So I’ve done a few factory replica / tribute bikes, but never documented one as I went thru the process. The best I’ve done is posted in the Bike Checks once complete. As I’m just getting started on the next project, figured I’d try to keep an up to date post on the process. So here goes…..
As I was getting ready to head out to Salt Lake SX, May 2024, a 1992 CR125 popped up on FB marketplace. It didn’t look great, but maybe wasn’t to bad, so figured I’d take a look given we don’t see these all that often in the Pacific NW.
A 1992 Peak / Splitfire / Pro Circuit MC bike has been high on my list and even though this was one was rough, the price was right and I pulled the trigger. I was told it ran, but had an ignition issue and figured I’d give it a once over when I got back from SLC. Even at that, I knew it would be sitting for a bit as I was knee deep in a 96 CR250 MC project and trying to get a 97 KX125 RC project across the finish line as well. I got home and parts had shown up, a quick afternoon project got spark back to the bike. With that, into the barn it went until I would have time to tackle it full time.
Here is the bike as it rolled out of the trailer in May 2024 and the end goal, McGrath’s 92 CR125.
Even though I was busy on other projects, I was busy collecting parts for this build. Graphics, seat cover, color correct plastics, correct air box all showed up and found there way into the cabinet. One of the biggest challenges to get this build right would be finding the Pro Circuit ignition cover. I reached out to Chuck Davies in the UK, who in my opinion sets the bar for the rest of us who restore these old 2 strokes, and I was in luck. Chuck went above and beyond to help me get my hands on this one and I was just about complete in terms of sourcing parts. Here’s the piece on the MC bike at Pro Circuit, the raw unit and how it finished up after powder coat.
Late September 2024 as I started tearing into the bike. The more I unbolted, the more problems I found. Frame was in miserable shape, bottom rails were cracked and tore up. Swingarm bolt was stuck. Upper fork tubes were rotted out. Rear shock adjuster was frozen. It seemed to go on and on.
Started banging out one project at a time. Tackled the frame first. Had everything fixed and was able to get some specs on frame supports added by PC back in the day, so had those added as well.
Correct air box for build, before restoration.
The Shop
Luxon 4-Post Bar Mounts
$189.95 - $239.95
DeCal Works Huge Plastic Inventory of UFO and Polisport kits.
Linkage before and after vapor blasting and engraving
The original clutch cover on this bike had a cracked mounting hole. I sourced a new one, but had this one refinished / powder coated anyway and had MC sign it to add to the collection.
As luck would have it, another 92 popped up on marketplace in January of this year. After inspection, the forks and shock were in great shape so I bought it. Just got it pulled apart and suspension is out for rebuild. Sent the caps and upper shock adjuster out for anodizing. Here’s bike #2 which will become a later project.
Cylinder after vapor blasting. It is currently out for mods, going with a 134cc big bore kit.
Starting the rebuild process, cases powder coated and ready to go.
What’s the difference between the stock air box and, the one you’re using if you don’t mind? I’m always curious about the one off stuff. Thanks.
Stock 92 CR was white, 92 PC bikes were gray from a 91 CR.
You hv to keep it a 125. 134 hv a totally different sound . The 91 to the end of 125 racing the PC porting was a Rocket ship. 91 Millville Jeremy flew to Rochester Ny. By mistake . He barely made it to Millville. I was flying a lot then for work all alone & kinda of new at it . I related because it’s easy to do, when your tired & stuff. After the 1st turn MC & the other Peak bikes sounded sooo good. It was all square holes the Peak bikes had a sharp pop sound . They sounded killer pulling on the pipe too.
Here, the airbox is white (oem 92)...pre-season?
Agree, a lot of indiscrepancies on these. If you look at the pic of MC’s bike in his trophy room, it’s got white side plates on it. There’s all kinds of little differences photo to photo.
Here’s the swingarm ready to go. Lots of time sanding and vapor blasting, but really happy with how this one turned out. This was an eBay find as the original was severely damaged in the removal of the swingarm bolt and had to be replaced.
And a couple as I’m mocking up plastics. Waiting on suspension and making sure everything is looking ok. Throttle Jockey printed the original graphics kit back in the day and they’ve done an amazing job for me recreating the kit. All the little details are coming together.
Wow, you're doing amazing work here. I've gotta ask though, wouldn't it be worth it to start out with a cleaner example? I'd think the time you're putting in has to be worth more than the difference......unless you just really enjoy it. In that case, resurrecting a pile of junk like that is admirable. Can't wait to see this progress
Yes, it probably would if they were readily available. Certain bikes just seem to be easy to find, others not so much. These 92s have been tough to come by. At the end of the day, I'll be into this one about $1000 more than some I have done that may be a little nicer starting point. This is project #4 for me and even the "nice" one I bought, ended up costing me more money than I anticipated in the end. I like these bikes to be as close to perfect as possible, and try to pay attention to detail. I do realize, it ends up costing me a few more bucks.
There is also something to be said about taking something that is totally roached and destined for the junk yard and giving it a second lease on life. Go look at my 97 RC KX125 in bike checks. I posted a picture of how that one started, makes this starting point look good.
Pit Row
Nice work!
You're doing a great job, man! ✌️
I've always liked the CR125 92, I don't know why, maybe because it has the 90-91 plastic shape in nuclear red with white airbox, or its powerful engine...
I was looking for one for a while to build and race at my local super evo series, but when I found it, it was in such good condition, original and with so few hours that I decided to leave it as it was.
I'll follow your build!
Cheers.
Not sure what’s going on with the site tonight, being a pain in the ass. I have made multiple attempts to post pics of the restored tank. Try this a different way, pics will be on their own.
How it came off the bike…
Resto complete. This one will be display only / no fuel. Have a second one that isn’t quite as nice that will be to run the bike.
Both the front and rear rims on this bike were shot, split at the welds. I was able to find a period correct DID, 19” rear and a good OE 21” front as replacements and they both turned out pretty good. Vapor blasted and powder coated both hubs, relaced with new spokes and nipples and mounted up a set of Bridgestones. As soon as suspension work is done, we’ll get this thing back into rolling form.
Airbox before and after.![]()
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Enjoying the Honda build. Keep up the great work sir.
Engine done. Absolutely new everything. Powder coated cases and covers, vapor blasted everything that was staying raw. New OE Honda crank, all new bearings and seals, Millenium 134cc kit and work over. Carb completely rebuilt. Need to swap out a few bolts so they are correct, but almost there. I snuck in a quick trip to Daytona SX over the weekend, but did a little work Sunday night when I got home and got it back in the bike.
Looking awesome Chris - keep up the good work!
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