1991 KX125 Restoration

Brenduro
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Brenduro
Edited Date/Time 8/27/2022 8:27am











I Bought this bike 10 years ago when I was 15 and FINALLY decided to restore it after sitting in the shed for years doing nothing. I only paid 100 euro for it after the owner had the engine rebuilt and about 30mins of riding later it seized and he had enough and just wanted rid of it, turns out however that who ever built it didn't tighten the clutch basket properly and it slipped out of place, all I had to do was out the basket back in place and it fired right up!

I didn't use it though as I had bought it to restore in the first place and it was in horrible condition. So below is a list of the work that was done (bare in mind that this was my first ever restoration) its still not finished, but 90% complete I reckon

Frame - stripped and powder coated
Engine - stripped, vapour blasted and rebuilt, cylinder was sent to the uk and Re-plated (every single bearing replaced, along with new crank, piston, gaskets etc..) every nut and bolt was replaced with brand new OEM hardware
Suspension - vapour blasted and rebuilt by DMX tuning - new fork upper sourced as mine where rotten
Bearings - Every bearing replaced with allballs bearings, steering, linkage, wheels, swing arm, chain rollers etc..
Wheels - stripped, hubs vapour blasted and laced with new excel spokes and rims finished with new bearing kit F&R, dunlop mx33 tyres/ new tubes, rim locks and rim tape
Fuel - tank sent to the UK to be refurbished
Controls - new renthal bars, allballs throttle/clutch cable, new oem clutch lever/perch, new renthal grips
Brakes - vapour blasted and rebuilt with allballs seal kits including the master cylinders, new braided brake lines, all cable guides replaced with new OEM parts and with OEM screws, new OEM rear disc guard and front NOS disc guard sourced from the states
Drive - new renthal chain and sprockets, new OEM chain guides and Block
Plastics - new UFO kit and Tim Douglas graphics, new evomx seat cover
Exhaust - stripped, vapour blasted and rebuilt
Electrics - all bullet connectors replaced, new coil/spark plug/cap and kill switch
Hardware - every nut and bolt has been replaced with either OEM or specbolt hardware
12
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RAD60
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RAD60 7/7/2020 7:37am
7/7/2020 7:37am
Nice job that is a beautiful looking bike !
Brenduro
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Brenduro 7/7/2020 12:05pm
7/7/2020 12:05pm
RAD60 wrote:
Nice job that is a beautiful looking bike !
Thanks dude 😎👍

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Brenduro
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Brenduro 7/8/2020 10:18am
7/8/2020 10:18am
queen of spodes wrote:
I have some sweet NOS pink plastic for that year KX if interested.
Thanks for the offer but I'm good for now, if I change my mind I'll give you a shout 👍

Don't suppose you have a pink renthal bar pad? 👀👀👀
Manbearpig
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Manbearpig 7/11/2020 8:16am
7/11/2020 8:16am
Brenduro wrote:
[img]https://p.vitalmx.com/photos/forums/2020/07/07/436695/s1200_20181030_172239.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436693/s1200_FB_IMG_1578228724432.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436697/s1200_IMG_20200106_200926.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436694/s1200_IMG_20200109_230149_292.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436701/s1200_IMG_20200627_161746.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436700/s1200_IMG_20200627_162907.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436696/s1200_IMG_6afd2148a17a7146013917b168045efd_V.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436698/s1200_IMG_85007ed5c37b41ba7728e00b9388dc06_V.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436699/s1200_IMG_20200107_WA0001.jpg[/img] I Bought this bike 10 years ago when I was 15 and FINALLY decided to restore it...











I Bought this bike 10 years ago when I was 15 and FINALLY decided to restore it after sitting in the shed for years doing nothing. I only paid 100 euro for it after the owner had the engine rebuilt and about 30mins of riding later it seized and he had enough and just wanted rid of it, turns out however that who ever built it didn't tighten the clutch basket properly and it slipped out of place, all I had to do was out the basket back in place and it fired right up!

