1991 KX125 restoration project...

[CHOPPA]

Not sure why i want to but i can so i will!

1991 KX125, its already a very tidy bike considering its 18 years old! Picked it up for $1200 feel a bit bad cause it would have been a great bike for a first bike or whatever. Once its done though my apprentice will have a good little bike to ride....

Will keep you updated...

[flyingcr250]

Not sure why i want to but i can so i will!

1991 KX125, its already a very tidy bike considering its 18 years old! Picked it up for $1200 feel a bit bad cause it would have been a great bike for a first bike or whatever. Once its done though my apprentice will have a good little bike to ride....

Will keep you updated...

ive thought of restoring an old bike, gotta be easier than cars............

[4stroke]

thats a nice lil project, and a nice stack of trophies in the second pic :first:

[Ktmboy]

We used to fit them with aftermarket Answer mufflers etc. Made one hell of a difference.
These days I suppose a FMF knarly(depending on what type of riding he will do) pipe would be a good addition.

Nice bit of jewellery in the back ground you have there Choppa.
You holding out on your achievements?

[4stroke]

most of them are circuit trophies tho arent they?

[CHOPPA]

most of them are circuit trophies tho arent they?

lol thats just the bottom shelf.... Na only got about 4 RR trophys...

Frame ready for powder coating, wheels just have to be stripped but letting the crc do its work over night!

Does anyone know if powder coating with the heat wreck the wheel bearings??

[CHOPPA]

We used to fit them with aftermarket Answer mufflers etc. Made one hell of a difference.
These days I suppose a FMF knarly(depending on what type of riding he will do) pipe would be a good addition.


Ive had a look around id say a pro circuit system is going to be the ticket, mainly just for looks..

[barty5]

lol thats just the bottom shelf.... Na only got about 4 RR trophys...

Frame ready for powder coating, wheels just have to be stripped but letting the crc do its work over night!

Does anyone know if powder coating with the heat wreck the wheel bearings??

the heat wont but the pre soak and deagrease tey go through before painting willl more than likely ( its some rather wicked solvents that are heated in the last part as well as some deep soaking prior)

[Taz]

The 91 KX125 was my first MXer. Was quite weak compared to the 91 CR125 :(

[theblacksmith]

Sweet project mate - Im working on an 87 KX125.
New bearings fitted throughout motor- new cylinder sleeve fitted. Needs a new piston kit and motor will be done.
Frame is stripped,next job on that is to weld and re-drill holes in footpeg brackets(bit sloppy as they are)- was thinking of getting it sandblasted as well.
Seat is re-covered ready.
I need to get a new suspension linkage kit and swing arm bearing kit. Front forks need an overhaul as well.Just going as I can afford at the moment(very slow lol)
The tank I have for it has a small leak so Im after another plastic tank for it. If anyone knows where I can get parts for this model - any info would be appreciated.
I will take some photos as i start re-assembling it.

[Taz]

Sweet project mate - Im working on an 87 KX125.
New bearings fitted throughout motor- new cylinder sleeve fitted. Needs a new piston kit and motor will be done.
Frame is stripped,next job on that is to weld and re-drill holes in footpeg brackets(bit sloppy as they are)- was thinking of getting it sandblasted as well.
Seat is re-covered ready.
I need to get a new suspension linkage kit and swing arm bearing kit. Front forks need an overhaul as well.Just going as I can afford at the moment(very slow lol)
The tank I have for it has a small leak so Im after another plastic tank for it. If anyone knows where I can get parts for this model - any info would be appreciated.
I will take some photos as i start re-assembling it.

If the leak is somewhere not visible you could repair it.

[vr4king]

Ive had a look around id say a pro circuit system is going to be the ticket, mainly just for looks..


Email this guy he sems to have a few pipes come up on tardme he may have one to suit his username is "kiwi_racer1" on tardme
I think hes the NZ distrubuter for them

[CHOPPA]

Email this guy he sems to have a few pipes come up on tardme he may have one to suit his username is "kiwi_racer1" on tardme
I think hes the NZ distrubuter for them

Yeah thats crown kiwi, i emailed them but didnt hear back so i ordered a system from ebay and some other bits and pieces :)

[crazyxr250rider]

Don't powder coat the wheels yuck.... Polish the rims with auto solv and fit new spokes.

[CHOPPA]

Don't powder coat the wheels yuck.... Polish the rims with auto solv and fit new spokes.

Just gonna buy new rims and spokes and get the hubs powder coated or anodised... Spose i could save some money and just polish the rims...

