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

Discussion for swapping a KDX motor in a MX frame...
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Goat
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Re: Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

Post by Goat »

That does look like dream machine! Tear it up.
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Re: Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

Post by 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.

04/05 KX220 Hybrid all decked out
18 KTM 500 EXC-F Dual Sport/Sumo toy
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Re: Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

Post by 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.
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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
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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.
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04/05 KX220 Hybrid all decked out
18 KTM 500 EXC-F Dual Sport/Sumo toy
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Re: Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

Post by SS109 »

I like it! :supz:
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Old KDX: '90 KDX200 -White/Blue
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Re: Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

Post by 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.
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(testing my fog machine before our Halloween party)
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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:
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Last edited by Tyl3r on 10:45 am Jan 20 2023, edited 1 time in total.
04/05 KX220 Hybrid all decked out
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Re: Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

Post by 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:
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After:
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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.
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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.
Last edited by Tyl3r on 10:54 am Jan 20 2023, edited 2 times in total.
04/05 KX220 Hybrid all decked out
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Re: Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

Post by 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.
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Then I shortened my lever to go along with it:
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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:
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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.
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Re: Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

Post by bufftester »

Nice work on the wiring and all the mods.
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Re: Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

Post by Tyl3r »

SS109 wrote: 07:29 pm Dec 09 2022 I like it! :supz:
bufftester wrote: 11:35 am Jan 20 2023 Nice work on the wiring and all the mods.
Thank you, sirs!
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Re: Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

Post by 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.
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Re: Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

Post by 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
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Re: Tyl3r's 05/04 KX/DX Hybrid Build - DONE!

Post by Goat »

Aha! 🤣
Hope it works good! Ty.
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