This is a KX125 frame/KDX200 enginne/KX250 suspension project.
Ignore the dirty motor. I am having it totally rebuilt and will clean it and paint it at that time.
The swingarm and rear motor mount lines up now. The swing arm was cut and the rear mout was milled 2mm larger to accomidate the KX swingarm pin.
For reference, the steel sleeve in the engine case that makes up the rear motor mount is not a solid sleeve. It is aproximatly .75 inches. In between the two sleeves is empty space. If you mill the case 9mm each side, you will loose most of the actual mount strength.
Another thing, the swing arm bearing is about an inch long. Cutting 9mm off of each swing arm on the inside does nothng but remove empty space. The only load bearing surface if the swingarm bearing and that is untouched as shown below. What is removed is just filler. Beteen the bearing and the inside seal is just air. A much better option in my opinion i to remove the matrial that has no load. Additionally, the KDX has a swing arm mounting diamater of the newly cut KX swingarm. The CAD image is courtsy of TT member Bucket.:applause:
I had a machine shop do the work with a mill. It is dead nuts accurate.
The head stay lines up just fine. I removed the front motor mounts as you can see and I have a mock up. I'll cut them and tack them then weld them. Look at the bottom motor mount though, Doh! It does not line up. Apparently the 99 frame lines up. the 2000-2002 frame does not.
The bottom motor mount is actually a double layer mount so that will be tougher to reproduce. More griding too. Dang...
After the mounts are welded I will blast the powder coat off and blow a new coat of paint on the bike using OEM colors. The I'll bolt it all up. Somewhere in there the motor will be getting a full on rebuild. The enture suspension has already been fully disassembled inspected and rebuilt. It is better than new. I even blew on a new coat of Plum Crazy thermal paint on the rear shock spring.
Ignore the dirty motor. I am having it totally rebuilt and will clean it and paint it at that time.
The swingarm and rear motor mount lines up now. The swing arm was cut and the rear mout was milled 2mm larger to accomidate the KX swingarm pin.
For reference, the steel sleeve in the engine case that makes up the rear motor mount is not a solid sleeve. It is aproximatly .75 inches. In between the two sleeves is empty space. If you mill the case 9mm each side, you will loose most of the actual mount strength.
Another thing, the swing arm bearing is about an inch long. Cutting 9mm off of each swing arm on the inside does nothng but remove empty space. The only load bearing surface if the swingarm bearing and that is untouched as shown below. What is removed is just filler. Beteen the bearing and the inside seal is just air. A much better option in my opinion i to remove the matrial that has no load. Additionally, the KDX has a swing arm mounting diamater of the newly cut KX swingarm. The CAD image is courtsy of TT member Bucket.:applause:
I had a machine shop do the work with a mill. It is dead nuts accurate.
The head stay lines up just fine. I removed the front motor mounts as you can see and I have a mock up. I'll cut them and tack them then weld them. Look at the bottom motor mount though, Doh! It does not line up. Apparently the 99 frame lines up. the 2000-2002 frame does not.
The bottom motor mount is actually a double layer mount so that will be tougher to reproduce. More griding too. Dang...
After the mounts are welded I will blast the powder coat off and blow a new coat of paint on the bike using OEM colors. The I'll bolt it all up. Somewhere in there the motor will be getting a full on rebuild. The enture suspension has already been fully disassembled inspected and rebuilt. It is better than new. I even blew on a new coat of Plum Crazy thermal paint on the rear shock spring.