KX Riders
Maintenance & Technical => KX250 / KX125 => Topic started by: MXonaKawi on June 23, 2013, 12:52:16 PM
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Here we are at the beginning. I'm hoping that you can all enjoy watching this rebuild come to fruition as much as I've watched those of others who have inspired me to do this!
When I picked the bike up, it was poorly maintained. many bolts were incorrect sizes, not for a motorcycle, seized or stripped. The plastics were shot with ugly stickers everywhere, and the bike was just downright dirty. But it started!
So I took it completely apart, and cleaned each part while I made a 'parts list' for replacement parts and chucked the ones that were really bad.
Started on 5/4/2013 - 2000 Kawasaki KX 125
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Taking it apart was definitely an education on all of the parts that I had forgotten about and also a valuable experience that I'm sure will help me in the future when maintaining and working on this bike!
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...
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Some parts just needed to go and in their place came newer shinier ones.
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i could have continued shopping forever but the chassis was most important so I needed to rehab it asap so that I would have something to attach all the new goodies to.
So since the subframe was worn and the threads were raped by a previous owner, I decided to go for an AC Racing subframe to replace it.
(http://i40.tinypic.com/1zm1csz.jpg)
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The frame was in surprisingly good condition so I decided to Powder Coat it. I originally wanted to go with black but many have gone that route and to be honest, it just doesn't pop. It almost looks like it's not even there. Plus I am planning on going with black side panels and possibly black radiator shrouds so too much black tends to look too dark, bland and plain. So I decided to go with Gloss White.
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My swingarm was in great shape with the exception of an ugly dent on top underneath where the chain is located. At $450, OEM replacement was not an option. Similar ones on ebay had badly scuffed sides which seemed worse to me as it is more visible. So thanks to Sandblaster's suggestion I got the dented filled in by a welder for $25 bucks. The guy who did my powder coating brought it next door to his shop to fabricator and he was glad to help out.
I originally wanted to get the swingarm coated black but it kind of starts to blend in with the tire and just looks like the wheel is floating. So I went with the same white as my frame and did them together!
(http://i42.tinypic.com/ic1y0i.jpg)
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Looking great!
I only have one suggestion....
Any time you have your computer on and your taking pictures, make sure it's on KXRiders :-D
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Looking great!
I only have one suggestion....
Any time you have your computer on and your taking pictures, make sure it's on KXRiders :-D
Thanks! Haha that I can do
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Looks good I kinda like the white it should really stand out!! :-D
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Looks great! How much did it cost to get your frame and swingarm painted?? I'm rebuilding my 2007 kx 250 and I'm considering the same color after seeing yours!
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Looks great! How much did it cost to get your frame and swingarm painted?? I'm rebuilding my 2007 kx 250 and I'm considering the same color after seeing yours!
$175 for frame and swingarm - $125 for frame and $50 for swingarm
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I don't know why all the manufacturers sell their bikes with those ugly half see through white radiator screens that get super dirty and look gross after 3 rides. So for me it was between black and green screens for my radiators. Since I wanted a pop of color off of my white frame and to go with my my green radiator hoses, I went with green. After all a KX should be green!
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Are you getting a new pipe? I noticed you've got some good-sized dents going.
If so, great, but there's no need to trash the one you've got. I have sent my Pro Circuit pipe to Pacific Crest Pipe repair twice (fixed, crashed, fixed again) and it's come back in great shape both times. I am sure they can do the same for you.
Meanwhile, I picked up a FMF Fatty on eBay for a good price. Next comes an E-Line pipe guard. Pacific Crest does a great job, but I'd rather avoid the dents in the first place.
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Nearly EVERY part of this bike is being replaced. I will definitely be getting a new pipe. I am going to go with a pro circuit with an r-304 shorty silencer. (I chose the shorty over factory sound because I like low-end pull and also love that sound!). I will probably have to go with the platinum pipe but I wish they still made the works pipe and the silencer without the end cap for this bike. That would be true early 00's style.
The one I've got is for sale on ebay. I probably won't do the pipe guard. I thought about it, but I'd rather show off the pipe then hide it.
When I'm done with this rebuild, there will be only a handful of parts separating it from a fully modded 2000 KX 125 that you would have bought brand new THAT year!