I didn't use it though as I had bought it to restore in the first place and it was in horrible condition. So below is a list of the work that was done (bare in mind that this was my first ever restoration) its still not finished, but 90% complete I reckon

Frame - stripped and powder coated
Engine - stripped, vapour blasted and rebuilt, cylinder was sent to the uk and Re-plated (every single bearing replaced, along with new crank, piston, gaskets etc..) every nut and bolt was replaced with brand new OEM hardware
Suspension - vapour blasted and rebuilt by DMX tuning - new fork upper sourced as mine where rotten
Bearings - Every bearing replaced with allballs bearings, steering, linkage, wheels, swing arm, chain rollers etc..
Wheels - stripped, hubs vapour blasted and laced with new excel spokes and rims finished with new bearing kit F&R, dunlop mx33 tyres/ new tubes, rim locks and rim tape
Fuel - tank sent to the UK to be refurbished
Controls - new renthal bars, allballs throttle/clutch cable, new oem clutch lever/perch, new renthal grips
Brakes - vapour blasted and rebuilt with allballs seal kits including the master cylinders, new braided brake lines, all cable guides replaced with new OEM parts and with OEM screws, new OEM rear disc guard and front NOS disc guard sourced from the states
Drive - new renthal chain and sprockets, new OEM chain guides and Block
Plastics - new UFO kit and Tim Douglas graphics, new evomx seat cover
Exhaust - stripped, vapour blasted and rebuilt
Electrics - all bullet connectors replaced, new coil/spark plug/cap and kill switch
Hardware - every nut and bolt has been replaced with either OEM or specbolt hardware
Nice work! Parts for those bikes aren't easy.
Brenduro
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Brenduro 7/12/2020 12:37am
7/12/2020 12:37am
Brenduro wrote:
[img]https://p.vitalmx.com/photos/forums/2020/07/07/436695/s1200_20181030_172239.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436693/s1200_FB_IMG_1578228724432.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436697/s1200_IMG_20200106_200926.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436694/s1200_IMG_20200109_230149_292.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436701/s1200_IMG_20200627_161746.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436700/s1200_IMG_20200627_162907.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436696/s1200_IMG_6afd2148a17a7146013917b168045efd_V.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436698/s1200_IMG_85007ed5c37b41ba7728e00b9388dc06_V.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436699/s1200_IMG_20200107_WA0001.jpg[/img] I Bought this bike 10 years ago when I was 15 and FINALLY decided to restore it...











I Bought this bike 10 years ago when I was 15 and FINALLY decided to restore it after sitting in the shed for years doing nothing. I only paid 100 euro for it after the owner had the engine rebuilt and about 30mins of riding later it seized and he had enough and just wanted rid of it, turns out however that who ever built it didn't tighten the clutch basket properly and it slipped out of place, all I had to do was out the basket back in place and it fired right up!

I didn't use it though as I had bought it to restore in the first place and it was in horrible condition. So below is a list of the work that was done (bare in mind that this was my first ever restoration) its still not finished, but 90% complete I reckon

