Posts
219
Joined
12/6/2010
Location
White Lake, MI
US
Started this build this weekend. My brother and I are both restoring 125's to do some local sprint enduros and ultimately the Jack Pine Enduro on later this year. About to head out of state for a week but 80% of the parts are already on order, the full tear down is done, frame will get prepped and painted next Sunday the 29th, then the following weekend the top end will get done and reassembly of everything we can get to/have the parts for. Its turning into quite an extensive build for an old 125 but its going to be fun!
Build List:
Engine:
Pro X clutch kit
Weisco Racer Elite Piston
Cometic Gaskets
VForce 3 Reeds
Controls:
Pro Taper Universial Bar mounts
Pro Taper ACF Bars - for more room to cut them a bit and fit full wrap handguards
Works Connection Elite Clutch Perch
Acerbis X-Factor hand Guards
Pro Taper 1/3 waffle soft grips
Galfer Steel braided front and rear brake lines
Front and Rear Master cylinder rebuild
Front and Rear Caliper rebuild
Protection:
Acerbis Carbon Front Disk Guard
Devol Radiator Guards
Devol Rear Disk Guard
Works Connection Rear Caliper guard
Hyde Racing Skid Plate
Body (Frame will be painted black):
UFO Black Replica plastics
Acerbis Updated front fender and number plate in grey
Graphics will be a custom black/grey with blue accents to match some of the blue bling parts we are putting on both bikes.
Suspension:
TBD
Does anyone know how to get the specs for the linkage bearings? The bike is at our race shop which is an hour away from where I live... I should have pressed them out and brought them with me but from research I'd like to go to a bearing supply place and piece together high quality bearings vs buying an aftermarket kit... problem is i cant find the specs online anywhere for each bearing/bushing.
Its not just the bearings but the seals and inner shafts. It will cost you 4-5x more through a bearing shop and you still wont have a complete kit.
If you're that much against aftermarket, go buy OEM. The parts fiche lists the bearing numbers as well.
I saw someone build this a while ago. Looks sweet.
The Shop
Free shipping: VITALMX
DeCal Works Huge Plastic Inventory of UFO and Polisport kits.
Luxon 4-Post Bar Mounts
$189.95 - $239.95
Yup, i ended up just sucking it up and ordering a pivot works kit for now. We will see how it holds up.
That is a really sweet build! I wont be going with lights on it but setting it up for sprint enduros and some local off road races that don't require lighting so mainly just getting it set up with the necessary protection for the woods and as optimal for fast woods riding as a 125 can be.
Made a little progress yesterday. Unpackaged a bunch of the parts that showed up, prepped the frame and began painting. One set back discovering that the new pegs i ordered for a newer 450 wont actually fit this bike without some grinding and fab work unlike what I had read in another thread on here. Those will be going back and I will just settle for the IMS pegs that are available for this specific bike. Next weekend ill have 2 full days to really make some progress and get this thing back to looking like a dirtbike again.
Some more progress made this weekend. Was hoping for more but the weekend got cut short so here is where we got:
Fresh Top end installed
Engine cleaned up, no its not factory clean or vapor blast clean but id bet its the cleanest this thing has been in over 20years. Took some serious time to remove the previous owners rattle can job on the engine and power valve covers.
VForce 3 reeds swapped out for a Boyesen Rad Valve to take care of the leaky air boot
Engine in the frame
Radiators, new blue hoses and devol radiator guards installed.
Found out i need to order some new bolts for the power valve cover and some new swingarm bearings that i thought just needed repacked with grease.
Peep my brothers 03 RM125 build going on in the background as well.
Got a couple busy weeks ahead so not sure when ill get back up to the shop next
If you run a KDX200/220 sub-frame, you can run the stock over-flow system…including it's very accommodating good-sized bottle that’s even been used for extra gas on the Team Green Baja - Best in the Desert bikes.
Those “frame loops” that the KDX frame has can be seen on some 500s used for MX (SR frames) and the aforementioned Baja racers, too.
There was a point in time…I don’t remember how long ago…that we were able to run the 200s lighting coils. We also had a few KDX gear boxes in some of our 125 engines…again…I don’t recall if that was waaaay back in the late 80s-early 90s…or newer…?
You've got a really nice project going on!
hmmm very interesting info and i'm going to dig into this for sure! Thanks man, I'm excited to get it into the woods and show some people that a 125 is not only still fun to ride but can be competitive locally in the woods too!
Finalized the graphics for both my KX build and my brothers RM build. Going with this scheme to make both bikes match for the Jack Pine Enduro even though they are different brands. Can always bring back the Kawi green later if wanted.
Will be another week before I am back up to the shop to make some more progress.
Sorry for the lack of updates... Been out of town a lot for training at my new job but the bike is almost finished! Few small things left to do and we will be ready for the enduro season! First ride will be this weekend just to work out any kinks from the build.
Looks great. I always wanted a custom graphic kit like what yours. But I went with the same ol pc build.
Awesome you have a matching RM!
The RM is actually my brothers. We built these bikes to run the Michigan Sprint Enduro Series and the Jack Pine Enduro race this summer. Will be fun to mix it up with all the modern bikes on 125s lol
Nice!! Blue moose handguards would look good imo.
I actually went with a set of Black Enduro Engineering handguards for a couple reasons.
1) They are local and an amazing group of guys.
2) They have mounts that mount directly to the clutch and brake perch which was key because of the ridiculous design of the oversized fuel tank on these bikes, typical style mounts will hit the tank with the bars at about 75% turned
3) Their open ended guards are really impressive and so strong/impact resistant that I will be running them instead of full wraps.
4) Thought about Blue but went with black just to tone things down a bit. This build actually turned out to have a bit more pop than originally planned lol
Post a reply to: 2002 KX125 Off Road Build