Are you getting a new pipe? I noticed you've got some good-sized dents going.
If so, great, but there's no need to trash the one you've got. I have sent my Pro Circuit pipe to Pacific Crest Pipe repair twice (fixed, crashed, fixed again) and it's come back in great shape both times. I am sure they can do the same for you.
Meanwhile, I picked up a FMF Fatty on eBay for a good price. Next comes an E-Line pipe guard. Pacific Crest does a great job, but I'd rather avoid the dents in the first place.
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So I attached the new radiators to the frame and got the stock brand new OEM frame guards. I didn't like the works connection ones the bike came with plus I wanted to keep with the black and white look of the hardware stuff. The will look worn pretty quickly...I know...but they will look great in the pics once the bike is complete and I can always look back on how nice it once was haha.
Footpegs are on their way and should be on in the next couple of days!
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New footpeg hardware was necessary. The old stuff was extremely rusted and pitted.
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The airbox that came with the bike was obviously original. And nasty. Plain and simple, I wanted a new one.
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I went on ebay and bought 2 new chain rollers for $12.99 each. Cheaper than OEM.
However, the bolts are not nearly long enough so I spent altogether about $2 on the OEM bolts, but used the washers and nut that came with the rollers.
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Of course I would like a pair of $200 pair of custom titanium footpegs, however, many brands don't make footpegs for this bike anymore and I really don't think I ride at the level where the footpegs make much of a difference. So I decided to go with these gunmetal footpegs that I got on ebay for $22 for the pair. I thought the deal was pretty good seeing as how the OEM ones are $60 for the pair. Unfortunately they are a little heavier than stock but they are also wider which I really like and since they are so close to black in color, they look really trick with the black and white look I've got going so far.
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Any update? :?
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Very soon...
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Here is the bike in it's current state. I bought a UFO Black Mud Flap and Acerbis Green Rear Fender.
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Just a cool shot of the Radiators through the frame.
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Here is a shot of my brand new OEM Airbox and the brand new Maxima Air Filter that I bought.
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This is a photo of my new forks. I purchased these mint condition forks from a 99' KX 250 with only 20 hours on it. I added these brand new UFO Black fork guards as well.
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wow...that's lookin sharp!....good work.
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Looks great so far - keep going! :lol:
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I also got these mint condition triple clamps on ebay from the same bike as the forks I purchased.
They are currently at the Powder Coaters and I will post pics once I get them on the bike with brand new steering stem bearings.
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I will post pics once I get them on the bike with brand new steering stem bearings.
Those bearings look fine. Clean 'em, grease 'em and call it good.
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I will post pics once I get them on the bike with brand new steering stem bearings.
Those bearings look fine. Clean 'em, grease 'em and call it good.
I would but the bottom one was slightly damaged getting the stem out of the bottom triple clamp before I brought the clamps to the powder coater.
Also, I left the races in the steering stem when I got the frame coated so they got a bit if powder on them. So I took them out and I figured I'd just start over with a matched set.
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I bought this Motion Pro Bearing Remover Tool. This better work!
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I also bought new bearings for the Shock, Swingarm and Linkage. Hopefully, I can get them installed with my new tool.
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(http://i44.tinypic.com/vhvuc9.jpg)
I bought this Motion Pro Bearing Remover Tool. This better work!
(http://i44.tinypic.com/2akfius.jpg)
I also bought new bearings for the Shock, Swingarm and Linkage. Hopefully, I can get them installed with my new tool.
I just finished changing all of those bearings in my KX500, and used that very same Motion Pro Bearing driver / removal tool kit. Works very well. 8-)
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I just finished changing all of those bearings in my KX500, and used that very same Motion Pro Bearing driver / removal tool kit. Works very well. 8-)
Awesome! I'm tackling my linkage, swingarm, front and rear hubs, and shock today. I may ask you some questions!
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I found the cheapest OEM tank at Partzilla.
It was on backorder for over a month but finally arrived from Japan and made me a happy man.
Here it is...
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Completely rebuilt Pro Circuit Linkage.
Brand new OEM Nuts, Bolts & Bearing Kit.
Brand new Bel Ray Grease too.
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Brand new Acerbis Radiator Shrouds.
