KX Riders
Maintenance & Technical => KX250 / KX125 => Topic started by: queen of spodes on December 31, 2013, 05:03:32 AM
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The original owner of the bike I just bought thought it would be smart to weld the front sprocket to the countershaft. As you see below, there's as much weld as there is sprocket.
My question is can the countershaft be removed by sliding it to the outside of the case? If not, would it better to try and grind down the end of the countershaft or put a torch on it?
(http://i162.photobucket.com/albums/t274/queen_of_spodes/20131231_115624_zps37b6c952.jpg)
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I wouldn't use a cutting torch. I think you'll have better control with a grinder with a flap-disc or a soft disc mounted in the chuck.
By the time you grind the welds and shaft until they're flush with the face of the sprocket I would expect the sprocket to separate from the shaft.
Unfortunately, the countershaft itself will have to be replaced. I don't see a way around this. Sandblaster might have a replacement available for you.
The previous owner probably lost the clip and decided that a weld was just as good.
How does the rest of the bike look? Hopefully, this is the worst mechanical issue you'll encounter and not the "tip of the iceberg."
If memory serves, 1989 was a very good year for the KX 125.
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I agree with the grinding method...but, just going based off the luck that I don't ever seem to have...don't be surprised if the snap ring groove on the shaft is damaged/useless from the weld :x
...then you're gonna have to pull the motor and open it up to fix it....or, you could weld on another sprocket :-P
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...then you're gonna have to pull the motor and open it up to fix it
My hope is that the countershaft is still available from Kawasaki. I plan to pull this motor apart to bead-blast cases, cylinder & head in addition to replacing seals/gaskets, bearings, ect. It will get a full rebuild.
If the countershaft is NLA then I'm more inclined to part this machine out. kawasakipartswarehouse.com has the part showing as available but I've learned that doesn't mean much.
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13128-1163 is discontinued but, 89-93 is the same.
I don't have one but they are available used on eBay.
http://www.ebay.com/itm/92-93-Kx125-Trans-Transmission-Gears-Kawasaki-Kx-125-1992-1993-/141136787568?pt=Motorcycles_Parts_Accessories&hash=item20dc687870&vxp=mtr (http://www.ebay.com/itm/92-93-Kx125-Trans-Transmission-Gears-Kawasaki-Kx-125-1992-1993-/141136787568?pt=Motorcycles_Parts_Accessories&hash=item20dc687870&vxp=mtr)
http://www.ebay.com/itm/1991-KX125-TRANSMISIIONS-GEARS-SHAFTS-KX-125-TRANS-TRANNY-GEAR-/181218697732?pt=Motorcycles_Parts_Accessories&hash=item2a3179e204&vxp=mtr (http://www.ebay.com/itm/1991-KX125-TRANSMISIIONS-GEARS-SHAFTS-KX-125-TRANS-TRANNY-GEAR-/181218697732?pt=Motorcycles_Parts_Accessories&hash=item2a3179e204&vxp=mtr)
http://www.ebay.com/itm/1991-KAWASAKI-91-KX125-KX-125-KX125-H2-TRANSMISSION-INPUT-SHAFT-AND-GEARS-/111185536219?pt=Motorcycles_Parts_Accessories&hash=item19e32ca4db&vxp=mtr (http://www.ebay.com/itm/1991-KAWASAKI-91-KX125-KX-125-KX125-H2-TRANSMISSION-INPUT-SHAFT-AND-GEARS-/111185536219?pt=Motorcycles_Parts_Accessories&hash=item19e32ca4db&vxp=mtr)
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Unfortunately, the countershaft itself will have to be replaced. I don't see a way around this. Sandblaster might have a replacement available for you.
Who/what is Sandblaster? Am I correct in assuming the countershaft is NLA?
How does the rest of the bike look? Hopefully, this is the worst mechanical issue you'll encounter and not the "tip of the iceberg."
The rest of the bike is in bad condition, but I couldn't spot any frame cracks. The engine looks terrible, so it would be the first thing I tear down. I suspect one of the cases has a crack in the bottom, but haven't had time to confirm yet.
If memory serves, 1989 was a very good year for the KX 125.
The 89 was bike of the year for MXA and Dirt Bike if I remember. It was hands down the best of the 125s that year. The 46mm conventional forks were some of the best to come on that era of mx bikes. I previously owned a '85 and '86 KX125 and loved both dearly. They were my first full size mx bikes! So there is some nostalgia tied up in this purchase.
If I can source some new parts for the engine (countershaft and who knows what else when I get inside), I may do a full resto. Piston, crank, bearings, ect -- not worried about those since they are relatively easy to come by. The radiator is garbage, and the carb looks like it was "worked on" with vice grips. The rest of the bike isn't a pretty sight, but here's what I did with a 87 RM250 a few years ago
before
(http://i162.photobucket.com/albums/t274/queen_of_spodes/562446_10150700038819067_450868428_n_zps9e557ca4.jpg)
after
(http://i162.photobucket.com/albums/t274/queen_of_spodes/after_zpsb8c48c15.jpg)
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13128-1163 is discontinued but, 89-93 is the same.
