2002 Hybrid Build

[frankenschwinn]

This will be my documentary page

I started with these:
2002 KDX200



2002 KX125


I started tearing down the KX:


The shrouds looked like this when I started:


I was able to remove all of the paint:


Ultimately I will replace plastics but I need to save $$$ where I can.

I went throught the linkage and swingarm bearings. I was surprised to find they had apparently been greased and were in good condition

[Indawoods]

On the shrouds... Get a new graphics kit... use a heat gun to remove the stress marks... Good to go!

[frankenschwinn]

Those stress marks are actually just the flash from the camera. Graphics are a good idea though.

Who paints plastics anyway?

[Indawoods]

Tards...

[scheckaet]

I have a full set of my old plastics if yours are really bad.
You ain't gonna get much out of your KX bottom end
Watch out for the position of your engine, I'd mock up everything with wheel and chain but without the shock on.
I have to keep my chain really loose or it gets way too tight on jumps or when the rear is compressed.

[frankenschwinn]

I have a full set of my old plastics if yours are really bad.
You ain't gonna get much out of your KX bottom end
Watch out for the position of your engine, I'd mock up everything with wheel and chain but without the shock on.
I have to keep my chain really loose or it gets way too tight on jumps or when the rear is compressed.

How do you get the measurement on where to cut the swingarm?

one of my side plates is cracked and the rear fender is broken off. I can use the shrouds I have. I would be interested in the plastics to replace those items if what you have is good. What do you want for them?


I scored a 99 KX250 silencer off ebay for 25.00 shipped I also found a gripper seat cover new for 15.00 (hopefully it is not trash...)

I was going to wait awhile but I think after I ride this weekend I am going to start tearing the KDX down

[frankenschwinn]

Made some progress:

Swingarm cut, Case drilled





Will mock up motor mounts tonight when it cools off in the shop

[frankenschwinn]

Fabricated and welded motor mounts to frame. Cut rear head stay from motor. Molded tank to clear water inlet on top of head. started airbox mod.









Still need to complete airbox and pipe fit.

Hope to be ready for paint this weekend.

[Tedh98]

Looking good. Looks like you'll have very little downtime on that build.

Did you ream the cases or have a machine shop do it?

[frankenschwinn]

Looking good. Looks like you'll have very little downtime on that build.

Did you ream the cases or have a machine shop do it?

I did it. Hoping to be riding it in two weeks

[Tedh98]

How did you do it? That was the only piece that I had outsourced.

I couldn't figure out a good way to hold the motor in place on my little drill press table and didn't want to risk screwing up the cases.

[frankenschwinn]

hand drill. Lots of oil on the bit. It was not perfect like a machine shop bore job would be, but close enough.

[KarlP]

I did mine by hand, also.

I tried pretty hard to get it mounted in my little drill press also but it wasn't going to work. 3+ years so far no problem

[frankenschwinn]

I did mine by hand, also.

I tried pretty hard to get it mounted in my little drill press also but it wasn't going to work. 3+ years so far no problem

That is good to hear...

[bulabula09]

nice job man! keep it up! i like the "simulated" black KX plastics lol im anxious to see what its gonna end up lookin like

[frankenschwinn]

Almost done. I scored some new plastics from the clearance rack at cycle gear. I found that it has a radiator leak when I did my brief test ride.

Should have the fork seals and rear fender by tue.

[KarlP]

The black on green doesn't really work, does it?

I did all black plastics on my CR. They got scratched up pretty quick.

I went for about 6 months with a leaky radiator. I actually stopped the leak with a tablespoon of Bars Leak while I was shopping for a new one. I never came across one for a '99 CR250. 'Course, it wasn't leaking so I was not trying too hard. When the leak came back I took the radiator off and fixed it with Water Weld (As seen on T.V.......) Its been holding ever since.

I'm not making saying this as a recommendation. If you are as CHEAP and LAZY as I am..............

[frankenschwinn]

The black on green doesn't really work, does it?

I did all black plastics on my CR. They got scratched up pretty quick.

I went for about 6 months with a leaky radiator. I actually stopped the leak with a tablespoon of Bars Leak while I was shopping for a new one. I never came across one for a '99 CR250. 'Course, it wasn't leaking so I was not trying too hard. When the leak came back I took the radiator off and fixed it with Water Weld (As seen on T.V.......) Its been holding ever since.

I'm not making saying this as a recommendation. If you are as CHEAP and LAZY as I am..............

No It will be silver after a good test ride. I just did not want to paint it and find out I needed major adjustment. I will put pre-printed backgrounds on the side plates and I have some graphics for the shrouds to offset some of the black. I found a radiator on ebay and there is a local radiator shop that will fix this on for 35.00

[frankenschwinn]

Here is a pic with the new rear fender mounted.

[Indawoods]

Looks Wicked!

BTW... I like the green frame myself.....