Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

[Goat]

That does look like dream machine! Tear it up.

[Tyl3r]

Thanks Goat!

Working on getting the Lectron dialed back in. Here's a short video of me going up a powerline behind my house. I'm going to need to aim that camera up a bit higher for the next one.

[Tyl3r]

Last winter I did the AC/DC conversion with a trailtech regulator/rectifier, added a battery, floated the ground, moved the CDI up to the head tube, added a headlight and a taillight. I think I am going to re-do the wiring again though over this winter, I can do better the second time around for sure, I also don't think I like having the CDI where it is, too much going on up there. I may try and put it in the airbox. Wanted to share what I had so far though.

20221128_195746.jpg (3.7 MiB) Viewed 4747 times

I got the idea to mount everything in the headlight from the Baja Designs dual sport kit I had on another bike. I just used aluminum from a street sign, it worked out perfectly, not too heavy and just sturdy enough to be a solid and secure mounting point. Mounted the battery, a distribution block, and the reg/rec on there then I used 4 screws to secure it to the headlight shell. When its mounted, all the stuff is between the aluminum and the headlight so its protected and I made a little cover to go over top and clean it up

20221128_184026.jpg (2.89 MiB) Viewed 4747 times

Excuse the dirt, I took some photos while I was adding in a power connection for a Voyager Pro GPS dock. I had it mounted on my KTM and realized I could just buy another dock and use it on both bikes and get twice the use out of it, so why not? When I re-do and cleanup the wiring over the winter, I will add in a temp sensor and a pick-up for the tach/hour meter. Also want to get some weatherpacks and clean up the connections behind the headlight. I used good heat shrink weathertight connectors, but would like to reduce the 7 or 8 connections down to like 2. Will also try and move the CDI to the airbox probably.

20221119_195150.jpg (2.43 MiB) Viewed 4747 times

20221119_195211.jpg (2.64 MiB) Viewed 4747 times

20221119_195141.jpg (2.71 MiB) Viewed 4747 times

[SS109]

I like it!

[Tyl3r]

Just wanted to update the ole build thread with some recent mods, I realized I missed a couple in between posts and had a couple recent ones to add too.

20221020_145358.jpg (64.47 KiB) Viewed 4618 times

(testing my fog machine before our Halloween party)

20221010_170547.jpg (149.06 KiB) Viewed 4618 times

I did the 07 KX250F kick starter mod. Just had to do a bit of grinding to make it fit, no biggie. Tucks in better than anything else I've tried so far (KDX, KX125, or KX250). Just wish I had more clearance at the clutch cover when it goes all the way around. Might try to get wider footpegs to help stop it sooner:

20221206_195803.jpg (109.84 KiB) Viewed 4618 times

20221206_195815.jpg (60.35 KiB) Viewed 4618 times

20221206_195905.jpg (74.92 KiB) Viewed 4618 times

[Tyl3r]

I got tired of the bars twisting in the rubber mounts every time I laid it down. To stop that, I was able to get Luxon to modify a set of KTM bar mounts with the integrated hand guard mounts to work on the KX125 triple clamp. Love how they look and work great. The bottom part is one piece and the top part is one piece, so its super solid. Also, awesome customer support from them.

Before:

20220406_194651.jpg (47.12 KiB) Viewed 4617 times

After:

20220917_131154.jpg (73.32 KiB) Viewed 4617 times

I updated the tool kit with everything I need to work on the bike. I have been trying to minimize tools needed to fix things on the bike so I only need to carry minimal amount of tools. At the same time, trying to also eliminate as many failure points as possible, things like minimize electrical connections, running mousses so I can't get a flat, keeping up with routine maintenance and bolt checks, have a brake-snake, folding brake and shift lever tips, solid bark busters to protect the levers, etc... Its already inherently simpler than a lot of modern bikes being that it has a mechanical power valve, no fuel injection or electric starter to have issues with, no valves/cam/timing chain/timing chain adjuster... you've heard the story. I was thinking about it, comparing to my 2018 KTM 4-stroke, I bet the KTM has like 100 more things that could go wrong with it than this bike haha. Anyways, love the dirt-bike-gear low profile fender bag and tool wrap. Had one come with a KDX I bought a while back and it held up great over time.

