2001 Cr-kdx200

[legendboy]

Figured I would snap some pictures of my build for you guys.

I own a 93 kdx200, for about 3 years now

Picked up an 01 CR-125 with no motor. Figured I would throw a KDX motor in it.

I bought an engine on egay, which turned out to be a bit of a turd so i am going to use the engine out of my bike for the CR.


About what it looked like when i bought it.

Fit-up

 

[legendboy]

The rear engine mount hole is about 7 thou under what the cr mount/swing arm axle is. 17mm reamer is the right tool for the job.

 

[legendboy]

Together!

I have to grind the frame a bit, will post pics tonight.

I will post some detailed pictures of the swingarm bushings/bearings/seals hopefully tonight.

 

[karlp]

I built the same last summer
What year CR Frame?
I cut the cases to fit the CR swingarm, though.

Works real well. I'll be running some of the SERA/SETRA Enduro series on it.

 

[karlp]

http://www.kdxrider.net/forums/viewtopic.php?t=4539&postdays=0&postorder=asc&&start=20

 

[legendboy]

Good to see someone else who did the exact same thing!

My CR is a 2001 125. I am really looking forward to riding a CR compaired to my old KDX.

I choose to cut the swing arm and only ream the motor. Not really sure why, didn't want to hack up the rear motor mount i guess.

Hopefully I will have most of it done this weekend. I am going to re use the stock CR bottom engine mount, just have to turn some bushings to take up the space.

I also am going to do a similar top mount that you did. I have a tig and can weld aluminum but the stock mounts are sooooo beefy i think i am going to use them instead of cutting them off.

I have a fatty pipe that came with the CR and i have a KDX pipe too. I figured the pipe would be the trickiest part of this whole project.

What do you think about using the 125 FMF pipe?

 

[karlp]

I don't see why not on the CR 125 pipe.
The carb on the CR was what size? I bet the CR pipe will flow just fine.
I guess the pipe is a crap shoot;what you get is what you get.

I couldn't use the the stock lower engine mounts. The motor would have been tipped forward too much and the KIPS actuating cover ran into the frame. Put your cylinder and head on without the piston just to check. That CR 125 frame may be different.

 

[ebeck]

I'd like to see what you did for the motor mounts.

The rear swing arm that you cut off is just air. The load in on the outside by the frame. The problem with cutting the cases is that the cases have a steel sleeve that is about .75 inches long. You can see it in your pics. If you mill the cases you also mill the sleeve significantly weakining the rear motor mout. You did optimal thing.

 

[legendboy]

Good idea on the head Karlp, thanks for the heads up!

I actually didn't hardly leave the couch this whole weekend so i didn't get anything else done lol

ebeck, when i machined out the motor mount, i thought the chips looked alot like cast iron!



I have all my parts in, just have to get my rear end out to the garage :blah:

 

[legendboy]

Got a bit of work done tonight

Had to grind more then i wanted to off the swingarm race to clear the kickstart assembley, should be find tho

Doesn't matter how many power tools and machines you have, sometimes a hacksaw is still the best choice :cool:

Getting close!

 

[legendboy]

Will cut the tops of these brackets off and weld new ones on tonight

 

[karlp]

Looking good - the end is in sight!
Air box O.K.? The carb isn't going to run into the frame, is it?

 

[legendboy]

haven't checked yet, but i have lots of silicone couplers and stuff here, should be no biggie

 

[legendboy]

getting ready to cut my new brackets

rough cut

fit up with a transfer punch

done

 

[legendboy]

done

 

[karlp]

That fits nice!
Nice work

 

[SVandal]

That looks really good. Are there any fit issues with the water pump or where the radiator hoses enter and exit the bike?

 

[legendboy]

Thanks, nope, the pic looks bad but there is lots of room between the outlet and the frame.

 

[Rich Rohrich]

Did you have to v-cut the new bracket piece to get root penetration on the attaching weld?

 

[legendboy]

no i just butt welded it, no root pass with bevel or anything like that. it is plenty strong welded all the way around, at max heat.

 

[jrf4x4]

Seeing that you had access to a mill it wouldn't have been a bad idea to bevel it.

 

[legendboy]

no need. trust me guys, been welding and doing fab work for a long time :cool:

 

[SVandal]

Curious, why use a mill to bevel when a belt sander would do the job a whole lot faster? Is there that big of a concern about weld contamination from the sand on the belt?

 

[jrf4x4]

Curious, why use a mill to bevel when a belt sander would do the job a whole lot faster? Is there that big of a concern about weld contamination from the sand on the belt?

No a belt sander would be fine, i'm just a machinist and just use to going by a drawing and doing with a mill.

 

[ebeck]

Nice, I like to see things done right!
Any problems with strenth after welding the aluminum?