99 hybrid project started!

[bulabula09]

ok, iv been working on it for a few months now...im in college and $ is kinda tight but its slowly coming along. next step is powdercoating and my biggest challenge so far..the air box here are a few pictures..sorry for the crappy quality..i took them on my phone

before the cutting


and after..i took it to a machine shop the one of my buddies works at and he cut the top mount off and drilled the rear case out all for only $20!





this is a 2000 model KDX 200 motor and how it lines up on the 99 frame..you could either shave the bottom of the case or cut the bottom mounts off..i opted to cut the mounts off as i didnt want to compromise anything by grinding anymore on the case


swing arm cut and mounted!


this is a pro circuit platinum pipe i bought off ebay. it fits, but we did have to weld in a 10mm section for it to clear the front of the frame. it still has to be dented..in two places believe it or not..one is by the radiator and the other is by the harness for the clutch cable on the motor





motor mounts getting fitted and refined for welding








tacked on with a tig



thats all i have for now..ill have more up soon!

[Dale]

Looking good so far! Be careful and pay special attention to the front sproket/ swing arm pivot/rear axle geometry. Compare geometry to other bikes you have and then put the sprockets and chain on and check your chain slack in all stages of swing arm travel. My first hybrid I had the geometry wrong and the chain became tight as the swing arm was depressed. Had to reweld all motor mounts! Good luck and keep the pictures coming.

[KarlP]

Nice job!

I'd fit the carb and silencer and airbox before welding anymore on mounts....

You'd hate to get surprised by 1/8" of two things needing to occupy the same space

[bulabula09]

just got the frame, rims, and hubs back from the powdercoat shop...they charged me a reasonable price of $210 for everything....just started putting her together yesterday!!! its starting to look like an actual dirtbike rather that just a big pile of parts! The spring on my rear suspension is an experimental. The guys at the powdercoat shop had never done one and my origional was shot so they painted it for free to if it would hold up to the compressions..lets hope it does lol she is a wheel barrow right now but expect more pics to come when i get her rolling within the next day or so!













let me know what you guys think, constructive criticism is welcomed..i dont want this project turning out bad thanks guys!

[sr5bidder]

good job silver looks much better

[ldspowersports]

This looks great. The silver looks really goos. It looks like the 99 Frame isn't too difficult compared to others that I have seen.

Luke