KDXRIDER.NET

Hi everyone, new to the forum. Reading all of the hybrid builds on here really made me want to start one. So I picked up a 03 rm125 roller and have a 03 kdx200 motor that I have just started to put in. I have already ran into a few issues, one being the gas tank hitting the top of the motor. Once I get going on it I will be posting pics.

Sweet cant wait to see the progress.

So I see that every one cuts the swing arm down to fit the engine in, Wouldn't that mess up the fitment of the bearings and the seals? Can you cut into the engine case? Any input will be greatly appreciated.

With the KX swing arm, the part you cut doesn't support the bearing. It is just dead space and doesn't impact the bearing or seal.

You can cut the cases or the swingarm or both, depending what needs to happen.
Your best bet is probably to get the RM swingarm and the KDX motor on the bench and see what needs to happen.

OK thanks guys I think Im going to cut into the case.

If you add "pg" to the end of your URL the pix will work

Wow! That flows great!

Hello everybody, I am new to the forum and planning a hybrid to replace my Husky WR250. I always thought the RMs handled nice and seems like I can make them fit me, sort of, I'm really tall. I know this post is a couple months old but I was hoping there was some progress made on your Suzuki. Have you run in to any show stoppers during construction? I may be doing the same thing as I just scored a KDX200 and I'm keeping an eye on the local KXs and RMs. Thanks and good luck.

Hi Yugmoto, im having trouble finding time to work on the hybrid, but it is almost done, and the only thing that seems to be different with the RM and KX is the top radiator mount on the engine hits the gas tank so you have to fabricate one that points up (I will post a pic of it)

Did you cut the case or the swing arm?

I cut the case and a little on the swing arm, but I definitely wish I just cut the swing arm, kind of a stupid mistake but it will work.

I know what you mean about time and projects, I haven't time to put my CR500 back together, and there is no fab work there! The RM swingarm was the biggest question I had. I kinda figured I'd try the rm anyway, but after your experience it just got bumped to the top. I found an 03 locally last night with a blown up engine, but I think he wants too much for it. I think he has some title issues to work out as well. Does it look like a desert tank might fit? If you don't have one I guess it would be hard to tell, if there are no fitment issues with the stocker it might be a good indicator. I'll keep you posted if I pick one up, maybe two builds at once will make them both pick up speed.
Thanks

Im not sure if a larger tank would fit but I have a friend with one and I will check. Good luck picking up a bike!

So I fitted a IMS over sized tank and the bottom of it just barely hits the engine in two spots.

You can use a heat gun to mold the tank around the engine where it hits. Just take your time and do it slowly so you don't melt a hole clean through. I did it on my hybrid where the tank just hit the head, was able to mold it around and get 1/2" clearance, then fixed some heat shield to the tank around the area, never had a problem with it.