2003 KTM 125SX: $400 Craigslist Special

Goatsby
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34
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11/20/2017
Location
North Las Vegas, NV US
Edited Date/Time 10/28/2019 4:06am
So I picked up this bike for 400 bucks, missing some bits and low compression. Been heavily considering parting it out as opposed to rebuilding it as some guys recommended me on an orange forum, the argument being "if you part this out and get some more money together you can get something pretty nice." I've been looking.. and it seems the 3k-4k bikes out there are STILL going to need some work, and I'm not quite ready to drop so much down on the hobby, with my skill level the bike probably won't make a difference.

So my goal here is to (hopefully) keep everything under 2 grand including the cost of the bike, and have a nice, fresh, fully rebuilt bike. Won't be tricking it out with all the hard parts, but hopefully I can get it sorted and have it be a nice bike for the next year or 2 until I get a bit better riding and figure out what I really want before dropping a lot on a bike.






As you guys can see..Missing a few bits. Now into the engine! So when I got the bike, did a quick compression test and was low, holding 90 consistently. I got home and pulled the head off and..Brand new piston, never fired. cylinder completely dry, no oil. Which could contribute to the low PSI, but I noticed the power valve actuator arm was rusty, which had me a bit concerned. So I decided to split the cases and figure out what's what before I put the time and effort into sorting the top end. There was some rust on an aftermarket crank, and a circlip dropped in the cases. So at this point I'm already budgeting for a crank rebuild.











Opening up the right side of the engine we find...Water. A good amount of water. And a few pieces of hair! The inner clutch basket has one of the posts snapped off, it will have to be replaced. What's curious about this all is that everything looks brand new, the bearings, there is assembly lube on some of the components, etc. It'll all have to get replaced of course because it was sitting in water, but I'm just curious as to what the hell happened. Someone was in the process of rebuilding but never finished? and left it with the head off and it got moisture? internal leak? Rage quit the project when they were putting it all together and dropped a circlip inside? Next update I should have the tools to split the case and see what else is going on here.

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Acidreamer
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1794
Joined
8/25/2015
Location
Mansfield, OH US
11/20/2017 9:12am
Man id be so pissed if i found all that in a bike i just got. Guess you cant expect anything less for $400. The guy clearly knew he done fucked up on the motor assembly
Goatsby
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34
Joined
11/20/2017
Location
North Las Vegas, NV US
11/20/2017 9:15am
It's not too bad! Well, let me rephrase that lol. It's not unexpected.
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samcampbell
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209
Joined
3/31/2016
Location
Bozeman, MT US
11/20/2017 9:24am
I've got a bunch of parts that will fit your bike that you may be interested in. I've got cylinder heads, cranks that are in good shape, vforce reed cages, etc. Willing to let them go cheap as I have no use for them and would like to help out another member. Send me an email at samcam28@gmail.com If interested.
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Goatsby
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34
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11/20/2017
Location
North Las Vegas, NV US
11/20/2017 9:30am
That would be AWESOME Sam, I'll get in touch with you right now.

The Shop

Barrett57
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2270
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8/31/2010
Location
GB
11/20/2017 10:05am
At least you will have a decent bike when it's done, I had one of these and I remember it being a rocket.
kawiX522
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105
Joined
10/24/2017
Location
Yonkers, NY US
11/20/2017 11:01am
I must say 400$ for that is a pretty great deal, for me at least here in ny. If I could find a bike like that for 400$ near me Id 110% grab it. deff a fun project. Looking forward to seeing the end result!
Goatsby
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34
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11/20/2017
Location
North Las Vegas, NV US
11/20/2017 1:07pm
Sam here helped me out with all kinds of bits, hopefully getting a care package here at the end of the week!
Bruneval
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574
Joined
6/7/2016
Location
Bristol GB
11/20/2017 2:09pm
I remember these bikes when they were new and they were lightning fast! There's also lots and lots of Ohlins and Trax PDS shocks knocking about, so you could even find one of those and work out a way of making it fit it your budget allows. Enjoy the build!
sandman768
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6071
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3/21/2014
Location
Saratoga Springs, NY US
11/20/2017 2:42pm
We all like to see a good rescue build....bring her back!
harescrambled
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1889
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4/1/2008
Location
Warren, OH US
Fantasy
1942nd
11/20/2017 3:14pm
Goatsby wrote:
It's not too bad! Well, let me rephrase that lol. It's not unexpected.
Not to rain on the parade but looking at the pics, it seems like the intake port opposite from the exhaust is cracked on the top edge of it...better look closely at that
Goatsby
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34
Joined
11/20/2017
Location
North Las Vegas, NV US
11/20/2017 3:25pm
So looking at it I think you're right, that puts a bit of a damper on things. Here are some more pics, looks like a chunk is taken from the wall almost. Now that being said, should I spring for a 200 conversion if I'm going to have to replace this either way? I found a guy who has a 2016 200 cylinder with the complete power valve and he wants 400 shipped. I'd still need the crank and head.





JMX82
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1391
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5/9/2013
Location
Hyllykallio FI
11/21/2017 1:51am
Cool bike! You could build a Langston replica out of it.

FWYT
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3308
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5/25/2014
Location
San Diego, CA US
11/23/2017 8:13am
Sounds like a sweet deal!!