Frame - stripped and powder coated
Engine - stripped, vapour blasted and rebuilt, cylinder was sent to the uk and Re-plated (every single bearing replaced, along with new crank, piston, gaskets etc..) every nut and bolt was replaced with brand new OEM hardware
Suspension - vapour blasted and rebuilt by DMX tuning - new fork upper sourced as mine where rotten
Bearings - Every bearing replaced with allballs bearings, steering, linkage, wheels, swing arm, chain rollers etc..
Wheels - stripped, hubs vapour blasted and laced with new excel spokes and rims finished with new bearing kit F&R, dunlop mx33 tyres/ new tubes, rim locks and rim tape
Fuel - tank sent to the UK to be refurbished
Controls - new renthal bars, allballs throttle/clutch cable, new oem clutch lever/perch, new renthal grips
Brakes - vapour blasted and rebuilt with allballs seal kits including the master cylinders, new braided brake lines, all cable guides replaced with new OEM parts and with OEM screws, new OEM rear disc guard and front NOS disc guard sourced from the states
Drive - new renthal chain and sprockets, new OEM chain guides and Block
Plastics - new UFO kit and Tim Douglas graphics, new evomx seat cover
Exhaust - stripped, vapour blasted and rebuilt
Electrics - all bullet connectors replaced, new coil/spark plug/cap and kill switch
Hardware - every nut and bolt has been replaced with either OEM or specbolt hardware
Manbearpig wrote:
Nice work! Parts for those bikes aren't easy.
Thank man, truth be told parts arnt as hard as you would think. I had trouble sourcing a disc guard for the front but after about 6 months of searching I finally found a new one! It's currently in the post 😎
2
Manbearpig
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Manbearpig 7/12/2020 10:00am
7/12/2020 10:00am
Brenduro wrote:
[img]https://p.vitalmx.com/photos/forums/2020/07/07/436695/s1200_20181030_172239.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436693/s1200_FB_IMG_1578228724432.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436697/s1200_IMG_20200106_200926.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436694/s1200_IMG_20200109_230149_292.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436701/s1200_IMG_20200627_161746.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436700/s1200_IMG_20200627_162907.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436696/s1200_IMG_6afd2148a17a7146013917b168045efd_V.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436698/s1200_IMG_85007ed5c37b41ba7728e00b9388dc06_V.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2020/07/07/436699/s1200_IMG_20200107_WA0001.jpg[/img] I Bought this bike 10 years ago when I was 15 and FINALLY decided to restore it...











I Bought this bike 10 years ago when I was 15 and FINALLY decided to restore it after sitting in the shed for years doing nothing. I only paid 100 euro for it after the owner had the engine rebuilt and about 30mins of riding later it seized and he had enough and just wanted rid of it, turns out however that who ever built it didn't tighten the clutch basket properly and it slipped out of place, all I had to do was out the basket back in place and it fired right up!

I didn't use it though as I had bought it to restore in the first place and it was in horrible condition. So below is a list of the work that was done (bare in mind that this was my first ever restoration) its still not finished, but 90% complete I reckon

Frame - stripped and powder coated
Engine - stripped, vapour blasted and rebuilt, cylinder was sent to the uk and Re-plated (every single bearing replaced, along with new crank, piston, gaskets etc..) every nut and bolt was replaced with brand new OEM hardware
Suspension - vapour blasted and rebuilt by DMX tuning - new fork upper sourced as mine where rotten
Bearings - Every bearing replaced with allballs bearings, steering, linkage, wheels, swing arm, chain rollers etc..
Wheels - stripped, hubs vapour blasted and laced with new excel spokes and rims finished with new bearing kit F&R, dunlop mx33 tyres/ new tubes, rim locks and rim tape
Fuel - tank sent to the UK to be refurbished
Controls - new renthal bars, allballs throttle/clutch cable, new oem clutch lever/perch, new renthal grips
Brakes - vapour blasted and rebuilt with allballs seal kits including the master cylinders, new braided brake lines, all cable guides replaced with new OEM parts and with OEM screws, new OEM rear disc guard and front NOS disc guard sourced from the states
Drive - new renthal chain and sprockets, new OEM chain guides and Block
Plastics - new UFO kit and Tim Douglas graphics, new evomx seat cover
Exhaust - stripped, vapour blasted and rebuilt
Electrics - all bullet connectors replaced, new coil/spark plug/cap and kill switch
Hardware - every nut and bolt has been replaced with either OEM or specbolt hardware
Manbearpig wrote:
Nice work! Parts for those bikes aren't easy.
Brenduro wrote:
Thank man, truth be told parts arnt as hard as you would think. I had trouble sourcing a disc guard for the front but after about...
Thank man, truth be told parts arnt as hard as you would think. I had trouble sourcing a disc guard for the front but after about 6 months of searching I finally found a new one! It's currently in the post 😎
I had a hard time sourcing the powervalve governor cover and rubber boot but those were the most difficult parts for me to find on mine.
Brenduro
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Brenduro 7/12/2020 10:11am
7/12/2020 10:11am
Manbearpig wrote:
Nice work! Parts for those bikes aren't easy.
Brenduro wrote:
Thank man, truth be told parts arnt as hard as you would think. I had trouble sourcing a disc guard for the front but after about...
Thank man, truth be told parts arnt as hard as you would think. I had trouble sourcing a disc guard for the front but after about 6 months of searching I finally found a new one! It's currently in the post 😎
Manbearpig wrote:
I had a hard time sourcing the powervalve governor cover and rubber boot but those were the most difficult parts for me to find on mine.
The govenor cover is actually the same on the 91 KDX200 which can still be got from kawasaki 😉👍