20230120_093810.jpg (83.96 KiB) Viewed 4617 times

20230120_093819.jpg (105.72 KiB) Viewed 4617 times

20230120_094102.jpg (132.21 KiB) Viewed 4617 times

6,8,10,12,13mm 1/4" sockets, extension, ratchet, master link, combination wrenches 8/9mm, 10/11mm, 12/13mm, 15/17mm, 13/16" spark plug wrench, FRP axle wrench (22/32mm I believe), metric hex keys, spark plug, and of course, zip ties. In my backpack I also have spare levers, they just didn't fit so nicely in the bag, this about maxes out what can fit in there. I had a bigger bag on there at first with more stuff in it and on the test ride, it bent the fender under and into the rear tire haha didn't like that.

[Tyl3r]

I did the clutch actuator lever extension mod that I copied from others on the site. Haven't got to test this one on the trail yet, but it felt awesome riding through my neighborhood for a quick spin. Total length increase, going in straight line from pivot to pivot was about 9mm in the end. A little dog leg was incorporated based off of advice of others, also added two washers to the cable mounting point on the motor to take up some slack in the cable.

20230107_124638.jpg (66.98 KiB) Viewed 4617 times

20230107_141415.jpg (91.77 KiB) Viewed 4617 times

Then I shortened my lever to go along with it:

20230107_143136.jpg (108.43 KiB) Viewed 4617 times

20230107_151301.jpg (107.38 KiB) Viewed 4617 times

Right now I'm in the middle of re-wiring the bike again. This time its like 100% better than before. Once its finished, I'll post up some photos of the progress and finished product. I did move the CDI to the airbox. I ran mostly all new wires and put them inside of heat protector sleeving to keep them all together and protected. I eliminated a bunch of connections and added metri-pack sealed connectors to consolidate the necessary connections. Super happy with how its coming out. Also got a label maker...might have went a little overboard with it hahaha but at least I'll always know whats what:

20230118_204931.jpg (109.89 KiB) Viewed 4617 times

Also, if you are looking for electrical connectors, check out this place: Cycle Terminal. I stumbled across them looking for factory connectors for the KTM, but they have lots of other great stuff too. I just ordered some metri-packs from them and a metri-pack sealed fuse holder that should really make this all look pretty legit, if I do say so myself. Mainly waiting on some connectors and a new light switch to arrive and I can wrap this up. Also will be switching from KX125 front brake line to a KDX one for better headlight clearance: the KDX one is about 4" longer.

[bufftester]

Nice work on the wiring and all the mods.

[Tyl3r]

I like it!

Nice work on the wiring and all the mods.

Thank you, sirs!

[Goat]

Looks fantastic! Did you add any reinforcement for the trail tech kickstand? I miss mine.
I installed it similarly, with little fiddling for adapting to frame & roller bolt positions. Worked great but very subject to getting in the way in the hard stuff Kept banging it on rocks since it hangs below the footpegs. After rewelding the little chain roller mount 2x….I decided to take it off. Just curious if you had any better ideas.

[Tyl3r]

Thank you! and yea, I know what you mean. I originally had this kickstand on a KDX and I didn't like it much, hung down like you said. I ended up taking it off of there and putting it on this bike, which it was actually intended for. It fits this bike nicely, not additional bracing needed. I haven't hit it off anything yet...but just watch. Next time I go out I bet I do lol

[Goat]

Aha!
Hope it works good! Ty.

[Kawiman]

Excellent build! First post from a new member. I’ve had an 2004 KX125 (now a “KDX150R”) since new and have decided to build a 2004 KX220 hybrid. I use the Fastway kickstand on my 04 KX and can vouch for how great it is! I’ll be adding one to my hybrid.

[Tyl3r]

Excellent build! First post from a new member. I’ve had an 2004 KX125 (now a “KDX150R”) since new and have decided to build a 2004 KX220 hybrid. I use the Fastway kickstand on my 04 KX and can vouch for how great it is! I’ll be adding one to my hybrid.

Awesome, its totally worth it! Be sure to take lots of pics to share, looking forward to seeing how it turns out.

[Kawiman]

Well, I’ve got the engine in the frame now. Struggling to get the engine angle correct. If I tilt the engine all the way forward, I can get the stock carb and KX250 air boot to clear the shock, but the lower right radiator hose points directly at the governor cover. If I tilt it back (even a small amount) I loose the clearance I need for the carburetor, air boot, and shock. Tyl3r, could you post a picture of the left side of your bike? Specifically the clearance between the frame and the cylinder? Did you need to do anything special with the lower right radiator hose?

Thanks for your help!

[Chuck78]

Great inspiration here Tyl3r!

