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KDX hybrid build......

Discussion in 'Canadian Daves JustKDX' started by HRDROKN, Aug 24, 2010.

  1. HRDROKN

    HRDROKN Subscriber

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    Hey Guys...



    I just wanted to share with you all my 99' KX125 / 03' KDX220 build. This build is in progress and comments are welcome!

    I had picked up a fairly clean 2003 KDX 220R a few months back for $900. I had been riding this bike comparing it to my 300exc... if there is such a thing. There are a few things I like about the KDX and many things I like about the KTM! The KDX is easy to ride... the KTM can be a handful and I feel it the next day, but she handles so much better at speed. So rather than my original plan of a KX fork conversion etc. I picked up a 99' KX125 for the best of both worlds? Of course that is only what I have read...

    :cool:
     
  2. HRDROKN

    HRDROKN Subscriber

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    Started stripping down the KX chassis early this morning and noticed that my lower motor mounts are of the double variety? Thought I read that that was different in the 99' compared to the 00'-02' frames. Not a big deal by any means... wonder if it was a change that some of the later production frames received in that year?


    [​IMG]

    Also ordered up a 18" wheel and spokes to mate up with the KX hub.

    I think I will take the forks and shock up to Dicks Racing for a rebuild/re-valve, since they are local.
     
    #2 HRDROKN, Aug 24, 2010
    Last edited: Aug 25, 2010
  3. HRDROKN

    HRDROKN Subscriber

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    As of this morning the KX motor is out....

    [​IMG]

    [​IMG]

    :cool:
     
    #3 HRDROKN, Aug 24, 2010
    Last edited: Aug 25, 2010
  4. HRDROKN

    HRDROKN Subscriber

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    And now the KDX.....

    [​IMG]

    [​IMG]

    :coocoo:
     
    #4 HRDROKN, Aug 25, 2010
    Last edited: Aug 25, 2010
  5. HRDROKN

    HRDROKN Subscriber

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    After getting a first hand look at whats needed, I see that the actual cut on the swing arm is the least critical of the operation... you can do this with a hacksaw and file!

    Did all the measurments and 9mm on each side is sufficient....

    [​IMG]

    [​IMG]

    :whoa:
     
  6. HRDROKN

    HRDROKN Subscriber

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    The greatest concern and area to get correct is the swing arm bushing. It has to be fairly darn close, as it will set the overall compressed length.

    [​IMG]

    Drilled the cases by 64ths to 21/32's then used a 17mm ream to finish....

    [​IMG]

    [​IMG]

    :nod:
     
  7. HRDROKN

    HRDROKN Subscriber

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    Figured out a good way to hold the bushings while cutting.... I used the swingarm bolt in the vise!

    [​IMG]

    I then used a flapper wheel to clean the cut, then hit the bushings on a carborundum disc and then a course stone to the target dimension.

    :cool:
     
  8. 99220sr

    99220sr Rookie
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    Great Info, keep it coming.
     
  9. HRDROKN

    HRDROKN Subscriber

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    With all the swingarm mods out of the way, it was time to see how she was going to line up in the chassis...

    [​IMG]

    And would the lower mounts line up..... it was close! So I will cut the lowers out and fab new ones....

    [​IMG]

    ;)
     
  10. HRDROKN

    HRDROKN Subscriber

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    Interesting...

    Ive been playing with motor location as it compares to the pipe, airbox and fuel tank.... looks like things fit better the more you rotate the motor forward.

    The boot on the airbox is too long and it seems as though the KDX boot would be a better fit....
    [​IMG]

    With forward rotation, the pipe just misses the down tube.... a little dent in the pipe should provide desired clearance...
    [​IMG]

    When you rotate the moto forward you lose the lower mount position...
    [​IMG]

    And I have a solution....
     

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