I'm not sure about the rubber boot however.
1
Manbearpig
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Manbearpig 7/12/2020 10:16am
7/12/2020 10:16am
Brenduro wrote:
The govenor cover is actually the same on the 91 KDX200 which can still be got from kawasaki 😉👍 I'm not sure about the rubber boot...
The govenor cover is actually the same on the 91 KDX200 which can still be got from kawasaki 😉👍

I'm not sure about the rubber boot however.
That's what I ended up finding out on the governor cover as well. It just took some time for me to figure it out.
1
Brenduro
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Brenduro 7/12/2020 10:36am
7/12/2020 10:36am
Brenduro wrote:
The govenor cover is actually the same on the 91 KDX200 which can still be got from kawasaki 😉👍 I'm not sure about the rubber boot...
The govenor cover is actually the same on the 91 KDX200 which can still be got from kawasaki 😉👍

I'm not sure about the rubber boot however.
Manbearpig wrote:
That's what I ended up finding out on the governor cover as well. It just took some time for me to figure it out. [img]https://p.vitalmx.com/photos/forums/2020/07/12/437423/s1200_20200418_210233.jpg[/img]
That's what I ended up finding out on the governor cover as well. It just took some time for me to figure it out.
Ahh dude, thatmxguy on Instagram? I was messaging you back and forth a few months haha.. I deleted my Instagram but I seen your build. Looks killer!!
1
Manbearpig
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Manbearpig 7/12/2020 10:46am
7/12/2020 10:46am
Brenduro wrote:
Ahh dude, thatmxguy on Instagram? I was messaging you back and forth a few months haha.. I deleted my Instagram but I seen your build. Looks...
Ahh dude, thatmxguy on Instagram? I was messaging you back and forth a few months haha.. I deleted my Instagram but I seen your build. Looks killer!!
Haha. I was wondering if this was your build. Its turning out great man. Nice job!
Brenduro
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Brenduro 7/12/2020 10:57am
7/12/2020 10:57am
Brenduro wrote:
Ahh dude, thatmxguy on Instagram? I was messaging you back and forth a few months haha.. I deleted my Instagram but I seen your build. Looks...
Ahh dude, thatmxguy on Instagram? I was messaging you back and forth a few months haha.. I deleted my Instagram but I seen your build. Looks killer!!
Manbearpig wrote:
Haha. I was wondering if this was your build. Its turning out great man. Nice job!
Thanks dude.. Not on the same level as yours but definitely something I'm proud of! Do you have a thread on this for your build?
1
Manbearpig
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Manbearpig 7/13/2020 11:11pm
7/13/2020 11:11pm
Brenduro wrote:
Ahh dude, thatmxguy on Instagram? I was messaging you back and forth a few months haha.. I deleted my Instagram but I seen your build. Looks...
Ahh dude, thatmxguy on Instagram? I was messaging you back and forth a few months haha.. I deleted my Instagram but I seen your build. Looks killer!!
Manbearpig wrote:
Haha. I was wondering if this was your build. Its turning out great man. Nice job!
Brenduro wrote:
Thanks dude.. Not on the same level as yours but definitely something I'm proud of! Do you have a thread on this for your build?
I do. It's the thread called pile of crap kx125 I believe lol
pkiczuk
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pkiczuk 7/14/2020 4:40am
7/14/2020 4:40am
excellent job on this! The pictures being out of order threw me off at first lol, but starting with the side by side comparison of the cleaned up case vs its original "glory" was a great first impression. Absolutely beautiful!