Brand new OEM Gas Tank w/ Petcock that came on the bike.
Brand new SDG Seat. I am going to make a template out of this cover and have a custom one made.
(http://i43.tinypic.com/1zwyd1j.jpg)
Mint Condition 99' KX 250 Triple Clamps bought on ebay and Powder Coated white to match the frame.
(http://i43.tinypic.com/10gcoqc.jpg)
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Brand new Swingarm bearings from Pivot Works.
Finally got the Swingarm attached to the frane and it's starting to look like a motorcycle again.
I attached the Linkage as well.
(http://i39.tinypic.com/2ijgb2e.jpg)
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You guys that do this in your living room never stop amazing me. God a seems lately I need a machine shop just to change the oil.
Awesome work. Keep it up.
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+1 excellent work... Congrats..
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+1 excellent work... Congrats..
Thanks man! This has been such a learning experience for me. Removing and replacing the bearings was by the far the most daunting task so far and whether or not I ever do it myself again, it was a great experience as each step of this process has been. Not at the finish line yet, but I'm excited for the rest!
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Be sure to double-check where you put those washers in the linkage. None of the washers goes directly under a bolt head or nut flange. Your photo of the Pro Circuit linkage (jealous!) shows one of the washers under a nut flange.
I say this because my linkage was assembled the wrong way when I first got my '00 KX125. Fortunately I replaced the bearings and most of the bolts before I rode the bike, and was able to get the linkage correctly assembled during the process.
As long as you don't get water inside the linkage (such as when using a pressure washer) the grease should last a long time. Re-grease periodically and you may not have to replace any bearings for years and years.
I have noticed that the lower shock bearing has a little play even when brand new. It also gets contaminated faster than the other bearings. Be sure to especially keep an eye on that one.
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Be sure to double-check where you put those washers in the linkage. None of the washers goes directly under a bolt head or nut flange. Your photo of the Pro Circuit linkage (jealous!) shows one of the washers under a nut flange.
I say this because my linkage was assembled the wrong way when I first got my '00 KX125. Fortunately I replaced the bearings and most of the bolts before I rode the bike, and was able to get the linkage correctly assembled during the process.
As long as you don't get water inside the linkage (such as when using a pressure washer) the grease should last a long time. Re-grease periodically and you may not have to replace any bearings for years and years.
I have noticed that the lower shock bearing has a little play even when brand new. It also gets contaminated faster than the other bearings. Be sure to especially keep an eye on that one.
Kevin, thanks for all the info my man! I will definitely keep an eye on the lower shock bearing and keep these bad boys greased regularly. Yea now that you mention it, that washer looks out of place. I wonder where it's supposed to go? I thought I followed the OEM diagram correctly.
http://www.procaliber.com/oempartfinder.htm?aribrand=KUS#/Kawasaki/KX125-L2_KX125_(2000)/REAR_SUSPENSION/KX125-L2-2000/C19C1922F2150
Judging by what I'm going by here, it looks like the washers are supposed to be on the inside of the linkage arms. OoOps. Thanks for pointing that out!
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Just got my Custom Made OEM Style Gripper Seat Cover in.
I had it made in 3 parts.
-Black Gripper Top
-Black Sanded Gripper Sides
-Green Gripper Sides
(http://i42.tinypic.com/qr1c0x.jpg)
My buddy over at Traction MX Seating took care of this for me and quickly. I sent it out last Thursday from SoCal, he received it on Saturday in New Jersey, and one week later to the day I have received and installed it on my bike.
The green plastics and green seat colors match almost perfectly in natural light. I took this photo at night in bad lighting.
For custom seats of any kind, please visit:
https://www.facebook.com/pages/Traction-Mx-Seating/181117742034871
He will hook it up!
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Can he do lettering like my seat has?? Would love a kx550 seat cover
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Can he do lettering like my seat has?? Would love a kx550 seat cover
I wouldn't doubt it. Check out his facebook page and take a look at some of the intricate work he does. Let him know I sent you!
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Looks great! I really like when these great bikes are brought back to life!
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That looks awesome mate !!
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I went with Black UFO Side Panels.
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I'm not a white fan but that looks excellent. Keep up the good work.
