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

[KDXGarage]

So far, so good!

If you decide to not use the current shrouds or seat cover, let me know. (and possibly other 2005 KX125 parts)

[KDXohio]

Looking good

[Tyl3r]

I'm definitely keeping the seat cover lol its the nicest/newest thing on the whole freakin bike right now!

At some point, I plan to replace all of the plastics at one time. You are welcome to the shrouds, number plates and front fender. Back fender is in terrible shape as it was zip tied on for a while. Number plates are in good shape. One of the shrouds has a little crack up at the top of it and both have stress marks, they aren't the prettiest. Front fender is in perfect structural condition but super faded. I think it could be cleaned up if you are into that kind of thing.

Any interest in the motor that needs a top end or a good carb? Both are pulled from the bike and awaiting my lazy ass to post them for sale on the interwebs.

[Tyl3r]

Looks like I will be doing an 04 KDX/05 KX hybrid! (I think thats the last year for both in the US?)

I picked up this gem off the local c-list:


Here she is all tucked in next to the KX; they cant wait to become one!


Guy was pretty firm at $1900 for it, I was able to talk him down to $1700. I couldn't get him down any further because there haven't been any for sale around here lately, and I couldn't find anything wrong with the bike to nitpick on lol So I spent a couple hundred more on it than I wanted, but this thing is super nice. I think I'm going to put some new gas in it, change the oil, lube the chain, clean the plug and air filter and take her for a rip this weekend. I'll ride it till it starts to snow, then I'll begin surgery. By the time the snow goes away, I'm hoping to be all done. I'm just super excited right now to have a bike again, I'm tired of 4-wheels in the dirt!

[Tyl3r]

I took her out this weekend.... was like a kid in Disneyland! haha I ride every weekend, but this is first time on 2-wheels in about 2 years. Took a while to get the constant feeling of the front end washing out to go away, but once it did, it didn't take too long for me to get acquainted with the difference in handling.

I rode with 2 guys, one on a 125sx and one on a 250xc (orange bikes). My green bike that is 7 or 8 years older and 1/4 the price, kept up just fine. I had to make sure I let them know how much less money I spent to go just as fast as them and lug even lower than them all day haha!

I'm so use to sitting down on the quad. When I got in a tight spot or got a little nervous, I would immediately sit down on the bike and I think that was causing me some problems. I'm trying to think of any other bad habits that I may be bringing over from riding quads to try to improve my 2-wheel riding skills. Has anyone else ever made the transitions from 4 to 2 wheels before? Its weird

[Tyl3r]

Well, I'm getting closer to starting my build. This weekend, I built a work bench in my garage that I feel should actually be suitable for building a bike on. 89 bucks at home depot and 4 hours later, wala:


Still want add a couple of things, but you get the idea. Now I just need to get my v-force 3 reed valve, and some drill bits and a reamer and I will have everything I need to start mocking up the motor and welding in new mounts. I plan to do all of the work myself in regards to drilling/reaming the motor and cutting the swing arm and sleeves. I figured that I could use the sleeves that are currently in the KX for mock up and cut them with an angle grinder. Then take a brand new set into work to have them turned down to the correct length on the lathe once I know the correct final lengths; that would be the only part I wouldn't do myself.

I've been slacking on getting this started because I have been having fun riding the kdx every weekend. As soon as the snow starts to fall here, I won't be able to resist working on this. Actual build updates should be coming soon, in the next couple of weeks, stay tuned!

[6 Riders]

Nice work bench! It just needs some peg board and hooks

[Tyl3r]

Funny you should say that, I was thinking the same thing!

[Tyl3r]

Ok, progress has offically begun! Yesterday, I tore the 125 down to the frame, organized everything into keep/junk piles, organized bolts and all that fun stuff.

Just need to get on ordering the stuff I need and I can start putting the KDX motor in. I am having a much harder time than anticipated when it comes to tearing that KDX apart haha. I've never stripped down a perfectly good bike before. O well lol it'll be worth it in the end! I have a good bit of time off around Christmas. I am hoping to get most, if not all of the fab work hammered out then

I think I've finally decided on the color scheme. Going to do the frame, swingarm, rims, triples and some other stuff gloss black. Then I'm going to do a bunch of small things like the hubs, calipers, foot controls, and some other stuff gold. Plastic will be green with black number plates and fork guards.