Man, it's weird what some people do with their bikes, isn't it? Like, did the bro leave the motor out in
in the rain disassembled or something? Tweakers!
Goatsby
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34
Joined
11/20/2017
Location
North Las Vegas, NV US
11/23/2017 8:52am
JMX82, that's what I was thinking, that or either update the plastics style with a new airbox/subframe/tank. I'll have to be replacing due to someone cutting holes in them/ old age. Chip, that seems like exactly what happened lol. Someone left the bike outside with no head on.

Parts coming in:

Almost new 200 cylinder and head, 2016.
Brand new hot rods bottom end kit.
New Wiseco 200 piston kit.
A box of parts from a fellow VitalMX member.

Quickly running out of budget, but we'll make do!
shuggs
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1574
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8/6/2008
Location
Dunfermline GB
11/23/2017 9:23am
If your going 200 route you HAVE to build it, loved mine

Looking forward to see how this goes
Goatsby
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34
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11/20/2017
Location
North Las Vegas, NV US
11/23/2017 9:30am
What kind of set up did you run on yours?
JMX82
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1391
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5/9/2013
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Hyllykallio FI
11/23/2017 10:36am
It seems that you already have radiator shrouds, front fender and front number plate from 2006 model. You could use subframe, airbox, seat and rear fender from a 2004-2006 model to complete the look. I think it's direct bolt on modification and was quite popular back In the day.
FWYT
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3308
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5/25/2014
Location
San Diego, CA US
11/23/2017 9:50pm
You're going to make it a 200??!!! Hell, yeah!!! It will RULE!
I have a 200EXC and it is friggin AWESOME. Perfect motor. You will love it!!
JMX82
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5/9/2013
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Hyllykallio FI
11/23/2017 11:03pm
If you choose to go with newer style plastics you could build a Tyla Rattray replica.



6
JMX82
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1391
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5/9/2013
Location
Hyllykallio FI
11/24/2017 12:24pm
I think this will be useful when you start rebuilding the engine Engine manual
1
Goatsby
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34
Joined
11/20/2017
Location
North Las Vegas, NV US
11/24/2017 3:08pm
That looks sweet JMX82. And thanks for the manual, I found the same one online, should definitely come in handy!
Goatsby
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34
Joined
11/20/2017
Location
North Las Vegas, NV US
11/25/2017 12:01pm
I got a package in, it looks nice. Just waiting on the new bottom end kit.

Goatsby
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34
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11/20/2017
Location
North Las Vegas, NV US
11/27/2017 9:27am
Waiting for more parts still, completely forgot about the transmission bearings as well, so those will get ordered today. Did this in the meantime! Waiting for it to cure a few days, and then going to wrap the high wear areas in a clear protective vinyl.



Rockinar
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1064
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9/16/2016
Location
Katy, TX US
11/28/2017 1:43am
Hold on to that cylinder. It might be repairible. I had one that looked worse than that. Sent it to Ken O Konner Racing. He TIG welded it, machined it down then replated it. Looked brand new when I got it back.
Goatsby
Posts
34
Joined
11/20/2017
Location
North Las Vegas, NV US
11/28/2017 7:00am
I've gone up to a 200 bore so it won't be much use unfortunately. It's very clean though, same with the power valve. I'll probably have them up on ebay today.
Goatsby
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34
Joined
11/20/2017
Location
North Las Vegas, NV US
12/26/2017 9:12am
A long awaited update! I got busy and couldn't put much work into the bike for a while but I'm back at it now.

New bottom end bits arrived, and the cases are sealed.



I was ready to put the whole engine back together today, and was quite surprised the previous owner's attempt at rebuilding the engine didn't result in any lost parts when...



The Driver Hub of the kickstarter is missing! I posted on a KTM specific board to see if anyone has that piece laying around who could give me some measurements. I'd like to make one today out of aluminum just to bypass waiting 2 weeks from the OEM supplier for a 3 dollar part to finish the engine.

FarleyMX25
Posts
215
Joined
10/2/2017
Location
Harrison, TN US
1/9/2018 7:39am
Goatsby wrote:
Waiting for more parts still, completely forgot about the transmission bearings as well, so those will get ordered today. Did this in the meantime! Waiting for...
Waiting for more parts still, completely forgot about the transmission bearings as well, so those will get ordered today. Did this in the meantime! Waiting for it to cure a few days, and then going to wrap the high wear areas in a clear protective vinyl.



What paint did you use? i have the same model bike im planning to frame up also
Goatsby
Posts
34
Joined
11/20/2017
Location
North Las Vegas, NV US
1/31/2018 7:36pm
Sorry I just saw your post! I rattle canned it with krylon and primer. It looks good at 10 feet but there is orange peel. If I were to do it again I'd use an HLVP and sand blast it. If I wasn't a cheap bastard and would do it again I'd have it powdercoated. But it'll do.

Long time no update guys, was in the UK for a month staying with my girlfriend. Got back a week ago and starting to work on the bike again. This is the current state of things. A quick question on that note - is the reed cage gasket supposed to go between the case and the reed cage, or the reed cage and the carb boot? The gasket doesn't fit on the OEM cage case side, but does on an older V-force reed set I have. Tomorrow I'll hang the engine in the frame and do a compression test.



Goatsby
Posts
34
Joined
11/20/2017
Location
North Las Vegas, NV US
2/1/2018 8:14am
Had a bit of an unexpected development, time to look for a new swingarm!

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