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I decided to go with a Works Connection rear brake caliper guard and skip the easily scuffed plastic OEM one. Plus this one just looks sweeter. Also, this is a good pic of the slider that the brake caliper gets attached to. I had it powder coated black.
(http://i58.tinypic.com/23twua.jpg)
I threw the old shock back on the bike with completely new OEM hardware. I was going to wait to have the suspension done by a pro and have them throw on a new spring, but I'm going to wait until I'm a couple of rides in so that I know what I like and don't like about it.
(http://i60.tinypic.com/nwzbwz.jpg)
Got a brand new OEM chain slider and new OEM hardware to match. I got the Acerbis black rubber chain guide for the inside. Also note, the rear wheel adjuster bolts are brand new as well.
(http://i57.tinypic.com/296mcm9.jpg)
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Mint Condition 99' KX 250 Triple Clamps bought on ebay and Powder Coated white to match the frame.
(http://i43.tinypic.com/10gcoqc.jpg)
About these clamps. I didn't realize they were different than the stock KX 125 ones when I bought them and sold mine, but they are rubber mounted while my stock ones were solid mounted. I know that the rubber mounted ones reduce vibration, and since I am getting 1 1/8" renthals it actually opens up a lot more options for aftermarket bar mounts, but did I make a good move going with rubber mounted top clamp?
If so, I did it inadvertently.
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Brand New Excel Rims and Spokes, pivot works wheel bearings, oem axles & completely new wheel hardware.
(http://i60.tinypic.com/5y9t2a.jpg)
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Getting closer eh! Looking good man, get that thing in the dirt
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Nice build. Did you think about trying white for the side plates & rear fender? Would look super sharp esp if you could get a white tank for it too.
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I think the fact that the bike is in your living room improves the look of the white frame... :-D
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this thread needs a lil...
(http://upload.wikimedia.org/wikipedia/commons/1/17/Belize_Speed_Bump_Sign.JPG)
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this thread needs a lil...
(http://upload.wikimedia.org/wikipedia/commons/1/17/Belize_Speed_Bump_Sign.JPG)
Updates to come! This bike is getting finished in the next two weeks!
P.S. How should I gap my spark plug? I'm going to be using the BR9EIX one.
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I keep getting the itch for one of these. Read your build (very nice!) and looked in the local ad's. One close by and cheap! Well, as your build shows, at least at first! Not sure I will jump on it but have enjoyed your build so far. Keep up the good work!
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Oh it's getting real close. The bike is finished except when I brought it into the shop for a few finishing touches, they found out that my brand new right radiator (off ebay) is leaking fluid when they put it in.
I'm planning on running to harbor freight and getting the aluminum rods to braze them and seal the leak before I refill them and try to kick the bike over.
Also, the voltage regulator (brand new) that I ordered from Kawasaki directly, does not fit the harness plug that it is supposed to fit. IDK what to do about that. I may just switch to my 01' harness/CDI setup and run that since it runs without a voltage regulator at all.
Thoughts?
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Post a pic of the plug you need.
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What an awesome rebuild! I love watching the transformation. I am getting my '99 KX250 this weekend and it is in worse condition than your 125 was before you started the rebuild. This gets me super excited to restore it. I won't be getting so many new parts, but will try and salvage as much as I can and give it many hours of elbow grease.
Keep up the posting, it's good inspiration. I will start my own thread once I start with my bike.
Ed
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My Name is Jan and i´m doing the same project as you with a engine-crashed KX125 2002.
Your stuff looks awesome, but here in Germany it´s very difficult to get new parts for those old bikes.
Would you please let me know, where i can get some of this nice green radiator screens?
I´m also looking for a new linkage, but i don´t want to buy OEM parts.
If you are interested in my rebuild, you can find it in a german supermoto forum:
http://supermoto-forum.de/viewtopic.php?f=26&t=26518
(I also robbed one of your pictures :lol: to decide for a black or white frame colour)
At the moment the frame and the swingarm will be pulver coated ind RAL9005, deepblack ;-)
other parts will be cleaned up and refreshed.
If you got any questions or ideas to do it better, feel free to contact me 8-)
Excuse my bad english :-D
Greeting form Germany,
Jan
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My Name is Jan and i´m doing the same project as you with a engine-crashed KX125 2002.
