A path less travelled 97 kx125

[bufftester]

IIRC they are both PWK36 carbs with the KX being the air stryker variant. Use the jetting for the KDX and pick the one in the best condition.

[Ridea200]

Well, there's still some to do, but here's some pics anyways. The opening on the kx box is a bit bigger, so I just cut the face off the kdx box, and trimmed to fit. At first, I used plastic epoxy, but it didn't hold, so I used a solder gun to melt it together, adding filler from scraps from the kdx box.

[Ridea200]

Bufftester: Ok. Unless the air striker has any performance advantage, I'll just use the kdx carb. There both in pretty good shape.
This is what I did for the desert tank petchock...

[Ridea200]

Nice convenient spot. Old cdi location.

[SS109]

The OEM KDX200 carb is a 35mm and the KX125 carb is 36mm. An air striker carb tends to have better throttle response, especially down low, than a standard PWK. Some same they are a bit more finicky with jetting and my own personal experience agrees with that.

[Ridea200]

Thanks for the info. I'll just try them both, and see what happens.
Got all the welding done. Now to sort out the wiring.

[Ridea200]

Got the wiring done. After installing the carb, I saw a little more on the desert tank that needs to be shaped.
I'm starting to get pretty excited, but don't want to get ahead of myself. There's still plenty to do...

[Ridea200]

Getting there...I think its time to start cleaning everything up, paint the frame, assemble (hopefully for the last time), then see if it starts...

[Ridea200]

Did some painting. Didn't do the hole frame. Just the spots that really needed it. God willing, I'll get it done tomorrow.

[Ridea200]

[KDXGarage]

SWEET!

Congratulations on all your hard work.

As always, check that chain tension. :-)

[SS109]

Alright! Now give us a ride report!

[Ridea200]

If anyone has any questions, or wants pics of something in particular, just ask.
Thanks for all the help. Not only on this thread, but to everyone else that's posted what they have done on there build.
So, the 200 has been sitting since about 09. When I got to the point of kicking it over, the wife and I took guesses how many kicks it would take...she got it at 3. Wormed it up, and went for a slow rip down the road, with the wife on her klx. Chain flopping around and all. was about all I could do. After dinner, I headed out again, but farther this time. On the way back, I ran out of gas...lol Pushed it back, put more than a splash in this time, and went for a decent paced 4 mile rip around the hill. (We live in the hills of eastern washington) All the while listening for odd sounds, other than the chain...Good ol kdx motor ran pretty good, and nothing fell apart/off. Today, I tightened the chain, (of course someone noticed...lol) swapped the pilot, and went for a faster paced rip around the hill. So far the bike feels solid. Only a few small/easy things have popped up so far.
I've wanted to do this for a long time, and thank God for the opportunity, you guys for all the good info, and my wife/kid for the support. Now time to finish jetting the carb, and tinker with suspension setup. Also, later, I'll go over the other stuff that was already done on the bike.

[Ridea200]

I've been debating putting a light on. I have this old ufo light sitting around, but the lights are busted, and the plastic has seen better days. Spent some time, and got the green to come back out. Might finish that up, and swap in some leds? I don't need it for racing, but might be nice around here at times...

[SS109]

A light can be very helpful asset when something happens out on the trail and you have to ride back in the dark. Do it!

[Ridea200]

Still need to finish up, but the shroud is green again, and found out I can get replacement lights at the hardware store...Also, went for a little longer ride today. Still nothing weird, so that's cool.

[Ridea200]

New lights. Still need the sockets though.

[Ridea200]

Here it is with the lights, and a black 05 style fender off my buddy's rmz. We went for a pretty good ride. Even did a little hill climbing. Neither of us made the top, but the bike ran pretty good. Broke my rear fender though...There's a reason the hill climb guys have extended swingarms.

[SS109]

Glad you finally out enjoying your KDX hybrid!