I'm still debating what to do with my spare 220 engine. pretty much any 1996 & up KX125 will make an awesome hybrid. 2004-2005 being the absolute pinnacle of refinements, although the 1996-ish frame geometry is pretty incredible looking for a woods bike (1,455mm wheelbase, steep 26° steering rake/caster angle vs 27° & 1,470mm on the '04-'08 - can lower the forks to get to the KDX's 26.5° at least!), + there's the chance of scoring purple 1996 shrouds... BUT...TFB Designs does make 1996-styled purple checkered flag graphics for the '03-'08 KX!
The aluminum subframe and more compact frame/tank are the biggest perks on a hybrid for me.
Rebuilding my spare 220 this winter with $1300 in titanium parts + '98 RM125 Showa fork & '01-'04 RM125 Showa shock, head mod etc will really give me a better idea on the ability to improve upon the KDX chassis to make it feel more like a KX125 hybrid. I think I can get the 220 weight nearly identical but with greater fuel capacity. A bit more $$$ on a titanium'ed out KDX vs a lot more labor into a hybrid, but ultimately the fuel tank placement and shape on the hybrid bikes is the one factor that's not really a negotiable on the H-Series KDX frame. Higher center of gravity.
Lectron Billetron Pro Series or a SmartCarb SC2 36 will reduce the need for an oversized tank on the hybrid, that's a huge plus on weight distribution and savings.

Keep posting up pics and vids of your sweet machine there

[Ridea200]

Tyl3r: Before I started my build, I read through your thread, along with others, but yours was the last straw...good job!

[Tyl3r]

Tyl3r, could you post a picture of the left side of your bike? Specifically the clearance between the frame and the cylinder? Did you need to do anything special with the lower right radiator hose?

Look back on page 4 of this thread, some discussion on it there. It was a long time ago, so trying to jog my memory. I used the top part of the KX hose and the bottom part of the KDX hose. I found a brass pex connector at Lowes that worked perfectly as a splice piece. Then hose clamped. Its pretty tight in there, but no issues with wear on anything in the 7 years I've had it.

asdfasfd.JPG (70.68 KiB) Viewed 2655 times

I was curious, so I looked over at my KTM 300 and saw its just about as tight with the pipe on the new bike, so it must not be that bad.

cvbxcvb.JPG (76.1 KiB) Viewed 2655 times

Tyl3r: Before I started my build, I read through your thread, along with others, but yours was the last straw...good job!

Glad I could help! Thanks man, I think I probably did the same when I decided to build mine lol

Great inspiration here Tyl3r!

I'm still debating what to do with my spare 220 engine. pretty much any 1996 & up KX125 will make an awesome hybrid. 2004-2005 being the absolute pinnacle of refinements, although the 1996-ish frame geometry is pretty incredible looking for a woods bike (1,455mm wheelbase, steep 26° steering rake/caster angle vs 27° & 1,470mm on the '04-'08 - can lower the forks to get to the KDX's 26.5° at least!), + there's the chance of scoring purple 1996 shrouds... BUT...TFB Designs does make 1996-styled purple checkered flag graphics for the '03-'08 KX!
The aluminum subframe and more compact frame/tank are the biggest perks on a hybrid for me.
Rebuilding my spare 220 this winter with $1300 in titanium parts + '98 RM125 Showa fork & '01-'04 RM125 Showa shock, head mod etc will really give me a better idea on the ability to improve upon the KDX chassis to make it feel more like a KX125 hybrid. I think I can get the 220 weight nearly identical but with greater fuel capacity. A bit more $$$ on a titanium'ed out KDX vs a lot more labor into a hybrid, but ultimately the fuel tank placement and shape on the hybrid bikes is the one factor that's not really a negotiable on the H-Series KDX frame. Higher center of gravity.
Lectron Billetron Pro Series or a SmartCarb SC2 36 will reduce the need for an oversized tank on the hybrid, that's a huge plus on weight distribution and savings.

Keep posting up pics and vids of your sweet machine there

Thanks man, appreciate the kind words. My vote is the hybrid for sure! The newer the starting point, the easier it will be to find aftermarket parts and stuff for it. I bet its a lot harder to find cool stuff for the 02 and earlier KX125's vs. 03 and up. A steel framed KTM I think would be an awesome starting point for a hybrid too if you found one with a blown motor.

The weight placement makes all the difference to me. When I had a regular 220 and my hybrid and I remember trying to figure out a jenky way to weight them both. I wasn't very accurate but I think they were within like 5 or 10 lbs of each other, but when you rode the two back to back, it felt way more like a 50 lb difference, even when picking it up to put on a stand it felt way lighter. Way easier to maneuver around in the tight stuff too I felt like, and it could ride harder for longer. The suspension on my hybrid was wayy better than the stock equipment I was running on the KDX, so I'm sure that has quite a bit to do with it as well.