KDX hybrid build......

[HRDROKN]

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]

I got tired of looking at petcocks with a reserve.

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....

:nod:

 

[HRDROKN]

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....

:whoa:

 

[HRDROKN]

And finally the tank end of things....

:cool:

 

[HRDROKN]

I got some new bars and AVS levers in yesterday. Still waiting on the new hub for the rear to show up.

Currently working on the pipe mount and silencer, going to see what I can do with using the KX can with the KDX internals etc..

I stripped the green off the subframe, the brushed look should work out...

Has anyone polished out the swingarm?

;)

 

[HRDROKN]

Got the new hub in the mail yesterday, so I got busy with getting her laced up...

:nod:

 

[whenfoxforks-ruled]

Them spokes will pass as rebar in 35 states, awesome. Keep this up, you may be riding her real soon!

 

[HRDROKN]

Not really liking the factory exhaust rubber mounts... not to mention how much they cost! I was looking for another option... so I picked these mounts from McMasterCarr for $6 each!

In this configuration the lower mount will be tight (I removed the FMF lower mount in favor of just making my own), but doable!

:whoa:

 

[HRDROKN]

Them spokes will pass as rebar in 35 states, awesome. Keep this up, you may be riding her real soon!

Ya... I got to get at least one ride in before I have hand surgery in November!

:ride:

 

[HRDROKN]

Finished lacing up the rear wheel....

:nod:

 

[HRDROKN]

Worked on the exhaust mounts....

A little extension here should cover it...

Will start on the silencer....

:whoa:

 

[HRDROKN]

I was able to get a little work in on the exhaust this morning. I used the FMF KX 125 silencer with the FMF KDX internals and stinger cut to fit...

:nod:

 

[_JOE_]

Aww dang! You're almost ready to rock!

 

[HRDROKN]

I've been slacking on the updates....

Finished the exhaust mounts.

Exhaust completed...

:nod:

 

[HRDROKN]

Electrics all mounted....

:ride:

 

[HRDROKN]

Lower radiator crossover hose just clears head stay mount...

With the motor sitting in the forward rotation the return hose is against the motor, so I will just have to keep an eye on it for wear...

:whoa:

 

[kawaJawki]

Let me know when you want to sell this bike.

 

[HRDROKN]

Let me know when you want to sell this bike.

I'll let you know when I get a KX roller ready to go with swingarm and mounts complete...

 

[HRDROKN]

And I she lives..I rode her around a bit today. I already feel the difference with the Ron Black mods. With the same jetting, the motor feels to have more bang through its range and it even feels like it lugs better. I suspect the top end will not have changed much with a woods pipe on,but the gears roll quicker with the new found acceleration.

I still have a few things, including replacing the the left side radiator... before hitting the trail.

:nod:

 

[_JOE_]

Damn nice work! That thing looks factory for sure. I bet it's a blast to ride, would probably be great on the track for any of us slow guys who like the bottom/mid...

 

[Joburble]

Dear Mr Kawasaki over there in japan, build us this and we will buy it.

Stunning work HRDROKN :cool: :cool:

 

[BSWIFT]

Congrats! Well done.

 

[antonyp]

I want one :nod:

:cool: :cool: :cool:

 

[johnnymoto]

Truly are impressive work of art backed up with very good talent. Congrat's. MY 92'kdx will never look the same now, thinking on how it should be made. The high end chopper building boys have nothing on you. Good Job!

 

[HRDROKN]

Thanks for the comps guys!

So I did have a chance to get out and ride this last Sunday. I can say it’s good and not so good….

The balance of the bike is great, definitely “feels” lighter than the KDX (not sure what the weight reduction actually is), easier to ride through the technical stuff than the KTM. As I made each consecutive loop I found myself less concerned with my lines, so it would seem that the suspension is at least in the ballpark.

With the RB carb mods, I have the 1/8-1/3 throttle bog when whacking the throttle with the bike on the flat… tried some different known setups including what RB sent without a cure at this point. On the trial when the motor is under load the bog does not exist… other than she feels just a tad lean, but even with that she would pull from virtually nothing to WOT without complaint. I would say that the head mods have really strengthened the low to mid torque, making the bike super nice in the technical stuff.

I have some jetting to get sorted out (after hand surgery that is) and have several things to try based on what others have found.

Currently:
PJ = 40
AS = 7/8 – 1.5
Slide = #7
NJ = JD red #5
MJ = 152