · Post by **HRDROKN** » 05:35 pm Oct 04 2010

Cut the fuel valve stops out of the petcock cover for a full 360 degree rotation. Reserve will now be straight pointing up, main straight pionting down and off straight across....

Post by **scheckaet** » 05:36 pm Oct 04 2010

HRDROKN · Post by **HRDROKN** » 12:03 am Oct 05 2010

>|QBB<[/url]

scheckaet wrote:

Ya... so you can see how the side outlet would put the fuel line right into the top of my carb. The difference being that my motor is rotated further forward than the typical hybrid...

Coop · Post by **Coop** » 06:39 am Oct 05 2010

Nice work!

KDXRIDER.NET

KDXRIDER.NET

99' KX / 03' KDX Hybrid build......