[Reckless]

Yeah thats crown kiwi, i emailed them but didnt hear back so i ordered a system from ebay and some other bits and pieces :)

Nice project chop! You probably be better off with the poor NZ$ vs US$ than the Crown Kiwi margin mate from the rumours I hear! Pics when is finished please! You gonna use it as a rider or keep it in the shed mate??

[honda_power]

Just gonna buy new rims and spokes and get the hubs powder coated or anodised... Spose i could save some money and just polish the rims...

wtf... just how much money are you planning on spending on the old girl? I just dont get the point of blinging an old bike up with coloured rims and all that...

allways wanted to do something like this though... def gonna get into it when im done with my bloody student year with no money...

wouldnt it be better to paint the frame than powdercoat? that shit scratches off like crazy. and for the hubs if you were gonna 'bling' it, wouldnt anodising be better?

will def. keep an eye on this... I gotta old MX100 [my first bike] sitting around that i suppose i could fix up a little

[scott411]

hey Choppa, i thought you wold be doing a 95 KTM125 given the chance, see if you can get it to start backwards again,

[CHOPPA]

wtf... just how much money are you planning on spending on the old girl? I just dont get the point of blinging an old bike up with coloured rims and all that...

allways wanted to do something like this though... def gonna get into it when im done with my bloody student year with no money...

wouldnt it be better to paint the frame than powdercoat? that shit scratches off like crazy. and for the hubs if you were gonna 'bling' it, wouldnt anodising be better?

will def. keep an eye on this... I gotta old MX100 [my first bike] sitting around that i suppose i could fix up a little

Probably wont end up riding it to be honest... Powder coating lasts better then paint though, not going to bling it up. More wanting to make it original if possibly...


hey Choppa, i thought you wold be doing a 95 KTM125 given the chance, see if you can get it to start backwards again,

hahaha funny you say that! We had that sitting in our shed for about 7 years so i tidied it up and took it to a maize paddock day with my overalls on, it went hard! oh i couldnt get it into reverse again though!

[carver]

apperentice?
MR most bins wins himself?

[CHOPPA]

apperentice?
MR most bins wins himself?

lol yeah he only lasted 1 1/2 laps before he crashed broke clutch perch bent the bars and knocked himself out!

[barty5]

onlt thing with poeder coaing i found when i did my TT600 was that it dont flex so when the frame dose it cracks. painting could be a better option with a flexing agent added.

[honda_power]

a guy i ride with painted his 07 RM125s frame pink with car paint... been like that for ages and hasnt cracked, boots have worn a bit off as expected with all painted frames though

[carver]

lol yeah he only lasted 1 1/2 laps before he crashed broke clutch perch bent the bars and knocked himself out!

haha, he told me about that.
pathos is way worse on a dirt bike, but both of them are road riders through and through!

[flyingcr250]

a guy i ride with painted his 07 RM125s frame pink with car paint... been like that for ages and hasnt cracked, boots have worn a bit off as expected with all painted frames though

im going to be giving my bike the big pull down in a couple of months, new piston bearings and what not, going to repaint the frame too and put that 3M stonechip stuff on were the paint has worn off.

[Sidewinder]

thats a nice lil project, and a nice stack of trophies in the second pic :first:

thats only the bottom self lol

[carver]

thats only the bottom self lol

you should let pathos ride it

[Sidewinder]

lol yeah he only lasted 1 1/2 laps before he crashed broke clutch perch bent the bars and knocked himself out!

haha then what? took the RMZ450 for a blast after?

[carver]

haha then what? took the RMZ450 for a blast after?

just put him straight on the 450.

he can handle it, if you can handle getting it up the bank he throws it over!:gob: :angry2:

[CHOPPA]

haha then what? took the RMZ450 for a blast after?

haha yeah you rode the 450 way better! Gotta look out for those breaking bumps lol

[Sidewinder]

haha yeah you rode the 450 way better! Gotta look out for those breaking bumps lol

haha yea.................. need to try all sports so i can try and get some pussy!

[telliman]

hey choppa, i have a never been used before PC platnum pipe thats been laying around the garage for a few years that you can have for the project, can hook up at a ride somtime or can just courier if ya like,
i bought it for my 91 then descovered it was a 125 in a 250 frame so didnt fit and has hung in the garage for 3-4 years.

[CHOPPA]

hey choppa, i have a never been used before PC platnum pipe thats been laying around the garage for a few years that you can have for the project, can hook up at a ride somtime or can just courier if ya like,
i bought it for my 91 then descovered it was a 125 in a 250 frame so didnt fit and has hung in the garage for 3-4 years.

