04 RM125 build for the rest of us...done

BAMX
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BAMX 12/8/2016 9:38pm
12/8/2016 9:38pm
Well, I have been doing a bunch of work that doesn't show like rebuilding the carb, replacing a bunch of bearings and constantly cleaning and refreshing each part. The bike wasn't in bad shape but I figure that it is this far down, I should do the little things now. Finally, I am starting to get through some of the stuff and bolt some parts on the frame. The main tasks today were rebuilding the carb and getting the wheels cleaned up.

The spokes cleaned up with some scotch brite and the same for the rim. The hub on the other hand was really stained and looked bad. I decided to take the Mag Wheel Cleaner to it and give it he oxidized Magnesium Factory look. I am pretty happy with how it came out.


As it sits now.


mattyhamz2 12/8/2016 10:01pm
12/8/2016 10:01pm
Looking good man! How much longer until the motor goes in?
BAMX
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BAMX 12/9/2016 8:30am
12/9/2016 8:30am
mattyhamz2 wrote:
Looking good man! How much longer until the motor goes in?
Thanks....The plan is to get it in by next weekend. I already have the bottom end kit and the rest of the stuff should be here either today or Monday less the piston. Unfortunately, there won't be anything going on with the build until Monday. I have stuff to do today and it is Kurt Caselli ride day at Glen Helen tomorrow so, that pretty much fills out the week.
BAMX
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BAMX 12/13/2016 4:57pm
12/13/2016 4:57pm
Well, my build has been lagging the last couple of days. I have been waiting n engine parts and the downside of buddy deals is that sometimes you have to wait a bit longer. In the meantime, I have been cleaning the last of the parts and fixing a few things. Today, I decided to fancy it up a bit and make some drilled washers.

The Shop

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BAMX
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BAMX 12/15/2016 8:53pm
12/15/2016 8:53pm
I finally had parts and time today so, I started to get the engine together. I didn't take any pics of it beforehand but I went with a Hot Rods complete bottom end kit. For $220 shipped to me, I got 1 new crank, 1 complete Vertex engine gasket and o ring kit. 1 Hot Rods engine seal kit, 1 main bearing and seal set. Everything looks to be of good quality. I checked the crank and it was well within spec using. It had about .0005 run-out using the Vee block method from the Suzuki manual. Suzuki allows for .002" so, it is well on the good side of that. Here is where it is as of this evening.


mikejones202
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mikejones202 12/16/2016 6:04pm
12/16/2016 6:04pm
God those cases look good. Wish I could get mine looking that good!
BAMX
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BAMX 12/16/2016 7:02pm
12/16/2016 7:02pm
Today was pretty productive on the bike. I was able to get the motor back together and put in the bike. It is finally starting to look like something. Of course, I remembered that I forgot to bend the washer over on the clutch hub so, that will have to come back off asap. At least, I didn't put oil in it yet.



The saga with the carb slide continues. I thought that was behind me but Sudco and I had a misunderstanding. He thought I said 250 and sent me the flat slide for a 250. When I went to straighten it out, he informed me that he can't sell me the right slide because it is a Suzuki only part. They did send me a label and take it back. I am still not clear if I can buy the right slide by asking for one from a Yamaha, Honda or Kawasaki since they all came with that carb. I guess that I will have to see. If anyone has bought one of the TMXx slides from somewhere other than OEM, please let me know. Here is the rebuilt carb less the slide.




BAMX
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BAMX 12/19/2016 9:53pm
12/19/2016 9:53pm
Well, today was a lot of assembly and hardware figuring out / cleaning. Since I bought it already apart, I wasn't able to keep the parts organized plus, a lot of the hardware was just wrong. If you ever need to figure out the length of the bolts, partzilla is pretty good. When you click on the part, there is usually both a pic and a description. The other thing of note for the day was installing an RMZ front fender. Hopefully, I can get the thing up and running tomorrow.




mikejones202
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mikejones202 12/20/2016 9:34am
12/20/2016 9:34am
Looks good! I'm hoping to have mine fully back together and running at some point next week!
BAMX
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BAMX 12/23/2016 1:08pm
12/23/2016 1:08pm
I spent some more time on my bike the other day. One of the last things to be rebuilt was the silencer. Since I am planning on racing a couple of enduros with it, it needs a USFS spark arrestor. Fortunately, I was able to find a cheap one on Ebay but it needed an new end cap. Since FMF sells parts, it was no problem and I am into the whole thing for like $90 all repacked and rebuilt. The kit came with everything needed less silicone. Here are the before and after pics.





BAMX
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BAMX 12/27/2016 4:18pm
12/27/2016 4:18pm
Other than a few small things, I am finally done with the build. In the end, I went a couple of hundred over budget. That was mainly because I had a lot of spare time on my hand this time of year. As a result, I made the thing a lot nicer than I had originally planned. It didn't make sense to cheap out on some new plastics, graphics when the rest of it looked essentially new. If budget were the main concern, I would have been able to stay right around the $1000 total. In the end, I ended up with a bike that is mechanically perfect and looks like new for less than I could have bought a nicer complete bike. Then again, I put a ton of time into it.


