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

HRDROKN · Post by **HRDROKN** » 06:44 pm Aug 23 2010

Just got back from dropping the forks and shock off at ****'s Racing for a full rebuild, revalve, springs and setup for my weight and riding.....

HRDROKN · Post by **HRDROKN** » 11:31 pm Aug 23 2010

Finished off the KDX airbox mount.....

Post by **Indawoods** » 11:40 pm Aug 23 2010

Nice work!

frankenschwinn · Post by **frankenschwinn** » 07:20 am Aug 24 2010

This is an interesting approach. I will be interested to see how the rear fender mates up. Good work. Your going to love this when done...

Tedh98 · Post by **Tedh98** » 07:35 am Aug 24 2010

Those aluminum plates look really nice - clean cuts and bends. What did you use?

Going back to an earlier question regarding the sprocket / swingarm alignment. My understanding is if they aren't aligned properly, you'll wear the chain guide prematurely. There may be other issues, but that is the one I came across in my research.

HRDROKN · Post by **HRDROKN** » 09:36 am Aug 24 2010

frankenschwinn wrote:This is an interesting approach. I will be interested to see how the rear fender mates up.

That may be a problem.....

EDIT: I put the fender on and it fits like it was made for it!!!

HRDROKN · Post by **HRDROKN** » 10:04 am Aug 24 2010

Tedh98 wrote:Those aluminum plates look really nice - clean cuts and bends. What did you use?

A band saw and vice...

Tedh98 wrote:Going back to an earlier question regarding the sprocket / swingarm alignment. My understanding is if they aren't aligned properly, you'll wear the chain guide prematurely. There may be other issues, but that is the one I came across in my research.

I've still been looking at this one as I have not finalized the mounts yet. It looks like the area of concern is how much break over angle the chain has at it passes over the swingarm pivot. In comparison with my other bikes... it looks to be OK.

What is the race sag measurement for this bike?

Post by **scheckaet** » 10:07 am Aug 24 2010

interesting approach, seems it'd be easier to fab an adapter plate to mount the kdx boot to the KX airbox...
Are you running into clearance issue with the shock spring?
The mounts look really good though. Let us know how that works.

HRDROKN · Post by **HRDROKN** » 10:20 am Aug 24 2010

scheckaet wrote:interesting approach, seems it'd be easier to fab an adapter plate to mount the kdx boot to the KX airbox...
Are you running into clearance issue with the shock spring?
The mounts look really good though. Let us know how that works.

I certainly was heading that direction, until I tried the KDX box and felt that it provided more room between the carb and airbox. With the adapter plate I would have been compressing the KDX boot by about .500" (and my motor is a little further forward).

As for the boot clearance around the shock spring.... looks like it did on the KDX, no issues!

Post by **scheckaet** » 10:48 am Aug 24 2010

interesting, I thought 99-02 kx were virtually the same frame, I have an 02 and din't have to compress the boot more than usual.

"As for the boot clearance around the shock spring.... looks like it did on the KDX, no issues!"

I'd test that on the kx frame 1st with the shock, the boxes and boot are different and your mounting bracket are different too...

HRDROKN · Post by **HRDROKN** » 12:35 pm Aug 24 2010

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scheckaet wrote: I'd test that on the kx frame 1st with the shock, the boxes and boot are different and your mounting bracket are different too...

Yes... I set it up with shock in place before taking all the suspension to ****'s. Hard to see from this pic, but there is at least .125" all the way around.

IDK.... I think that for some reason the 99' frame was different in some way? Others had said that the lower motor mount lines up on a 99' and mine didn't. Also my 99' had the doubled lower mounts as well?

I have another 99' frame sitting here that seems to more typical of whats been posted by others.

Here is the fender without the bolts in.... but they line up and the fender fits the contour of the box perfectly!

Post by **scheckaet** » 01:45 pm Aug 24 2010

on mine, the clearance issue is when I have the carb in place with the hose clamp, the clamp rubbs on the spring a bit and messed up the paint

I'll have to keep an eye on it.

HRDROKN · Post by **HRDROKN** » 06:18 am Aug 26 2010

Got after the lower mount tonight, so this is what I came up with...

And welded...

frankenschwinn · Post by **frankenschwinn** » 08:13 am Aug 26 2010

Very innovative. You really think outside the box. good work

Post by **Indawoods** » 08:28 am Aug 26 2010

Only problem I can see is mud getting packed in there.....

Post by **scheckaet** » 09:13 am Aug 26 2010

I like the idea. You ca pack some silicone or other material in there to avoid packing too much mud.
I bet those are STRONG

HRDROKN · Post by **HRDROKN** » 12:15 pm Aug 27 2010

Finished up with the front mount...

Pipe is sitting all the way in the head and looks like a small dent in the pipe to clear the downtube..... Hmmmm, just thinking that I don't have the exhaust gasket in there yet and that should give me some more clearance?

canuckhybrid125 · Post by **canuckhybrid125** » 08:17 pm Aug 28 2010

I used the torque ring from fredette to get a little more room for the pipe.

HRDROKN · Post by **HRDROKN** » 08:42 am Aug 31 2010

Picked up my suspension from ****'s Racing yesterday....

HRDROKN · Post by **HRDROKN** » 03:30 pm Sep 11 2010

Just got my head and carb back from Ron Black.....

Truly a nice guy and does one heck of a job on his machine work! I noticed that the carb I sent had a slight off-center bore and when it returned Ron had not only bored the carb, but corrected the factory machine work in centering the bore! In speaking with Ron it was apparent that he is all about a first class job!

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