kx125 engine rebuild

[xxblackbirdxx]

hi All,
i am currently working on a 2003 KX 125 which i purchased quite cheap (blown engine).
I purchased a new crank and piston and have split the cases. Here is the problem--- The manual suggests using kawi bond to put the cases back together since it does not have a gasket.
I was wondering if there was another substitute available that i could use instead of Kawibond to put the centre cases back together again. (let me know what and were i can get it)
any suggestions?
also,
would any one like me to post pictures of the entire rebuild process? i intend to replace a lot of the stuff and make it brand spanking new (or as close as possible)
already secured some bits and in the process of acquiring a few bits more.
Tell me what you think i should do to this bike.
I have a kx250f that i am using right now and this is just a project to keep me entertained..so time is not an issue.
Thanks and hope someone has afew suggestions

[Katman]

Threebond 1104.

Most bike shops should be able to supply, or source, it.

[barty5]

go to repco an get a tube of threebond best stuff same colour as casings so you dont see it after and can be used every where.

[CRF119]

Yip three bond is the best but not cheap! Last Two stroker i rebuilt for a mate that was on a budget i used Loctite blue max. Still well stuck. A lot of it is in the surface prep to.

Make sure you spend a bit of time making sure the power valve is mint! a lot of two strokes are slow because these gum up after a while. Make sure the carby is spotless while you are at it and inspect reeds.


Its a two stroke not much can go wrong.

[xxblackbirdxx]

thanks guys.
have the manual so will check the power valve and make sure the carbs serviced as well. just purchased a carb rebuild kit (thought i should do that)
Can't wait to ride a 2 stroke again

[gwynfryn]

Go ahead and post details of rebuild, everyone can then have their two cents worth .

[Jinxycat]

would any one like me to post pictures of the entire rebuild process? i intend to replace a lot of the stuff and make it brand spanking new (or as close as possible)


absolutly yes.

[xxblackbirdxx]

I have access to a 2007kx250f front end. Triple clamps, forks and wheel.
Will this fit on a 2003 kx125?
all these bits are sitting at my in-laws place in the south island. I was hoping to upgrade the front end on my kx125(03).
I know they use the same stem bearings and was hoping they would fit.
Can anyone shed some light.
On another note , the engine rebuild is coming along well. have ordered some boyesen case covers and V3 reeds. The pro circuit pipe and muffler are here already. so the hunt for more after market bits continue..
Let me know if you guys think there are bits i could use to improve the bike.

[scott411]

the 07 front end will bolt in, and it is a good improvement, the showa twin chamber forks are amoung the best available, (and is the same mod i want to do when i get a KX125, i want to use a 05 or later on tho)

the bearings are all the same,

the only issues comes from the steering stops, and the alloy frame uses a different system, you have to make up some from of steering stop to stop damage in a crash situation,

[xxblackbirdxx]

thanks scott. i happen to have a 2007 kx250f with me in auckland . will compare the two as far as the stops are concerned. Lucky i have not had the frame powder coated yet.

[gwynfryn]

What are you going to do with the 125 forks? I could be interested but would ideally need the triple tree and front wheel as well for a kdx200 upgrade.

[meteor]

What are you going to do with the 125 forks? I could be interested but would ideally need the triple tree and front wheel as well for a kdx200 upgrade.

Yes me too, keen to put them on my kdx200.
PM me with a price if gwynfryn isn't keen, Thanks.

Pete

[scott411]

those forks / triple clamp will fit straight into the KDX's, but you will have to run the kx front wheel as well, and maybe even the brake as well, (cant remember if the KDX brake caliper fits)

from memory you have to run the KDX steering head bearings,

[gwynfryn]

Its not totally straight forward. The kdx stem has to be pressed into the kx or kxf triples.The calipers will fit but there is dicking around with the brake line and as Scott mentioned the steering stops. If you want to keep the head light thats more work.
Apparently klx forks and triples will bolt straight up without stem issues and you can use the kdx front wheel.They have less flex than the kdx forks and you lose the underhang.
I love my kdx but have reached the limit with the (re sprung) standard forks.