Your stuff looks awesome, but here in Germany it´s very difficult to get new parts for those old bikes.
Would you please let me know, where i can get some of this nice green radiator screens?
I´m also looking for a new linkage, but i don´t want to buy OEM parts.
If you are interested in my rebuild, you can find it in a german supermoto forum:
http://supermoto-forum.de/viewtopic.php?f=26&t=26518
(I also robbed one of your pictures :lol: to decide for a black or white frame colour)
At the moment the frame and the swingarm will be pulver coated ind RAL9005, deepblack ;-)
other parts will be cleaned up and refreshed.
If you got any questions or ideas to do it better, feel free to contact me 8-)
Excuse my bad english :-D
Greeting form Germany,
Jan
Hey Jan,
I got my green rad screens from ebay. I have a pro circuit linkage which I rebuilt with new bearings and seals. Congrats on the rebuild. I look forward to seeing yours! I took my bike out to the track today for the first time and it ran amazing! It was definitely worth all the effort, blood, sweat and tears. My single best piece of advice would be to powder coat as few parts as possible. If I could go back, I would have gotten them sandblasted and left natural metal finish. The powder adds so much thickness, I spent hours sanding certain parts in order for things to fit together.
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What an awesome rebuild! I love watching the transformation. I am getting my '99 KX250 this weekend and it is in worse condition than your 125 was before you started the rebuild. This gets me super excited to restore it. I won't be getting so many new parts, but will try and salvage as much as I can and give it many hours of elbow grease.
Keep up the posting, it's good inspiration. I will start my own thread once I start with my bike.
Ed
Hey Ed,
Looking forward to seeing your rebuild come together. As nice as it is having all the new parts, I do kind of wish I would have gradually replaced them all so that I could have started riding sooner. Long live the two smokes!
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I was at the track as well and got to see this bike up close. The pics make it look nice, but it's even better in real life!
The good thing about such an in-depth rebuild is that you'll get many, many reliable hours out of it with only basic maintenance. You've done all the heavy lifting so now you get to enjoy the payoff.
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Thanks Kevin! Great seeing you out at Milestone! I'm loving this bike so far. Just have to get used to it and riding in general after over a decade away from the sport. Hopefully soon we will both be ripping up the Vet track together!
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What an awesome rebuild! I love watching the transformation. I am getting my '99 KX250 this weekend and it is in worse condition than your 125 was before you started the rebuild. This gets me super excited to restore it. I won't be getting so many new parts, but will try and salvage as much as I can and give it many hours of elbow grease.
Keep up the posting, it's good inspiration. I will start my own thread once I start with my bike.
Ed
Hey Ed,
Looking forward to seeing your rebuild come together. As nice as it is having all the new parts, I do kind of wish I would have gradually replaced them all so that I could have started riding sooner. Long live the two smokes!
I can only imagine your itch to ride the bike. That is, unfortunately, the downside of not replacing piece by piece. I prefer doing everything at once as you are doing it, but don't have that kind of capital or patience. I got the bike this morning and man, I have my work cut out for me. The previous owner (and the owners before him, for all I know) have done so many back yard fixes on it and its missing some parts. I will have my hands full for a while. I will be reaching out to people here on the forum for some help pretty soon too see what's missing and not.
Hope to see some progress pics of your bike soon.
Ed
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Ed,
My best advice is to start with a 250 piece Specbolt kit from ebay which will help you out throughout your entire build. It is essential and will save you hours of frustration.
Pics of mine coming soon!
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Thats true! Although, in order to save some money, there is a bolt and nut place pretty close to my work where I can take all the sizes and get stainless bolts and nuts for quite a lot cheaper than I think the sets come in. Buying the set will save me quite a lot of effort, but I know less effort = $ and since I will rather put the spare money I have into more important things, I will have to make the effort. I have started putting all the bolts, nuts and screws I've taken off the bike into separate packets and labeled them to not get too confused where they go. It takes some time but will save me some dough.
Thanks for the tip though! It's appreciated.
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Hey MXonaKawi, I started my, hopefully, budget rebuild thread. You can check it out here... http://www.kxriders.com/forums/index.php/topic,14317.0.html
How is yours going btw?
Ed