Oh that sucks man!! I ordered one off ebay! lol Be keen to catch up for a ride sometime though, give me a pm when your heading out ;)

[carver]

Oh that sucks man!! I ordered one off ebay! lol Be keen to catch up for a ride sometime though, give me a pm when your heading out ;)

i got my TY350 up and going..
might be a bit slow though

[flyingcr250]

my boss has a '95 kdx200 in a 125 frame i was thinking of fixing up.

[CHOPPA]

Hey guys, what would you do?? Ive just stripped the top end off the engine and the side casings. The engine looks mint! The barrel hasnt got any scores or anything and the bottom end doesnt have any slop up and down but it does have it side to side which i think is normal..?

Would you rebuild the bottom end just for the sake of it??

I havnt decided if ill actually ride it but if i do id be pretty hard on a 125 i think

[carver]

Hey guys, what would you do?? Ive just stripped the top end off the engine and the side casings. The engine looks mint! The barrel hasnt got any scores or anything and the bottom end doesnt have any slop up and down but it does have it side to side which i think is normal..?

Would you rebuild the bottom end just for the sake of it??

I havnt decided if ill actually ride it but if i do id be pretty hard on a 125 i think

let sidewinder ride it and bin it off a bank and rebuild it after that?

[CHOPPA]

let sidewinder ride it and bin it off a bank and rebuild it after that?

haha at the speed he rides on the dirt i wouldnt even change the rings! :Pokey:

[carver]

haha at the speed he rides on the dirt i wouldnt even change the rings! :Pokey:

if the engine is sweet, ya might as well leave it :2thumbsup

[barty5]

Hey guys, what would you do?? Ive just stripped the top end off the engine and the side casings. The engine looks mint! The barrel hasnt got any scores or anything and the bottom end doesnt have any slop up and down but it does have it side to side which i think is normal..?

Would you rebuild the bottom end just for the sake of it??

I havnt decided if ill actually ride it but if i do id be pretty hard on a 125 i think

pends on budget and how much sideways your talkin

[CHOPPA]

pends on budget and how much sideways your talkin

As far as budget goes... An extra $400 is not gonna be the end of the world but its just a hassle. Lots of sideways...

[cheese]

Well better to be safe?? Can you just get a hot crank kit?

[CHOPPA]

Well better to be safe?? Can you just get a hot crank kit?

Havnt asked any nz wholesalers but cant find a complete crank. Found hotrods big end bearings, seals and conrod kit...?

Anything else id need? What about the bearings in gearbox? Dont really wanna replace every moving part just for the sake of it but id be pissed if they failed

[Sidewinder]

Havnt asked any nz wholesalers but cant find a complete crank. Found hotrods big end bearings, seals and conrod kit...?

Anything else id need? What about the bearings in gearbox? Dont really wanna replace every moving part just for the sake of it but id be pissed if they failed

bro it will get broken to much to worry about the engine! its gona have bent bars and forks, snapped levers, broken plastics after like 2 laps!

[CHOPPA]

bro it will get broken to much to worry about the engine! its gona have bent bars and forks, snapped levers, broken plastics after like 2 laps!

Thats why we are gonna buy that 500... Then you will be bent broken and snapped!!

[Reckless]

Havnt asked any nz wholesalers but cant find a complete crank. Found hotrods big end bearings, seals and conrod kit...?

Anything else id need? What about the bearings in gearbox? Dont really wanna replace every moving part just for the sake of it but id be pissed if they failed

Hey Chop, The bearings in the box, any wear on the dogs and the crank shaft bearings and seals are probably more the points you'll find the most deterioration rather than the big end. So if you gonna spilt the cases best to have a look at the lot.

You probably won't find a new crank shaft it is quite rare to have to! A kit is the normal way! You split the halves off the pin, then press them back together over the new rod and bearing. Then the tricky bit is to get the correct tolerances on width and aligning the halves up. This is best done by someone with experience and a well set up rig and dial gauge. Its either right or wrong!

It is usual to do all or nothing. You basically decide to split the cases and do the lot because the big end needs replacing or you have a gear box problem? You wouldn't necessarily do the big end just for the sake of it, if you had a gearbox problem either unless it looked bad.

The big end will have alot of side to side standard its the up and down (or slop in the bearing) that's of concern. If it looks all good and the box was changin gears etc fine, I don't think I'd touch it till it needs it, unless you just wanna do the lot for piece of minds sake!
Just my 2c hope it helps!

[CHOPPA]

Hey Chop, The bearings in the box, any wear on the dogs and the crank shaft bearings and seals are probably more the points you'll find the most deterioration rather than the big end. So if you gonna spilt the cases best to have a look at the lot.

You probably won't find a new crank shaft it is quite rare to have to! A kit is the normal way! You split the halves off the pin, then press them back together over the new rod and bearing. Then the tricky bit is to get the correct tolerances on width and aligning the halves up. This is best done by someone with experience and a well set up rig and dial gauge. Its either right or wrong!

It is usual to do all or nothing. You basically decide to split the cases and do the lot because the big end needs replacing or you have a gear box problem? You wouldn't necessarily do the big end just for the sake of it, if you had a gearbox problem either unless it looked bad.

The big end will have alot of side to side standard its the up and down (or slop in the bearing) that's of concern. If it looks all good and the box was changin gears etc fine, I don't think I'd touch it till it needs it, unless you just wanna do the lot for piece of minds sake!
Just my 2c hope it helps!

Yeah mate very helpful thanks!! Yeah if i open it up then id be inclined to do everything....

Full gasket and seal kit, rod kit including big and little bearings and crank pin and main bearings only $136 but then i gotta get gearbox bearings and someone to do it and balance the crank. Im pretty fussy though so i might be better to bite the bullet!!

[Reckless]

Yeah mate very helpful thanks!! Yeah if i open it up then id be inclined to do everything....

Full gasket and seal kit, rod kit including big and little bearings and crank pin only $136 but then i gotta get gearbox bearings and someone to do it and balance the crank. Im pretty fussy though so i might be better to bite the bullet!!

I think the main reason we sometimes don't always do everything in a 2smoker like in a car engine or four stroke bike is they are so simple to strip down each time.
Your call Choppa, but be prepared on a bike that vintage to have to replace a few bits in there that maybe could have still gone for ever, especially if your fussy.
But then you'll know its done. Your probably thinking best to fix it now rather than after it breaks as its an older bike! Better be a keeper this bike after this much work!! LOL!!!
Cheers mate cya out there!

[barty5]

Yeah mate very helpful thanks!! Yeah if i open it up then id be inclined to do everything....

Full gasket and seal kit, rod kit including big and little bearings and crank pin and main bearings only $136 but then i gotta get gearbox bearings and someone to do it and balance the crank. Im pretty fussy though so i might be better to bite the bullet!!

If you pull it down take out all the bearing and take them to the local bearing shop they should be able to supply most of them. Most automotive bearings are V spec. Same thing ive done to all the bikes ive rebuilt works out heaps cheaper beats payin for a (dealer) labeled box. You may find the odd one they cant do though.

[barty5]

just priced up a Prox rod kit they retail at $209 but sure could shave a good chunk of that. A full crank can price in the morning but lookin more like a good $400 normal retail.

[CHOPPA]

Cheers guys! Bugger it, it looks mint so ill leave it! Never used to replace any bottom end bearings in my race bikes till they siezed lol Dont intend to ride this much cause i have the 450 anywho

[Reckless]

yeh mate have a look at the crank shaft seals if you get keen though. If they leak you'll loose fuel pressure up through the transfer ports. Thats bad for performance. If you take the clutch basket or whatever off to do this you can have a good tug on the end of the crank shafts to see how the big end bearings are and if there is any side movement as well. Then you'll have done pretty much all you can without splitting the cases apart.

[CHOPPA]

yeh mate have a look at the crank shaft seals if you get keen though. If they leak you'll loose fuel pressure up through the transfer ports. Thats bad for performance. If you take the clutch basket or whatever off to do this you can have a good tug on the end of the crank shafts to see how the big end bearings are and if there is any side movement as well. Then you'll have done pretty much all you can without splitting the cases apart.

Thanks for your help!! Cheers mate, i just heard back from the previous owner and the bottom end has been rebuilt at some stage so that has helped me make my decision! Back together it goes!

I cant believe the condition of inside this 18 yr old engine, no where on the clutch basket and everything looks mint! Bore is score free powervalves are mint, the old piston looked like brand new and it has new carbon reeds

[cheese]

you're probably that lucky guy that got the bike after the previous owner spent heaps on it.

[oldskool]

Probably owned by one of those people who likes to admire their bike, dreams about it, but hardly ever rides it. :Pokey:

[barty5]

Probably owned by one of those people who likes to admire their bike, dreams about it, but hardly ever rides it. :Pokey:

Are you picking on cheese or hemex???

[Hemex]

Probably owned by one of those people who likes to admire their bike, dreams about it, but hardly ever rides it. :Pokey:



Are you picking on cheese or hemex???