I don't have one but they are available used on eBay.
http://www.ebay.com/itm/92-93-Kx125-Trans-Transmission-Gears-Kawasaki-Kx-125-1992-1993-/141136787568?pt=Motorcycles_Parts_Accessories&hash=item20dc687870&vxp=mtr (http://www.ebay.com/itm/92-93-Kx125-Trans-Transmission-Gears-Kawasaki-Kx-125-1992-1993-/141136787568?pt=Motorcycles_Parts_Accessories&hash=item20dc687870&vxp=mtr)
http://www.ebay.com/itm/1991-KX125-TRANSMISIIONS-GEARS-SHAFTS-KX-125-TRANS-TRANNY-GEAR-/181218697732?pt=Motorcycles_Parts_Accessories&hash=item2a3179e204&vxp=mtr (http://www.ebay.com/itm/1991-KX125-TRANSMISIIONS-GEARS-SHAFTS-KX-125-TRANS-TRANNY-GEAR-/181218697732?pt=Motorcycles_Parts_Accessories&hash=item2a3179e204&vxp=mtr)
http://www.ebay.com/itm/1991-KAWASAKI-91-KX125-KX-125-KX125-H2-TRANSMISSION-INPUT-SHAFT-AND-GEARS-/111185536219?pt=Motorcycles_Parts_Accessories&hash=item19e32ca4db&vxp=mtr (http://www.ebay.com/itm/1991-KAWASAKI-91-KX125-KX-125-KX125-H2-TRANSMISSION-INPUT-SHAFT-AND-GEARS-/111185536219?pt=Motorcycles_Parts_Accessories&hash=item19e32ca4db&vxp=mtr)
Got it - thanks kindly.
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that RM came out nice...Bob Hannah would be proud.
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That RM is gorgeous!
My brother has an '87 RM 125 that's sitting around waiting for some funds and attention.
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I got very lucky and found a bunch of cosmetic NOS parts for the RM, including a brand new seat (OEM).
As I look over ebay and the parts fiche, I'm a little apprehensive that I'll be able to reproduce similar results with this KX125. I can get plastic, OEM graphics, most of the basic engine bits. But knowing I'll have to split cases to fix the countershaft, I'm wondering what else I'll run across.
The bike looks like it has been beat to death. So - shift forks could be out of spec. Only two are still available from Kaw. that leaves three that can't be replaced or I take chances with someone else's used shift forks on fleabay.
I think I can pick up necessary bearings and seals either with available OEM or aftermarket parts from NAPA. Con rods are still available.
I haven't checked the ignition system, so hopefully the ignition module and stator are OK. Coil is still available and affordable.
I need front brakes - the entire system was stripped off the bike.
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13128-1163 is discontinued but, 89-93 is the same.
Have you heard of anyone putting a newer model KX125 engine in the '88/89 frame? Was there a huge redesign in '94 up?
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yes....in 1990 Kawie changed to the perimeter frame...completely different.
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yes....in 1990 Kawie changed to the perimeter frame...completely different.
Yeah, I realized that. I read that the countershaft is the same 89-93 - was hoping I'd have more options as I have a bad feeling about the engine in my bike. If shift forks were newly available I'd feel much better.
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yes....in 1990 Kawie changed to the perimeter frame...completely different.
Yeah, I realized that. I read that the countershaft is the same 89-93 - was hoping I'd have more options as I have a bad feeling about the engine in my bike. If shift forks were newly available I'd feel much better.
it can be done....there's some guys on here that have done just about every conversion you can think of.
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Obsolete 13140-1070 FORK-SHIFT,2ND&3RD fits 82-91 kx125
Obsolete 13140-1123 FORK-SHIFT,5TH&TOP fits 85-91 kx125
Obsolete 13140-1124 FORK-SHIFT,LOW&4TH fits 85-91 kx125
I would keep my eyes open on eBay for a NOS set.
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Obsolete 13140-1070 FORK-SHIFT,2ND&3RD fits 82-91 kx125
Obsolete 13140-1123 FORK-SHIFT,5TH&TOP fits 85-91 kx125
Obsolete 13140-1124 FORK-SHIFT,LOW&4TH fits 85-91 kx125
I would keep my eyes open on eBay for a NOS set.
Will do - thanks for the part #s.
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I finally had a little more time to comb over the bike this evening. If the welded on sprocket wasn't enough proof, this bike is in sad shape.
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/20131231_115615_zps453db473.jpg)
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/20131231_115707_zps401628b8.jpg)
Shift mechanism is boogered - no spring action.
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/20140102_181009_zpsb3dfd5b5.jpg)
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/20140102_181250_zps67b11ee5.jpg)
Crusty intake boot
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/20140102_181519_zps2ad44348.jpg)
Left side peg mount:
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/20140102_181100_zpsc3a65402.jpg)
Right side peg mount:
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/20140102_181227_zps7ace6f17.jpg)
Looks like I'll be needing some new linkage components. Bearing completely gone on the lower shock joint:
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/20140102_181032_zps61c916d1.jpg)
Front wheel off of a 85-87 KX - note the black (not spray painted) hub:
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/20140102_181535_zpsaf8617ac.jpg)
TUF Racing "TUF II TWIST" handlebar stabilizer.. woohoo!
