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When I had stripped everything from the KX the frame looked fragile. I swear a xr100 frame looked stronger. So I made some custom gussets . I could have kept going but I had to stop somewhere.
These are pics of the frame before I had it powder coated. These pics should have been with the first post to be in order but I just found where I had hosted them.
I didn't even know Kawi Kid Jay and he had offered to weld the gussets on for me. I ended up working a deal with a welder for carpentry work and I didn't have to bother him. But I thought that was very generous that he was going to help someone he never met.
The swing arm area of the frame was fragile looking. I took some time making custom gussets and had them welded
This was under the tank
The bottom of the frame started out as small corner bracing and it turned into a glide plate
It's not Rob Bouchers skid plate. But coming from me, I'm impressed.
I would get nearly finished and take it apart and start over again. I don't know what my problem was. It's not like it was something difficult.
I have had fun with restoring it. I just want to ride some now the warm weather is here.
Hope to hear your solution. Thank you in advance.
My 1984 Kawasaki KX125:
https://p.vitalmx.com/photos/users/25684/photos/89478/s1600_1984_Kawasa…
My shock had low hours but still had light damping after rebuilding. I ended up buying a Noleen shock. As far as complete shocks go it's a bargain but to me the construction looks a good as any or better. Early single shocks weren't hardened and the body wore out quickly. I went for the complete shock because it's my only bike and I wanted a good handling bike to keep me from hitting the ground. I was looking for a 84 when I found my bike. The 84 KX is my favorite production bike ever
If you are going to gusset your frame it will be different on the 84. The frames are totally different . I imagine the swing arm pivot is still feeble. Take pics before you remove everything from the frame so you don't weld anything where it interferes with the rest of the bike. When you have the bare frame sitting there you won't believe how frail it looks. If I were to do it again I'd add more strength in the steering head area.
Come to find out the 17 year old kid that I purchased my 1984 Kawasaki KX125 from put a Suzuki RM125 shock on the bike (not sure which year), so I had actually just emailed Clark Jones about the cost of building a shock just yesterday.
I "may" also obtain a 1984 Kawasaki KX250 either tomorrow or Monday, and I would of course like to have them both set up the same way, so if I got Mr. Jones to build me a shock for my 125 then I would also have him build a matching set up for the 250 "if" I grab it within the next 2 days.
I luckily don't think that I will need any Frame Gusseting. The frame is in perfect condition, no cracks, no sagging foot pegs. If you see from the photo, there isn't even very much stock frame paint worn off. I obtained the bike from a 17 year old kid that I guess didn't ride it hard at all, and he got it from an Old Lady, and it had been her bike since new. It was on the STOCK PISTON, Lol. My riding style these days is pretty much avoid anything big, and find the smoothest line, I guess people would call it smooth or fluid, so I don't do much damage or put much stress on bikes.
Once again, thank you so very much for the reply. It is so greatly appreciated. Your bike is absolutely amazing. Great build.
You may want to call Clark. I find it easy to get ahold of him on the phone. Email is more of a delay. Shocks are 895.00 plus shipping. They come with a Ohlins Spring too. And he knows how to fit the hose and reservoir, it's a little cramped on the UniTrax It's easy to spend 400 making a old shock work. For another 500 you get a modern shock with compression and rebound adjustments. And it's as good as anything made 30 years after
Starting with a fresh frame is even better. Check the thickness of the metal that the swing arm bolts into. I'll bets it's really thin on the 84. If you strengthen that area now you will always have strait foot pegs..
Once they become all fatigued you will always be chasing cracks.
And get that 250
I am laid off right now, and have 2 projects right now, and also want to grab this 1984 KX250 so I am putting my Mercedes Benz up for sale to get the bikes completed the way that I want.
I will pick up the phone and call Clark on Tuesday. A pretty good Suspension Company here on the West Coast quoted me $399.95 to completely rebuild and revalve a stock 1984 KX125 shock (when I thought I had the stock shock), so yes sir $895 is not bad for a completely custom build shock.
I am going to go in the garage right now and take a look at the metal that the swing arm bolts onto.
Once again great build, and thank you for the replies, as they are very helpful.
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