2002 KDX/CR Hybrid build
- Thread starter sixstringsteve
- Start date
sixstringsteve
Well-Known Member
- Location
- UT
oh, cool. I didn't know there was a tool for that. That's exactly what I need. If the good ol' vice grips/heating/pounding doesn't work I'll have to borrow those from you unimog.
sixstringsteve
Well-Known Member
- Location
- UT
I went to my local vatozone and they had a stud remover kit. Thanks for the offer Unimog, it looks like I found one in time.
sixstringsteve
Well-Known Member
- Location
- UT
I installed the head studs and the head last night. Then I attacked the rear suspension linkage. It's the old 90/10 rule. Spend 90% of your time on 10% of the work. I've been fighting two of the bearings in the linkage. I got one out, and after 20 min of a chisel and a hammer and a vice, the last one is still stuck in there. I'll get it out tonight.
I'll try to get the radiator situation figured out tonight. Once I've got the radiators working, I can start putting stuff back together.
I wanted to be done by Saturday afternoon so I could take it on a trail ride, but I think that's a bit ambitious. I'd need a few helpers friday night to meet that reality, and I'd also need everything else to go super smooth. It'll probably be another 2 weeks 'till it's done.
I'll try to get the radiator situation figured out tonight. Once I've got the radiators working, I can start putting stuff back together.
I wanted to be done by Saturday afternoon so I could take it on a trail ride, but I think that's a bit ambitious. I'd need a few helpers friday night to meet that reality, and I'd also need everything else to go super smooth. It'll probably be another 2 weeks 'till it's done.
sixstringsteve
Well-Known Member
- Location
- UT
I took tomorrow off work so I could get close to finished on this thing. I need to get the throttle cable worked out.
It looks like the CR airbox mounts right to the KDX carb. It's too good to be true, so I must be missing something.
The pipe is going to be a tight fit, but I think it's going to work out nicely. My two biggest issues tomorrow are the radiator and carb. Once those are done, the rest should come together nicely.
It looks like the CR airbox mounts right to the KDX carb. It's too good to be true, so I must be missing something.
The pipe is going to be a tight fit, but I think it's going to work out nicely. My two biggest issues tomorrow are the radiator and carb. Once those are done, the rest should come together nicely.
- Location
- Smithfield Utah
What's going on with the throttle cable? The stock Honda cable should work fine in that carb if routing is the issue. I used my stock one when I swapped a Keihin onto my 02...
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sixstringsteve
Well-Known Member
- Location
- UT
The kdx has a funky cap that screws on to the carb. This cap takes up more slack in the cable than I have. Are all throttle cables and housing the same length?
- Location
- Smithfield Utah
Can you bottom out the adjustment on the top of the cap and also bottom out the adjuster on the twist throttle? There are a million different throttle cable lengths and sizes for various years makes and models which makes it a pain when mix matching.
sixstringsteve
Well-Known Member
- Location
- UT
dang. I think I'm just going to have to go get a new kdx throttle cable. I thought they were interchangeable.
It's 90% together. The pipe is hitting the frame in a few spots. That's going to be annoying, but I'd like to just get it out on the trail and slowly work out the kinks. I'm surprised with how well everything is fitting. The air box --> carb fitting is awfully close to the shock, but it's not touching. Aside from the exhaust, everything is looking like it's meant to be there.
Here's what's left to do today:
- make radiators work
- install tank
- get a new throttle cable
- wiring the headlight/taillight/turn signals/horn, etc
- bleed brakes, adjust clutch, throttle, etc
- add fluids
- take it for a ride
Looks like it might be ridable by tonight. Anyone want to go for a short ride later tonight in the AF/Alpine area?
It's 90% together. The pipe is hitting the frame in a few spots. That's going to be annoying, but I'd like to just get it out on the trail and slowly work out the kinks. I'm surprised with how well everything is fitting. The air box --> carb fitting is awfully close to the shock, but it's not touching. Aside from the exhaust, everything is looking like it's meant to be there.
Here's what's left to do today:
- make radiators work
- install tank
- get a new throttle cable
- wiring the headlight/taillight/turn signals/horn, etc
- bleed brakes, adjust clutch, throttle, etc
- add fluids
- take it for a ride
Looks like it might be ridable by tonight. Anyone want to go for a short ride later tonight in the AF/Alpine area?
- Location
- Smithfield Utah
:chris: more pics more pics!
Don't be afraid to dent the pipe in for frame/engine clearance. A lot of bikes come this way.
EDIT> I should have said dent in the expansion chamber if you must... Don't dent in the stinger (small part that attaches to the silencer).
Don't be afraid to dent the pipe in for frame/engine clearance. A lot of bikes come this way.
EDIT> I should have said dent in the expansion chamber if you must... Don't dent in the stinger (small part that attaches to the silencer).
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sixstringsteve
Well-Known Member
- Location
- UT
I think I'll be denting it up once I figure out how it does. There are about 4 place I'll need to dent it. What's the best way to dent it? Chisel and a hammer?
Corban_White
Well-Known Member
- Location
- Payson, AZ
Just a hammer. No chisel
If you still need a cable, RMATV sells the Motion Pro cables and it's in stock for your KDX.
sixstringsteve
Well-Known Member
- Location
- UT
thanks Caleb. I ran down to RMATV and picked up a clutch cable and a throttle cable.
sixstringsteve
Well-Known Member
- Location
- UT
I got a ton done today, but the bike still isn't finished. it's 95% there. I lost my slide spring (due to my messy garage).
Unfortunately the chain I ordered was too short. A stock kdx chain is a 108. A stock CR125 chain is a 110, so I figured a 112 would be plenty. I was wrong. I really need a 116, or maybe even a 118 to be safe. Hopefully I can swap 'em, or at least return the one i bought.
Here's what's left:
- find slide spring and install/adjust throttle cable
- adjust clutch cable
- mount and route electronics (really only a 5 min job)
- install gas tank
- make pipe mounts
- put oil in it.
- get a new chain
Unfortunately the chain I ordered was too short. A stock kdx chain is a 108. A stock CR125 chain is a 110, so I figured a 112 would be plenty. I was wrong. I really need a 116, or maybe even a 118 to be safe. Hopefully I can swap 'em, or at least return the one i bought.
Here's what's left:
- find slide spring and install/adjust throttle cable
- adjust clutch cable
- mount and route electronics (really only a 5 min job)
- install gas tank
- make pipe mounts
- put oil in it.
- get a new chain
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sixstringsteve
Well-Known Member
- Location
- UT
i'm sure my 112 is too short. I probably need a 114, but I'd rather order a 116 and cut out two links just to be safe.
sixstringsteve
Well-Known Member
- Location
- UT
Here ya go Andrew, I know you're dying for some pics:
cylinder sleeve looks new-ish:
I made my own upper head motor mounts out of the old CR mounts:
cylinder sleeve looks new-ish:
I made my own upper head motor mounts out of the old CR mounts:
sixstringsteve
Well-Known Member
- Location
- UT
next up was getting the pipe installed.
It didn't quite fit in between the wishbone part of the front lower frame. So I had to grind the welds a bit:
And that was just enough to fit:
It didn't quite fit in between the wishbone part of the front lower frame. So I had to grind the welds a bit:
And that was just enough to fit: