Posts
81
Joined
1/7/2016
Location
GB
Edited Date/Time
3/31/2016 12:05pm
So I picked up a 2002 rm 125 tonight with the plan to strip it and rebuild it from the ground up to race enduros! I thought I'd start a thread here to show the build as it progresses and bounce a few ideas around. I bought the bike with a blown bottom end so I started stripping it down as soon as I got the bike home and have it stripped to a bare frame and have the engine split already! The things a mess inside the motor so I'm currently putting a parts order together! As well as a new crank it looks like she will need a few new gears due to the usual rounded dogs! The clutch basket looks to be in real good condition surprisingly but I plan to change it for a Hinson basket as I run one in my 08 rm 125 and have been really impressed! 
I have an 03 that was one of Davi Millsaps bikes. It still has his suspension stickers on it. I had to totally go through it as somebody (person I bought it from) ran straight gas through it. It has the factory yellow wheels, the works connection glide plate and waterpump case saver welded in, as well as the factory black frame, no grey. Full PC accessories, OS front rotor, full Hinson clutch. I'm running 2 teeth added in the rear, VForce reeds, full PC exhaust, and now I've added a 5oz flywheel weight. The FWW is really a great mod, no downside. I can't notice a reduced rev up, but it reduced the stalling, and it feels like a thicker powerband. I love my little bike.
The Shop
Luxon 4-Post Bar Mounts
$189.95 - $239.95
DeCal Works Huge Plastic Inventory of UFO and Polisport kits.
I also found some damage to the cylinder head which looks as if it's had a major blow up at some point so will have to get this over to my engine builder justin at Gibbs performance to see what he thinks and if it can be repaired when it has some porting and head work done!
Shock coatings, rg3 billit clamps etc..... millsaps factory rm 125
That's a good looking bike you have! Is that a standard motor or any tuning work?
Pit Row
Well tonight I set about trying to bring some life back to the dep pipe that came with the bike! I know these pipes work well with the bike so I decided to tackle the surface rust armed with a wire wheel and wet and dry it's been quite successful! I'll post some after pictures when it's complete! Also stripped the rear silencer which looks as though it's never been re packed
Piston change every 20 hours, Pistonring 10 hours, crank bearings and rod 50 hours..
Be sure to change these items to prevent damaging more geardogs:
25355-37F00, 09440-04003 x2, 09209-05023 x2, 25323-34201, 25324-34201.
These were the parts I changed when i replaced worn gears and a worn "Shaft, drive".. Bike is shifting 100% correctly and is super smooth.
Since you are doing a enduro build you should send away either your cylinder or your head so the bike gets more bottom end because what i´ve felt there is no power down low at all ( a shorter silencer should help a little bit with more "pop" out of the corners)
Tonight I plan to finish cleaning up the pipe and repack the silencer and I might get stuck in to the front forks!
Although it was a funny bike, because after riding it a few times I thought it was bloody fast considering I'd just come off a ktm150 and it didn't seem that much slower, turned out the cheating barstools had been running it as a 144.
Last night I started to blueprint the engine starting with the exhaust port and also marked out the massive mismatch between the cases and the transfer ports! When the motor is going back together I will work out the port timings and durations to see what we can do! Has anyone got any porting specs for the 02 model?
I have also stripped, cleaned and rebuilt the carb which is jetted pretty close to stock right now!
Amongst a few other goodies that turned up today were these drc pegs! As it's an enduro bike I went with steel rather than the aluminium pegs commonly used today! I wanted some titanium raptor pegs but they don't make them for this model
These pegs are the mid height pegs and are slightly wider than stock and look like they will provide plenty of traction so for £36 I just had to give them a try!
I've also spent a bit more time cleaning the Swingarm and linkage, the frame is at my engineers having a bashplate and case savers fabricated and mounts welded to the frame before it gets powder coated! I'm just torn between gloss black or the stock metallic grey!
I've also managed to strip the wheels down ready for the hubs to be powder coated! Whilst cleaning them I discovered that after leaving them soaking in autosmart Ali cleaner they turned to a trick factory looking dark grey colour... I'll post pics tomorrow but this got me thinking!!!
In my left over parts from my 08 build I have the stock top clamp with oversize bar mounts so I am trying to source an 05 onwards lower clamp so I can use the later clamps with twin walls and a 22.5mm offset for improved front end traction!
Now I just need to decide on the colour scheme and would like some input here! I was originally thinking of white plastics with a blue seat and a white and blue version of stock graphics but I'm gradually swaying towards all yellow plastics or yellow with a black back end like my 08 bike!
Being an enduro bike I think that I need more of a stock/factory look rather than an all out bling bike!
Any ideas here guys???
Hit up cooper and ask him what ktm model of raptor foot pegs he ran. They will work. Then let me know what model it is after you buy them because I want to buy them too haha!
Post a reply to: Finished (for now) Rm 125 enduro build!