My Hybrid Build

[umberto]

I thought it would be fun to share some pictures of my hybrid build with everyone.  I purchased my bike with the motor installed, but in very rough shape.  It is a 2003 KX 250 frame, 2001 KDX 220 engine with an EFM auto cluch, and Showa A Kit suspension (verified with Pro Circuit). The previous owner is a very nice guy, but did not have the tools to really finish the bike.  The first order of business was to finish the motor mounts, head stay, and pipe mounts.  I apologize I don't have any really good pics of the mounts.  Next came the initial tear down:



I left the triple clamps on the bike, because they had been serviced recently.  I then stripped the frame and primed and painted it.



Then began the reconstruction process.  I put the bike back together:



I added all new plastic from Acerbis, and handlebars and grips from Pro Taper:



Because the EFM clutch does not use a clutch lever, the previous owner rather ingeniously adapted a KTM clutch cylinder to be a left side brake.  It uses a very long braided line and actually works really well. That is until you try to fan the clutch to get yourself out of a hole.  It makes up for this in ease of use on long downhills.  Here is how the brake line is ran around the engine.  There is also no rear brake pedal or master cylinder.  Hard to get used to, but easy to use.



Here is the bike all reassembled.  I painted the pipe using VHT high heat exhaust paint, using a heat gun to cook the paint.  It has held up pretty well, although I have considered Jet Hot coating on it at some point.  I also added N-Style graphics:



After riding it for a few times, I decided to add a headlight (because I could, I guess ).  Here is the final product as it sits today:



I love my little hybrid.  It may not be as fast as my 2004 KX 250, but it is so easy to ride and will climb a tree if asked.  If you are thinking about doing a hybrid, I don't think you will regret it.  

[LukeG]

That is a really nice looking bike!

[umberto]

Thank you LukeG!  It's been a ton of fun to work on and ride. 

[81cr450]

That is d**n nice looking, love the gold rims & forks.

[umberto]

Thank you sir. I can't take credit for the rims and forks.  The previous owner put the rims and forks on the bike.  I got such a great deal on the bike, I was originally going to flip it. Once I rode it, I just couldn't sell it.

[zz3gmc]

First one Ive seen using the 250 frame. Looks good! The 03 and 04 came with gold forks from the factory.

[umberto]

Thank you zz3gmc.  I stared at those forks (and shock) for so long trying to talk myself out of them being the A kit stuff.  I thought they were later model KXF forks.  I eventually called Pro Circuit and verified it with them.  I didn't even notice them when I first saw the bike.  The guy who was selling the bike took me to a local riding area, because he wanted me to ride the bike before I bought it.  He loved the bike so much, he wanted it to have a good home.  When the guy told me they were A Kit on the way back from the riding area, I nearly passed out.  I couldn't get the bike on the trailer fast enough.  In fact I ended up leaving my helmet at his place.  He was such a great guy he went and mailed it back to me.

Funny story, I actually contacted the guy two years earlier when he had the bike for sale with the KX engine in it.  I wanted to trade him a 2002 KX 250 (a little bit nicer bike) for it.  He told me he was going to make a hybrid, which ended up being the bike I bought.  I almost missed out on the hybrid the second time too.  The guy in front of me couldn't drive there until the weekend, and I could go that day.  Sometimes you do luck out.   

[zz3gmc]

A-Kit! Nice!

[oldkoot]

one tip I found out on my 2004/125 build is to buy the same frame year air boot from the KX250 bike. The KX125 is a case reed motor and the boot sits a little to low for the KDX intake.