[scott411]

Its not totally straight forward. The kdx stem has to be pressed into the kx or kxf triples.The calipers will fit but there is dicking around with the brake line and as Scott mentioned the steering stops. If you want to keep the head light thats more work.
Apparently klx forks and triples will bolt straight up without stem issues and you can use the kdx front wheel.They have less flex than the kdx forks and you lose the underhang.
I love my kdx but have reached the limit with the (re sprung) standard forks.

yes KLX forks will fit straight in, getting the brake line is fairly easy now as there are a number of places that make brake lines up,

will have to go back and do some research, but from memory i think you are right about the stem,

[gwynfryn]

yes KLX forks will fit straight in, getting the brake line is fairly easy now as there are a number of places that make brake lines up,

will have to go back and do some research, but from memory i think you are right about the stem,

Pretty sure I am correct as i have been thinking about this swap for a while . Pity they never came with these forks as standard .

[tim.napier]

I just use standard gasket paste on mine and it has never let me down. I have found that the rebuild kits off motox parts do the job very well also. I have used a normal plug with all the rebuilds off there and had not hassels yet a genuine kawa let me down pretty quick.

If you have a chance could you send me the rear rim dimensions on your bike. Or if you get sick of your project sell me the rear wheel!!!

[barty5]

if you find they dont fit due to being to long ( but im sure scottie will be right in saying they will fit) do as i did when i put a kx250 front end on an old tt600 take it to your local engineer and have them cut the thread a little longer and cut off the extra cost next to nothing.

[meteor]

Its not totally straight forward. The kdx stem has to be pressed into the kx or kxf triples.The calipers will fit but there is dicking around with the brake line and as Scott mentioned the steering stops. If you want to keep the head light thats more work.
Apparently klx forks and triples will bolt straight up without stem issues and you can use the kdx front wheel.They have less flex than the kdx forks and you lose the underhang.
I love my kdx but have reached the limit with the (re sprung) standard forks.

Thanks, good bit of advice. KDX is my sons, I'm usually on a CRF. I've collected the tank a couple of times due to that underhang in the ruts... really unpleasant.

[xxblackbirdxx]

Got my hands on some YAMABOND (5) for putting the engine cases back together.. will post some photos soon of the rebuild.
As far as the front forks are concerned, want to hold on to them for awhile after the transplant to make sure that the swap is all good .
will let you guys know when i don't need them anymore and want to put them up for sale (needless to say , kiwibikers get first dibs as always).

[barty5]

Got my hands on some YAMABOND (5) for putting the engine cases back together.. will post some photos soon of the rebuild.
As far as the front forks are concerned, want to hold on to them for awhile after the transplant to make sure that the swap is all good .
will let you guys know when i don't need them anymore and want to put them up for sale (needless to say , kiwibikers get first dibs as always).

yamabond kinda has an expensive sound to it

[xxblackbirdxx]

yamabond kinda has an expensive sound to it

Not really. a mate was coming back from the states and he picked some up for me. Only costed around US$9 for the tube. Also asked him to get me the reeds and engine casing covers(boysen).

[xxblackbirdxx]

I just use standard gasket paste on mine and it has never let me down. I have found that the rebuild kits off motox parts do the job very well also. I have used a normal plug with all the rebuilds off there and had not hassels yet a genuine kawa let me down pretty quick.

If you have a chance could you send me the rear rim dimensions on your bike. Or if you get sick of your project sell me the rear wheel!!!

its usually 1.85 x 19. i am retaining the rear wheel, only going to upgrade the front suspension and wheel with a 2007 kxf set up. will let you know if i locate a rear wheel..

[CRF119]

Not really. a mate was coming back from the states and he picked some up for me. Only costed around US$9 for the tube. Also asked him to get me the reeds and engine casing covers(boysen).

As long as it works better then Yamalube lol