1993 KX125 Build

Finally started to tear into this, the contest that Cam and others are hosting was a good motivation to get it started.



Teardown has gone pretty smoothly so far







I have found that there was a major sealing issue between the pipe and the silencer which has blown carbon all over the back of the cases, carb, air boot, shock, linkage, swingarm etc. On my RMs, there is a rubber seal between pipe and silencer, didn't have one on this bike. Is it missing or did these not come with those seals?

Also, any tips to get the carbon cleaned off the cases? pretty much everything is going to go in the parts washer, but trying to avoid splitting cases if I can.



Second problem, tab for the lower radiator mount on the left hand side of the bike has snapped off





Third problem, bolts holding the Works Connection frame guards on were pretty rusted, were able to crack 3 out of 4 loose, was struggling with the 4th and just thinking about adding some heat and penetrating oil when she rounded off on me. First time I have ever done that, so need to get to the store and buy and extractor.



Last thing, I have never seen a spark plug do this before.

I'm in the process of rebuilding a 93 KX 125 as well, for the second time.

https://www.vitalmx.com/forums/Bike-Builds,46/1993-KX-125,1368642

Make sure you check your frame over. My frame had a few cracks in it, this is why I'm rebuilding it again. I've learned a lot rebuilding it, if you need any help let me know.

jt.hagerty wrote:

I'm in the process of rebuilding a 93 KX 125 as well, for the second time.

https://www.vitalmx.com/forums/Bike-Builds,46/1993-KX-125,1368642

Make sure you check your frame over. My frame had a few cracks in it, this is why I'm rebuilding it again. I've learned a lot rebuilding it, if you need any help let me know.

Yeah I've gone through your build, looks great! Do you have any sort of rubber seal between expansion chamber and silencer? After I go through all the work to get this cleaned up, I don't want to blow carbon all over everything again

ArizonaKevin wrote:

Yeah I've gone through your build, looks great! Do you have any sort of rubber seal between expansion chamber and silencer? After I go through all the work to get this cleaned up, I don't want to blow carbon all over everything again

I didn't when I first built it, it was tuned pretty good and didn't have oil blow everywhere. I just ordered a rubber connector for a late model KTM 125, I've used these on other builds and they work great.

Heater hose and 2 zipties work.