:Pokey:
haahaha... 8 hours in the last 5 weeks... I'm leaving this non-riders club..

[cheese]

Well its a bit hard to ride my bike from China now isn't it.

[oldskool]

Well its a bit hard to ride my bike from China now isn't it.
:clap: because it keeps breaking down! :lol:

[Hemex]

Well its a bit hard to ride my bike from China now isn't it.

We'll start a 2 man team and show these oldies what riding is all about... give me a year... hahahaaha

EDIT: oldies = Oldstools and the GNCC winner for age group 35-39... :laugh:

[oldskool]

We'll start a 2 man team and show these oldies what riding is all about... give me a year... hahahaaha
make it 2 just to be on the safe side, by then you shoulda gotten a round tuit

[Hemex]

make it 2 just to be on the safe side, by then you shoulda gotten a round tuit

hahaha You think? I'll leave it as a year which includes, a 6 month contingency... What do ya reckon?!
All those punctuations must have barty confused..:lol:
sneak preview of a barty nightmare...,.;:'"";';':!!!???...

[oldskool]

hahaha You think? I'll leave it as a year which includes, a 6 month contingency... What do ya reckon?!
All those punctuations must have barty confused..:lol:
sneak preview of a barty nightmare...,.;:'"";';':!!!???...
hahaha you're funny but the irony is, he may have the last laugh when you go calling on him, balls cupped in hand, for some help with your restoration project!! :buggerd:

[Hemex]

hahaha you're funny but the irony is, he may have the last laugh when you go calling on him, balls cupped in hand, for some help with your restoration project!! :buggerd:

:shit::thud:nothing a case of JD's and coke wont resolve... Aye barty?:whistle: This time not sugar free either!!

[barty5]

:shit::thud:nothing a case of JD's and coke wont resolve... Aye barty?:whistle: This time not sugar free either!!

Im keepin th sugar free shit just for you. Going to make you drink one.
Ps my dreams dont need punctuation (speach not required)

[Hemex]

Im keepin th sugar free shit just for you. Going to make you drink one.
Ps my dreams dont need punctuation (speach not required)

:lol::lol: alright!
I made rupe have one the other night....Don't think he even realised ..haaha

no speech...but the punctuations show up...just like that..without anything around, floating in the air...hoardes of exclamations and comma's..
Hope I didnt scare you.. :laugh:

[Sammikins]

:lol::lol: alright!
I made rupe have one the other night....Don't think he even realised ..haaha

no speech...but the punctuations show up...just like that..without anything around, floating in the air...hoardes of exclamations and comma's..
Hope I didnt scare you.. :laugh:

ew sounds like it would scare me... imagine getting chased by a big exclamation mark.... :eek5:

[Sammikins]

We'll start a 2 man team and show these oldies what riding is all about... give me a year... hahahaaha

EDIT: oldies = Oldstools and the GNCC winner for age group 35-39... :laugh:

Ooh Ooh my calculations tell me that by 1 years time I will be a member of the Crusty Demons... so can we make it a 3 person team? :hug:

[That Guy]

Awesome!

I raced one back in 91 when they were new - it was a great bike then and even today a fresh top end and good rider wouldn't be shamed in club mx on it.

The only things I can remember we did to them (other than normal maintenance stuff and replacing the mild steel handlebars that bikes used to come with) was fit a more narrow front mud guard, 'cause the standard one was huge and when muddy it would get overloaded with mud and break, and for some reason the sub-frame used to crack around the welds after about 5 meets...check the sub frame carefully!

Look forward to seeing the finished article.

[CHOPPA]

Awesome!

I raced one back in 91 when they were new - it was a great bike then and even today a fresh top end and good rider wouldn't be shamed in club mx on it.

The only things I can remember we did to them (other than normal maintenance stuff and replacing the mild steel handlebars that bikes used to come with) was fit a more narrow front mud guard, 'cause the standard one was huge and when muddy it would get overloaded with mud and break, and for some reason the sub-frame used to crack around the welds after about 5 meets...check the sub frame carefully!

Look forward to seeing the finished article.

Yep got some after market bars and had the subframe repaired haha Just got the frame away getting chromed, yeah i know not original but its what was dont back in the day haha

I had a brand new 91 kx80 i was a bit young for a 125 then and a bit big for an 80 now haha

[CHOPPA]

Weather has been a bit shite lately so just finishing off the 125, thought i better put up some progress pics before i get it finished. The 500 has to be ready by saturday for the dash for cash too!

Excuse the mess by shed is tiny!!!!

[tommorth]

looking good braaap