aircooled KX hybrid

[arjay]

This is a project that I've been waiting to start for a long time. Many hours on Kawasaki.com parts diagrams later and I'm up and running.

The concept was to build a low tech woods bike that would be competitive (to a point) and that would weigh around 205 lb dry.

I've had a fully rebuilt 87 motor lying around waiting for a good home to go to. The cylinder's been rechromed and ready to go.

http://i4.photobucket.com/albums/y133/arjay1/DSC00620.jpg

http://i4.photobucket.com/albums/y133/arjay1/DSC00622.jpg

http://i4.photobucket.com/albums/y133/arjay1/DSC00624.jpg

I'll run it standard with VForce and PWK 36 to see how it goes, then maybe look into porting. I've got hold of a ding free FMF Gold Series for the year.

It's getting matched up with an 86 KX125 frame cradle, linkage and swingarm.

http://i4.photobucket.com/albums/y133/arjay1/DSC00615.jpg

http://i4.photobucket.com/albums/y133/arjay1/DSC00567.jpg

The forks, triples and front hub are off a 98 RM125 - 49mm conventional Showas. The shock is a piggyback style off an 87 KX125, along with rear caliper.

Low slung tank, subframe, airbox, boot, seat and side panels are 89 KX125. Seat foam will be harder but stock height with black gripper cover. Most of the parts are on their way courtesy of E**y. It's a nut and bolt rebuild so will be like new. Frame, hubs and subframe will be powder coated. Wider pegs, Excel rims and fresh spokes will finish it off.

There are a few hoops to get through. Cutting off redundant mounts and fabricating new ones, machining new steering stem and replacing the shock shaft to shorten it 3/4 inch.

Cut off...

http://i4.photobucket.com/albums/y133/arjay1/DSC00616.jpg

Ground down and filed...

http://i4.photobucket.com/albums/y133/arjay1/DSC00618.jpg

I'm hoping it will handle well, bit of a lottery I guess. It has almost identical trail/rake/wheelbase measurements as the KXF 250 so should be in the ballpark.

I'll keep you posted as the project progresses - basically whenever my wife lets me get into the garage.

 

[foots]

Gotta love them 49mm Showas

 

[arjay]

Nice :nod: Are those protectors custom made or stock? Any advice on fitting the triples?

 

[kmccune]

RM forks? never thought of that how is the fit up with the brake and wheel?

 

[foots]

Nice :nod: Are those protectors custom made or stock? Any advice on fitting the triples?

Protectors are for older KTMs with 50mm forks. I had to have a custom stem made and axle to use the stock wheel. Oh and wheel spacers also. But it's wasn't too much hassle and definately worth it.

 

[arjay]

Protectors are for older KTMs with 50mm forks. I had to have a custom stem made and axle to use the stock wheel. Oh and wheel spacers also. But it's wasn't too much hassle and definately worth it.

Did you make the new stem out of alloy or steel?

 

[Dan105]

ArJay--- I am going to do the same thing. A few years ago I came across a 86 Kx125 that was bought in 87, rode for a year and then blown up. Even though I have a new jug and parts I want to make a hybrid out of the bike.
Its strange all the bearings and stuff that should be worn are fine. Soo I am starting with a rolling chasis thats in good shape.
I am having a tough time finding a motor though. What are the benefits of using the 87 shock?
I have several pipes that I think I can use to fab one that works. I have a full pipe with stinger and then the stock one that is brand new but without the tail piece.
If I can find a motor I will get started.

 

[foots]

Did you make the new stem out of alloy or steel?

Stainless steel

 

[arjay]

ArJay--- I am going to do the same thing. A few years ago I came across a 86 Kx125 that was bought in 87, rode for a year and then blown up. Even though I have a new jug and parts I want to make a hybrid out of the bike.
Its strange all the bearings and stuff that should be worn are fine. Soo I am starting with a rolling chasis thats in good shape.
I am having a tough time finding a motor though. What are the benefits of using the 87 shock?
I have several pipes that I think I can use to fab one that works. I have a full pipe with stinger and then the stock one that is brand new but without the tail piece.
If I can find a motor I will get started.

Hi Dan, good to hear that someone else is on the same mission. :cool: The 87 shock is a piggyback reservoir rather than the remote type. It's just more compact and contemporary. (I've never been a fan of the remote res strapped onto the frame rail.) It also has an eye on the bottom like the 86, rather than a fork. This changed in 88. The 87 is 3/4" too long so needs to be shortened. I'm planning to get a new shaft made. I've got an 87 shock being shipped, so I'll soon let you know whether it fits. I doubt a 125 modified pipe would work well on the 200. The chamber wouldn't match the power of the motor. New aftermarket 200 pipes are still available from DG, and you can find FMF ones if you look around on e bay. The stinger tail pipe should fit ok. Hope you find a motor soon, let me know how things go.