2002 CR125 Build *Complete*

Trust me, I love the look of a factory pipe but just don't want to deal with the maintenance on them, especially if I go out on a multi-day trip and can't immediately clean it after riding. I'm hoping the nickel plating makes them somewhat resilient to rust.

These updates are getting tougher! Progress is slowing down since I'm so busy with work. I also just sold that CR250 from one of my previous posts. That was a mini project which distracted me from initially rebuilding my CR125. I wish I could've kept and ridden it but just didn't have the time/money/space.

Check out the before/after on this thing. I promise it's more than just a graphics kit that went into it.


Anyhow this thread is about my 125!

I found a used right radiator in great condition on eBay to replace my totally wrecked one. I'm trying to come up with something to straighten out the left radiator since it's still in decent shape. Other than that, I got my CDI on and the footpegs mounted back onto the frame for the time being. I'm thinking of getting some aftermarket pegs at some point, probably the Moose ones to match my YZ.


I should be making a bit more progress soon.

Dang dude, good call! I just picked up a set in good condition off eBay for $19. Thanks for the heads up, always a fan of the wider platforms.

I wasn't happy with the left radiator since I had to bend the louver quite a bit to fit it.
Not in terrible shape, but still bent enough to bug me:


So I figured what the heck and took a shot at straightening it. I think it was pretty successful, and I was able to get the louver on without any problems.

I decided to [attempt to] refinish the existing chain guide and make it somewhat clean.


Good enough for me:


Onward....

Back to the swingarm nightmare, I had to re-tap and helicoil that hole that we drilled out earlier on the mill. The threads weren't sharp enough to really hold the screw.


Steel insert:


Finally got the swingarm back together with all the new hardware. Pretty annoyed with those manufacturing defects that essentially look like cracks. I've seen them on other CRs too.


Hopefully another update tomorrow.

With the swingarm ready it was time to work on the linkage.


Refinished with some scotch brite. The smaller knuckle was tough because I was running out of elbow grease.


And here we are at the bike again. I know I'll have to take it off since it's an engine mount but I'll deal with that later.

I got a used 2000 CR250 seat to replace the SDG tall (semi-tall?) seat that was on the bike, and got to work fitting on a black N style gripper seat for it. Not a huge fan of look of the ribbed seat covers.


Of course, I ran into issues here too. Looks like I found a defect in the seat cover. There was a fold in the fabric and the machine just sewed right over it, which reduced the size of the front pocket and nearly made it impossible to fit the cover on.


I then decided to just cut off all the excess material around the seam to give myself more room to work with.


After wrestling with the cover for several hours (no kidding), I finally got it on. I've never had this much trouble getting a seat cover on before. I think N style needs to look at their quality process and their design again. The seat I got also has this extra lump at the front which I may need to cut off if I ever redo the cover.

My updates are getting smaller lately due to time constraints so I'll hold off on posting for a couple days. Doesn't seem to be too much interest here anyway. Still pushing forward!

Dang, sorry about that guys! Didn't realize so many were following. I'll do my best to continue with the smaller updates until I get more time.

@Richard Tease II Yeah I was bummed, I'd never broken an extractor bit before. The thing was really in there.

I learned that my parts should be back from powdercoat next week so I can finally work on the front end.

I scrubbed and aluminum brightened the subframe, unfortunately I don't have really any before pictures. Thing was filthy though.
I started getting a little antsy to get my graphics on so I started with the shrouds after scrubbing the gas tank and fuel petcock. I'm going for a darker/redder color scheme. Not too much white but definitely not too much black either. These mostly fit the bill. I added an aluminum gas cap since my plastic one was stripped (as it was on the 250). The aluminum one was about the same price as the plastic so I went for it.


Ignore the creases in the seat cover, this picture was taken before it was fully stapled. Just tried to get an idea of what this'll look like. You can also ever so slightly see the Works Connection radiator braces. Definitely don't trust them to do a thing from a side hit, but at least any moving hits should protect the rads. Other than that, just new hardware on the shroud (collars/bolts) for that extra bit of freshness.

Found some pics for a before/after!




Here's what the gas tank used to look like:

I got those new/used pegs off the 2013+ CRFs and they dropped right in, just as @wsc96 said. Thanks dude! Super cheap and simple upgrade.


I got to work on cleaning up the rear caliper & master cylinder, new hardware, fresh grease, etc. Got a trick Galfer black stainless braided line and mounted everything all up. I have another one coming in for the front.


I noticed I wasn't able to bolt my left shroud into my radiator, and saw that the nut plate was broken. I swapped it for one off the bent radiator I took off and had no more problems.


In addition, I got all my rad hoses mounted up with fresh hose clamps. Definitely a fan of the blue color especially once my spring comes in.


You'll also notice the newer CRF black rear brake guards, just for that extra touch of new-ness.

Big update today!

I popped the back wheel in just to see what it would look like and ended up just teasing myself with it.


Also come on Honda, what gives?! I haven't adjusted the chain on this in so long I guess I forgot the chain block adjusting mark is nearly completely covered. They could've at least engraved along the side too!


I forgot to explain how I got to that air box picture from before. Well I never thought I'd say this but I...rebuilt my air box. Yeah, you read that right. I tried scrubbing it as best as I could and still couldn't get it up to my standards.


So I decided to break it down:


Now that's a clean air box!


I ordered a 2007 air boot only to find that it's identical to my 2002 (presumably) air boot. What gives?


Before reassembling the box I added a PC racing inner seal.


Riveted the box back up and added the air box seal from the 03+ CRs. Can't believe the motor didn't grenade even after riding in sand.


Anxiously waiting for my parts to come back from paint so I can at least finish the front of the bike. My plan is to finish the whole bike without the motor since I don't have space to work on everything at once.

Hey buddy, I got them from RMATVMC as if I was ordering for the 2016 CRF450R. I'm definitely a fan of how they look over the white ones.

I think they started the black ones in 2015. Parts are 43330-KRN-A70ZB (disk guard) and 43340-MEN-A20 (caliper guard). Good look with your CR125 rebuild, I'll be following it!

Got the box mounted into the subframe along with the new airboot and the white air dam thing which I was missing. The old air boot had some dust in it, again pretty surprised the motor didn't blow!


And here we are, back at the bike and with the box graphics installed. I scrubbed the box with scotch brite to get rid of the scars and make it smooth for the graphics to adhere.


You'll also see a new black mud guard to replace the gross white one I had. Next thing is the rear fender. Really running out of things to do without those triple clamps.