Got brackets and mounts tacked up ready for someone that can weld , lectron pro carb sorted and fits like a glove, only issue left is the clash with the tank and cooling outlet off the top of engine which I don’t really want to start warming the tank and remoulding unless I have no other option, I may go down the route of modding or manufacture an alternative top section
Finally got 220 engine back, had a slight port for top end and a light skim of head and a vapour blaster, should have it all together in the next week and will upload pics along way
on my 220 hybrid in a 2001 KX125 frame I had to also heat and remould the tank. As Ridea200 said, take it slow with the heat gun. You don't have to have a ton of clearance, I got about 3/8 of an inch and have not had any issues with it in the last 10 years. One thing I did have issues with is the fuel line. Where yours looks like it's a little kinked right where it comes out of the petcock, mine was like that and the hose was riding on the bolt for the reed cage. Took 10 years, but this last summer turned on the gas one day and it just started dumping fuel where the bolt head had rubbed a hole in the fuel line. My fix was to go with a thicker fuel line, but just something to be aware of.
Thanks guys will look at the fuel hose once engine finished and looking to see if I can shave a bit off the top coolant connection along with warming up the tank to sort that issue .
Will keep you all updated
Engines in and been running although when warmed up seem to have a hairline crack on inner clutch case that has a minor oil leak , not a major issue as I’ve picked one up and cleaned up on home made vapour blaster and just waiting on water pump seal
Next issue is the frame and water pump protection , anyone any idea , I was thinking a kdx sump gaurd that wraps around to protect water pump and modding to fit the kx frame
1fletch wrote: 10:01 am Apr 26 2025
All finished ready for run out although just miss placed frame cover for right side which will turn up and hopefully give it a run out next week
Thanks guys took some time to get this one complete and learnt a lot along the way
Got the 1990 kdx 200 that I originally purchased to start on next although engine has been fully rebuilt as it was going in this although I have to pick up a rear hub / wheel as it has a crack in the one I have
Will start a new thread on that build and wanted to thank everyone for the input along the way for this build
KXD ready for next weekend , carb dialed in nice and crisp , modded yz 250 devol skid plate fitted to protect water pump and stator and kickstart from kx250 knuckle and kx125 lever
Bike ran great at the weekend , suspension needs a lot of dialling in , the gearing needs a bit of work also as 1st is none existent and 2nd will get you into trouble in wet.
The power seems to be right through although only managed 20mins on it and hopefully back out for an afternoon at the weekend having a good run out and will update again
I didn't see much of any info about what you had to do to get the engine mounted in and make the exhaust fit. Did you do any cutting and welding on the frame tubing itself? It looks as if perhaps you only had to modify the front and front lower crankcase engine mounting points as well as the exhaust mount point? No alterations to rerouting the frame tubing?
Or just make a spacer to extend the exhaust head pipe slightly?
In the long-term, I'm interested in potentially building a '97 or '98 KX 125 hybrid with my spare 220 engine. The main frames are generally all the same in the front '95-'98/'99-'02, it's only the seat subframe and other tank and shroud mounting points on the mainframe that are different. I'm still toying with the idea of a 134cc or 139cc torquey mid-range woods ported 150 class engine, however. My admiration for the 220 engine's ability to lug all day long is pretty high though, so the 220 is likely to win out.
, lectron pro carb sorted and fits like a glove, only issue left is the clash with the tank and cooling outlet off the top of engine which I don’t really want to start warming the tank and remoulding unless I have no other option, I may go down the route of modding or manufacture an alternative top section
