2002 Hybrid Build

[bulabula09]

sweet bike man! try powder coating your rims black or green thats what i did to mine and i havent had any problems with it it all, it holds up nicely

[frankenschwinn]

Here are some pics of the final mock-up. Gonna ride it this weekend then tear it down for paint...

[frankenschwinn]

Sun I pulled the motor and completed the final fab work. All Pieces are in place and temp paint is done.

I cut the frame loops from the KDX and welded them to the KX frame:



I had made a Skidplate for the KDX and it ifit perfectly. The one thing I hate about the skidplate was the hassle of getting it mounted. So I made plates with nuts welded to them and welded those to the frame to eliminate the loose skidplate mounting brackets:



I had bought some new footpegs that were a little bigger (the original ones were bent anyway) and found that I had to pull the motor to get the clutch side mounted. So I took the oportunity to install them while the motor was out. Also, riding trails without a kickstand really sucks so I bought a Trail tech for a 2003 KX125 (they don't make one for an 02) and modded it to fit::



While working on all of this I found that my kick starter was cracked. I have a KX250 kicker on the way but I welded this one for the time being:


Should I put the KX125 kicker on the 250 knuckle or just leave the 250 kicker?

All that is left is the 2002 WR250 petcock to resolve this clearance issue:


PJ1 does not make the Kawasaki green anymore so I bought some grabber green for the areas I welded and ground on. I will tear down this winter when the snow comes and have it powder coated silver or black.

[scheckaet]

"found that I had to pull the motor to get the clutch side mounted"

I have the same issue.

I'm interested about that WR petcock, what's the deal with it? shorter? Does it have a reserve setting unlike the stock kx?

I went around the petcock clearance by molding it in using the heat gun, work good so far.

Would you get a pic of the chain guide? Do you have a rubber part in it or does the chain rub on the metal?

[frankenschwinn]

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"found that I had to pull the motor to get the clutch side mounted"

I have the same issue.

I'm interested about that WR petcock, what's the deal with it? shorter? Does it have a reserve setting unlike the stock kx?

I went around the petcock clearance by molding it in using the heat gun, work good so far.

Would you get a pic of the chain guide? Do you have a rubber part in it or does the chain rub on the metal?

Here is a pic of the WR petcock:

You can see that the outlet points to the rear horizontally rather than down vertically and it does have a reserve. I should have it today or Mon.

On the chain guide. The stocker has a rubber block insert but mine was worn through. I replaced it with a primary drive unit. It was just a few $$$ more than the ruber insert for the stocker and I wanted black

Stocker I have already discarded the ruber part:


Primary drive chain guide:


This is the ruber insert:
http://www.rockymountainatvmc.com/produ ... Parts=true

This is the primary drive chain guide:
http://www.rockymountainatvmc.com/produ ... lyId=24705

I had to use the stock spacers for the top block

[HRDROKN]

Lookin good!

What mods did you have to do to get that kickstand to work?

[frankenschwinn]

The bracket was too long so I set it in place and marked where the top hole should be. Drilled a hole cut the bracket. Found a bolt/bushing to replace the sub frame bolt and cut an 1" off of the stand. I need a button head bolt for the top bolt but have not found one yet.

[scheckaet]

I want that same petcock, where did you get it? ebay?
That primary drive chain guide looks good, gonna have to order one myself, the stock is junk, can't even put a rubbing block on the bottom part

[frankenschwinn]

I want that same petcock, where did you get it? ebay?
That primary drive chain guide looks good, gonna have to order one myself, the stock is junk, can't even put a rubbing block on the bottom part

I had a guy I know in Austin order it for me. I am sure you could get it from bike bandit or something though. Or I can ask him to order another. You will have to pick it up at Cross Timbers or Stillwater 500 when I host the first annual Oklahoma Hybrid Rally.

[hockeyboysomers]

I used a new 1999 KX250 kickstart lever. I used it full size. It's lighter, stronger and longer than stock. It might not work for someone on the short side, I don't know. I had to use a washer under the nut to take up some slack. I prefer it to the stock lever. I've also heard that if you use the shorty lever, you hit your foot on the footpeg. Good luck!

[frankenschwinn]

Th KX250 kicker is too long to fit on my hybrid. The 125 kicker works nicely though. I have my motor rotated up and back so the kicker actually touches the frame but nothing to worry about.

[Bouillion]

Well done!

[500 HORS]

Please confirm, but it looks like you used the KX throttle cable and the KDX Keihin carb - is that correct?
thx.

[HRDROKN]

Please confirm, but it looks like you used the KX throttle cable and the KDX Keihin carb - is that correct?
thx.

Not sure what franken.... did, but this is what I found.

I ordered a motion pro throttle cable for a 99 KX125 and it was exactly like my 03 KDX cable and fit perfectly with the KX throttle. Ordered it from
motosport.com for $17.

[frankenschwinn]

Please confirm, but it looks like you used the KX throttle cable and the KDX Keihin carb - is that correct?
thx.

I used the KDX Throttle housing/tube/cable and carb. It all fit like a glove