[Tyl3r]

Got a pile of parts completely disassembled and ready to prep for gold powder coat. The only other gold-to-be parts that I need to take apart are the hubs. The rest of the parts will be powder coated some variation of gloss black (still deciding on glossiness)
progress..... slowly but surely!

[6 Riders]

Just an FYI.....You can't have seals or bearings, of any kind, in the parts going to powder. If you are going to powder the calipers, you'll need to strip them clean.

[Tyl3r]

Just an FYI.....You can't have seals or bearings, of any kind, in the parts going to powder. If you are going to powder the calipers, you'll need to strip them clean.

I actually have a small, part time powder coating business with a good friend of mine, so these are things that I am well aware of, but thanks for saying something anyways. I'm not sure many people realize that.

Those are all bare castings sitting there. I may end up turning this into a little bit of an advertisement for the business and get some graphics made with our company name on them... still thinking about it

[Tyl3r]

Well, finished up the gold powder coating. Everything came out really good. I saw that our usual powder supplier has a line of "super durable" powders. I decided to experiment and try out the super durable clear. We'll see if it holds up any better than regular clear. Now I can put all that stuff back together. I have one rim and the the trees stripped and ready to powder mirror black. I was going to use the same clear on those as well. I have my doubts with the black rims holding up, but we shall see. I filed down the parting lines on the trees and polished them smooth. They should look pretty good, excited to see the end result!

I got the new SKF wheel bearing/seal kits for the hubs, ready to press in. If you haven't seen those, the seals are supposed to be the cat's meow. I also have a slight chub for all things SKF haha. You pay more for them, but their high quality parts make my life a whole lot easier at work!

Suspension is at a local rebuilder. He said when he took them apart, everything was in terrible shape and hardly had any oil...I feel like he's dragging me through the coals with a $900 price to get em resprung, revalved, and replace all of the bad parts (SKF seals ). Does that sound bad to you? I've only heard good things about the guy, I really want to trust him, just don't know. He said he's using all oem parts, except for the SKF seals I asked for.

Now im just waiting on one last drill bit to show up in the mail. Once that comes, I'm ready to pull the motor and drill/ream the case...then the fun stuff begins! I am hoping that the kdx motor will be drilled in my next update. Wish me luck!

[ced64k]

I feel like he's dragging me through the coals with a $900 price to get em resprung, revalved, and replace all of the bad parts (SKF seals ). Does that sound bad to you?

Seems expensive. I had me KDX shock and KX fork rebuild for 500€ with new springs, kayaba parts, etc. It was in bad shape, the shock was never opened in 18 years. Now it's brand new.

[Tedh98]

Seems expensive.

I agree, it does seem on the high side. Has the tuner gone over exactly what is so worn out it needs to be replaced?

[Julien D]

That seems very high to me as well. I should think you could get a rebuild revalve for shock and forks for well under 500 bucks. There are certainly well known shops online for that price.

[6 Riders]

Had my RM forks done....Lowered, sprung, valved with "special" machining, special bushings and air valves drilled into the top...for $350 (cash price).....SO at $900 you should be able to score new forks (newer and better ones even) and have them rebuilt for about $5-$600 total.

[Tyl3r]

man...I didn't want to hear that. I'll have to get a complete breakdown of everything...and figure out a polite way to say I feel like being raked through the coals. Thanks for your responses, I appreciate your feedback.

[adam728]

Depends on what all you are getting. New springs, aftermarket valves, revalve, with all new wear parts, plus labor? Might not be too bad. Things so worn that you need a new shock shaft and the fork stanctions rechromed? Now it's not a bad price. Sure you can buy used stuff cheaper. But thats apples and oranges. Kind of like saying the dealer rapes everyone with new bike prices (even below msrp out the door) because you can buy a 10 year old one cheaper.

[6 Riders]

Depends on what all you are getting. New springs, aftermarket valves, revalve, with all new wear parts, plus labor? Might not be too bad. Things so worn that you need a new shock shaft and the fork stanctions rechromed? Now it's not a bad price. Sure you can buy used stuff cheaper. But thats apples and oranges. Kind of like saying the dealer rapes everyone with new bike prices (even below msrp out the door) because you can buy a 10 year old one cheaper.

You'll notice I said buy new (used) ones AND have them rebuilt. If the forks are so bad that they need $700 worth of work, they are probably shot and not even worth having done. If the builder NEEDS to use gold valves in KX forks, might not be "the guy" to have do the revalve anyways.