Harold Bawlzangya Racing

Harold Bawlzangya Racing

If I only knew what I was doing . . .


Patience finally paid off

I’ve had an eBay search set-up for at least 2 years for a JD jet kit for the KDX engines.  The other day this finally showed up and I jumped on it:


The only parts that really matter out of the kit:


Hinson-Rekluse EXP autoclutch conversion for sale


Used Hinson billet-proof basket modified and bolted to KDX gear.  Modified hub and pressure plate.  5 new clutch friction and steels.  Directions on installation and EXP set-up.

Does not include the Rekluse EXP auto-clutch.  I can give you the popular bikes to look for if you are interested in getting a used EXP.

Contact me HERE if interested.

Hybrid Airbox – Version 3.0

This is even more of a hybrid airbox as I’m introducing Honda parts into the mix.  I got most of what I needed from this auction:

eBayHondaAirBox - Copy

(click picture to enlarge)

After making a lot of aluminum shavings, here are the parts needed to put this together:


(click picture to enlarge)

The key to making the Honda boot work is this sealing/locking plate:


(click picture to enlarge)

By no means perfect, but not too shabby for free-hand with a router.  There was no way that I was going to be able to make a ring that would be the exact height, width and radius to match the groove in the airboot.  I decided to make the raised ring a little narrower and shorter so that with the help of some black RTV, I would have a perfect fit and seal between the plate and airboot.


(click picture to enlarge)

It fits in to the Honda filter holder like this:


(click picture to enlarge)

This is the groove the raised ring of the locking plate will be fitting into with the black RTV:


(click picture to enlarge)

Some RTV on the back of the sealing/locking plate and filter holder:

LockingPlateRTV (2)

(click picture to enlarge)

LockingPlateRTV (1)

(click picture to enlarge)

And then RTV in the grove of the air boot:


(click picture to enlarge)

All put together:

HondaHybridBootAssembled (2)

(click picture to enlarge)

HondaHybridBootAssembled (1)

(click picture to enlarge)

I had plenty of squeeze-out on the inside and outside of the boot, so I am confident I have this all sealed up.

Installing the Pro Seal gasket:

ProSealHybridAirboot (2)

(click picture to enlarge)

ProSealHybridAirboot (1)

(click picture to enlarge)

Installed in the KX airbox:

HondaHybridAirBoxFinished (3)

(click picture to enlarge)

HondaHybridAirBoxFinished (2)

(click picture to enlarge)

HondaHybridAirBoxFinished (1)

(click picture to enlarge)

OilingAirFilter (2)

(click picture to enlarge)

OilingAirFilter (1)

(click picture to enlarge)


HybridAirBoxInstalled (1)

(click picture to enlarge)

HybridAirBoxInstalled (5)

(click picture to enlarge)

New Rad Valve:

HybridAirBoxInstalled (3)

(click picture to enlarge)

Plenty of room around the shock:

HybridAirBoxInstalled (2)

(click picture to enlarge)

And now the money shot – the boot clamps right onto the carb without any modifications to the boot or carb.

HybridAirBoxInstalled (4)

(click picture to enlarge)

Well it finally happened . . .

I got kicked off one of the internets for not having enough pictures of beer or other types of alcohol in my pictures.  The last time I got warning was almost exactly two years ago.  Hopefully this picture will keep the other internet monitors happy.



Hybrid air box for sale

KDX – KX hybrid air box – $80 plus Priority shipping to lower 48

This air box will fit 2003, 2004-2005 KX frames.  The KDX air boot has been mated to the airbox.  Comes with a Twin Air and Moose airfilter.  Also comes with the PC Racing Pro Seal gasket.  Details of this air box set-up can be seen HERE.

HybridAirBox (5)  HybridAirBox (4)

HybridAirBox (3)  HybridAirBox (2)

HybridAirBox (7)  HybridAirBox (1)


EXP testing

So this is how I set-up the EXP a few days ago.  It has been too long since I rode my own bike with the EXP (485 days to be exact), so I can’t confidently say I remember how the medium wedge/red spring combo felt.  But from my questionable memory, I can’t say that the heavy wedge/silver spring combination felt much different.

But one new thing I did was put the EXP on the opposite side of the clutch pack.  I thought I would try this out since the KDX clutch expands opposite most other clutches.  So this is how I positioned it a few days ago:

220RekluseEXPTesting (5)

(click picture to enlarge)

I thought I would try to move it back to where I normally have the EXP positioned (2nd from the top) to see if it made any difference.  Before laying it over, I put the transmission in 6th gear:

220RekluseEXPTesting (2)

(click picture to enlarge)

Made sure I cleared the spokes:

220RekluseEXPTesting (3)

(click picture to enlarge)

220RekluseEXPTesting (4)

(click picture to enlarge)

I flipped the position of the EXP and put it back in:

220RekluseEXPTesting (1)

(click picture to enlarge)

I only lost a few drops of ATF in the process.  Without touching the cable tension, it slipped less.  Not a dramatic difference, but it was better.  I’m sure there is some physics thing happening that I don’t understand, but it looks like I will keep it there.

I adjusted the cable tension some more and got even less slipping.  I am assuming the the change in EXP position allowed me to fine tune the cable tension to get even better performance.   The engine is a little muddy right off idle, making it difficult tell if the clutch is slipping or if the engine is sputtering.  That is how I’m going to leave it until I can get a couple of smaller pilot jets.

220 break in

It has been 485 days since I last rode my hybrid.  I was getting eager to start-up the new engine and didn’t want to take any more time putting on plastics.  So with all the essential parts bolted in place, I’m ready to break in the 220.


(click picture to enlarge)

Before I put the carb on, I checked to see what jets I had in there the last time it was used on the 200.  155 main, 40 pilot and I set the clip 4 down on the DEK needle.  I knew the needle and main would be rich, but I didn’t want to take any chances during break in.


(click picture to enlarge)

Fresh gas, Yamalube mixed at 32:1 and the engine started on the 4th kick.  After letting it warm up until the radiators got hot, I got on the bike and took an easy ride for about 30 seconds just to make sure everything sounded good.  Then I rode it as hard as I could up and down the side yard for about 10 minutes.  The engine ran very well, but got a little smokey near WOT.  I figured that was a combination of the rich jetting and the excess premix I dumped into the bottom end during assembly.

I parked the bike and noticed a small drip of anti-freeze.  I traced that back to a hose clamp that I didn’t have tightened down enough.  While I was at it, I pulled the slide and moved the clip up one position to lean it out a little.


(click picture to enlarge)

I started the bike up again to check to make sure I took care of the anti-freeze leak.  While the engine was warming back up, I checked to see if the 40 pilot jet was correct.  Turns out a 40 is too rich as I was about 2 1/4 turns on the air screw to get the highest idle.  A 38 pilot is on the shopping list now.

I did a couple of laps around the yard and the change to the needle definitely made a positive change.

I figured any more riding today would be pressing my luck with the neighbors.  Tomorrow will be plastics and messing around with the Rekluse.


(click picture to enlarge)