Michael Scott 12/27/2016 5:09pm
12/27/2016 5:09pm
Damn fine looking bike, especially with that budget
mikejones202
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mikejones202 12/27/2016 6:18pm
12/27/2016 6:18pm
Looks awesome!!! I should have mine done here within the next week or so!
lumpy790
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lumpy790 12/27/2016 8:07pm
12/27/2016 8:07pm
Well done sir!
DF313
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DF313 12/27/2016 8:59pm
12/27/2016 8:59pm
This is exactly the type of thing I would want to do, what do you think you're into it money wise now?
mattyhamz2 12/27/2016 9:48pm
12/27/2016 9:48pm
And to think, that could have been in my garage :,(

Haha! She looks good man!! Post a video when you finally ride it!
BAMX
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BAMX 12/28/2016 8:57am
12/28/2016 8:57am
Thanks for the compliments. I will run a total of my costs and post them up. I spent a bit more than I had planned but not too bad. Some of it was necessary and some of it was because it was turning out so nice.
BAMX
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BAMX 12/28/2016 12:39pm
12/28/2016 12:39pm
Here is the tally. I broke it down to parts that I needed to make it a solid running bike. Then, there is an adder category for things that I did just to make it better and or nicer. Note: I did have some parts like bolts and a used but good rear sprocket and chain. All total, I am into it for around $1500 and a bunch of my labor. It was quite a bit more than my original estimate but not too bad. In hind sight, my estimate was really optimistic as nearly any used bike needs a clutch basket and some bearing kits. Regardless, I don't see any way that you could buy one this clean for what I have into it. Everyone who has seen it in person says that it looks new.

Mandatory
$550 Purchase price
$220 Hot Rods Complete bottom End Kit (crank, main bears, al seal, all gaskets)
$58 Pro X piston kit
$12 OEM top end bearing
$105 Billet Clutch Basket (Ebay)
$70 OEM transmission bearing (may have been Okay but not worth not changing)
$24 All Balls Carb Kit
$47 Bearing connections linkage kit
$27 Bearing Connections steering bearing kit
$20 Pivot Works rear wheel bearing kit
$1 Renthal front sprocket (yes it was on sale for $1 at Cycle Gear)
$25 Misc hardware and hoses that I bought in bulk
$19 Acerbis front fender RMZ
$21 Acerbis rear fender

Total $1199

Extras
$101 Acerbis side panels, shrouds and a RMZ front number plate
$27 N Style graphics kit (Ebay)
$75 Pro Circuit Pipe (Ebay)
$85 FMF Turbine Core 2 (Ebay, spark arrestor for enduros) this includes price of end cap repair kit

Total $288

Pit Row

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DF313
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DF313 12/28/2016 4:25pm
12/28/2016 4:25pm
BAMX wrote:
Here is the tally. I broke it down to parts that I needed to make it a solid running bike. Then, there is an adder category...
Here is the tally. I broke it down to parts that I needed to make it a solid running bike. Then, there is an adder category for things that I did just to make it better and or nicer. Note: I did have some parts like bolts and a used but good rear sprocket and chain. All total, I am into it for around $1500 and a bunch of my labor. It was quite a bit more than my original estimate but not too bad. In hind sight, my estimate was really optimistic as nearly any used bike needs a clutch basket and some bearing kits. Regardless, I don't see any way that you could buy one this clean for what I have into it. Everyone who has seen it in person says that it looks new.

Mandatory
$550 Purchase price
$220 Hot Rods Complete bottom End Kit (crank, main bears, al seal, all gaskets)
$58 Pro X piston kit
$12 OEM top end bearing
$105 Billet Clutch Basket (Ebay)
$70 OEM transmission bearing (may have been Okay but not worth not changing)
$24 All Balls Carb Kit
$47 Bearing connections linkage kit
$27 Bearing Connections steering bearing kit
$20 Pivot Works rear wheel bearing kit
$1 Renthal front sprocket (yes it was on sale for $1 at Cycle Gear)
$25 Misc hardware and hoses that I bought in bulk
$19 Acerbis front fender RMZ
$21 Acerbis rear fender

Total $1199

Extras
$101 Acerbis side panels, shrouds and a RMZ front number plate
$27 N Style graphics kit (Ebay)
$75 Pro Circuit Pipe (Ebay)
$85 FMF Turbine Core 2 (Ebay, spark arrestor for enduros) this includes price of end cap repair kit

Total $288

This is very encouraging, thanks again!
mikejones202
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mikejones202 4/25/2017 12:11pm
4/25/2017 12:11pm
How is she running? Also, how is the hot rods bottom end treating you?

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