Pit Row

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Brenduro
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Brenduro 7/14/2020 7:14am
7/14/2020 7:14am
Manbearpig wrote:
Haha. I was wondering if this was your build. Its turning out great man. Nice job!
Brenduro wrote:
Thanks dude.. Not on the same level as yours but definitely something I'm proud of! Do you have a thread on this for your build?
Manbearpig wrote:
I do. It's the thread called pile of crap kx125 I believe lol
🤣🤣 I'll check it out!
Brenduro
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Brenduro 7/14/2020 7:16am
7/14/2020 7:16am
pkiczuk wrote:
excellent job on this! The pictures being out of order threw me off at first lol, but starting with the side by side comparison of the...
excellent job on this! The pictures being out of order threw me off at first lol, but starting with the side by side comparison of the cleaned up case vs its original "glory" was a great first impression. Absolutely beautiful!
Thanks a lot man.. Yeah I selected them In the right order but it uploaded them arse ways for some reason! This was my first ever restoration and I've learned a lot, can't wait for the next project what ever that maybe!
seth505
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seth505 7/14/2020 7:39am
7/14/2020 7:39am
So sweet, I want to do a 90s 125 so bad.
chompino
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chompino 7/15/2020 7:28pm
7/15/2020 7:28pm
Awesome job! Seeing this gives me the motivation I need to make some progress on my 93. What color did you use for the swingarm? I'm having a hard time finding the paint I need.
Brenduro
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Brenduro 7/16/2020 2:11am
7/16/2020 2:11am
seth505 wrote:
So sweet, I want to do a 90s 125 so bad.
Yeah the bikes from the 90's are just awesome.. A lot of character behind them!
Brenduro
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Brenduro 7/16/2020 2:18am
7/16/2020 2:18am
chompino wrote:
Awesome job! Seeing this gives me the motivation I need to make some progress on my 93. What color did you use for the swingarm? I'm...
Awesome job! Seeing this gives me the motivation I need to make some progress on my 93. What color did you use for the swingarm? I'm having a hard time finding the paint I need.
Thanks dude!! As I said up above this was my first restoration so I kinda f**ked up on a few things.. One being the swing arm, this is raw. I never done anything to it after I vapour blasted it. In hindsight or the next project I do I'm going clear cerakote the raw parts so that they're protected and easy to clean!

This 125 is going on display so I'm not too concerned 😁
Jayson_Raney 7/28/2022 9:57pm
7/28/2022 9:57pm
queen of spodes wrote:
I have some sweet NOS pink plastic for that year KX if interested.
I know its been awile since you said you had the pink plastics but if you still have them ill gladly buy them,just let me know.
queen of spodes 7/29/2022 7:16am
7/29/2022 7:16am Edited Date/Time 7/29/2022 7:17am
queen of spodes wrote:
I have some sweet NOS pink plastic for that year KX if interested.
Jayson_Raney wrote:
I know its been awile since you said you had the pink plastics but if you still have them ill gladly buy them,just let me know.
I still have the pieces. Note that I don't have a full set - front fender, side/frame guards, and maybe a rear fender. i_dig_dirt@agirlandhertractor.com If I don't ping back in day or so please quote or dm me through vital again.

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