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/20140102_181757_zps97059e7b.jpg)
Radiator is damaged and bent. I'm sending pics & dimensions to a Chinese manufacturer in hopes they have cores long enough to reproduce this one.
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125_radiator/20140102_180944_zps5a0a5239.jpg)
But hey, cylinder has 155psi compression!
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/20140102_183031_zps951e9971.jpg)
I haven't ordered any parts yet, and may sit on it another month before deciding what to do.
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Honestly...it's not that bad...it's all there.
I would try to spend some time searching for the parts it needs before giving up too quickly.
You can soda blast most of the aluminum parts to give them a new look, same with the engine cases...most of the cosmetics you can still get, such as plastics, new seat cover, fork boots...etc
Yeah, it'll be a job finding the obsolete parts...but not impossible...do what Sandblaster suggested and search e-bay on a daily basis.
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Started disassembly this afternoon. Have a couple questions a little further down.
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/Jan%204%202014/20140104_164700_zpsc636c4e0.jpg)
Tell-tale signs of orange silicone:
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/Jan%204%202014/20140104_171001_zps6088f6ad.jpg)
I try not to think too hard about the things I find on this motorcycle:
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/Jan%204%202014/20140104_170910_zpsf7003691.jpg)
First question - were these rear brake line bracket studs originally bolts? Or is this how it's supposed to be?
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/Jan%204%202014/20140104_170902_zps58b21533.jpg)
Second question - WTF is the white powder and why is it here? Best way to clean it off the stator?
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/Jan%204%202014/20140104_174219_zpsb2afdaaa.jpg)
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/Jan%204%202014/20140104_174227_zpsfb1b3472.jpg)
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/Jan%204%202014/20140104_175558_zpsa7f427d3.jpg)
That's it for now!
(http://i162.photobucket.com/albums/t274/queen_of_spodes/89kx125/Jan%204%202014/20140104_175616_zpsc810ecf0.jpg)
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Bump for my two questions in the post above (white stuff & rear brake hose hardware).
Also a third question. Will newer brake calipers fit on the '89 legs? guessing the answer is no due to the switch from conventional to USD but worth asking!
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The front brake caliper mount holes are 78mm.
The newer forks use 60.5 and 102mm.
http://www.oem-cycle.com/KX125KAWASAKIBIKEID.shtml (http://www.oem-cycle.com/KX125KAWASAKIBIKEID.shtml)
Scroll to the right to my fork dimensions.
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The front brake caliper mount holes are 78mm.
The newer forks use 60.5 and 102mm.
http://www.oem-cycle.com/KX125KAWASAKIBIKEID.shtml (http://www.oem-cycle.com/KX125KAWASAKIBIKEID.shtml)
Scroll to the right to my fork dimensions.
Thanks - very useful site. Bookmarked.
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Any input on the other two questions a couple posts above?
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I didn't want to hog all the fun... :lol:
The fasteners that hold the rear brake hoses holders in place are usually a hex head fastener.
The white powder is aluminum oxide from water getting into the stator area and sitting there.
I would test the stator and see if it is still in spec.
If so, I would remove the flywheel and the stator.
Then I would use a dremel with a small wire wheel and clean off all the oxide from the cases.
I would also clean any rust off the flywheel.
You can spray the raw aluminum with WD-40.
For that matter spraying WD-40 on everything else including the stator does not hurt.
Inspect closely, wipe it all dry, reassemble, and double check the ohm specs before putting the stator cover on.
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On 88 and 89 the studs in the swingarm for the brake line are factory. Not sure about any other years. I owned both years when I was younger. I'm surprised both studs are still intact. They tend to snap off flush with the top of the swingarm so be gentle with them.
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On 88 and 89 the studs in the swingarm for the brake line are factory. Not sure about any other years. I owned both years when I was younger. I'm surprised both studs are still intact. They tend to snap off flush with the top of the swingarm so be gentle with them.
+1
I checked some pics I have from 88 and 89's we have parted and sure enough they used studs in those years.
Good catch Goat 8-)
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Bump for my two questions in the post above (white stuff & rear brake hose hardware).
Also a third question. Will newer brake calipers fit on the '89 legs? guessing the answer is no due to the switch from conventional to USD but worth asking!
my 83 kx250 with 1991 brake caliper on 88 fork legs with my handmade adapter... youŽll see its possible to make it...
(http://img.webme.com/pic/d/der-motopunk/abcd0006.jpg)
and the full build report with some more pics:
http://der-motopunk.de.tl/kx250c1_1983-die-wiedergeburt-.htm
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the white powder on your statorplate is aluminiumoxid caused of always wet behind the cover over years... there is also good to see the rust on the flywheel...
this weld on sprocket is awesome hillbilly-repair very rare to see pics ... :lol: ... iŽm just wondering if the seal behind is not melted by welding ...