Maintenance & Technical > KX250 / KX125
91 KX 125 H2 Rebuild - Bike finished 08.01.09 2nd page
2 smoke juan:
Hi guys
I finally got my rebuild underway a couple of weeks ago - not rushing it too much as it's getting built to race next season in the support class of the Scottish Twinshock championship.
I've had my little Kwacker since it was brand new, got it as a 14 year old in Sept '91 from Mickey Oates Motorcycles in Glasgow. I had to wait a full year to race it as the S.A.C.U didn't let kids ride 125's until they were 15 back in the day! I raced with the BYMX club and with Irvine motocross club through the 90's, firstly on this then a 95 KX 250 which unfortunately had to be sold later that year to pay rent whilst i was a student in Edinburgh.
I'm about to embark on a full resto of the bike below - it's a 1991 KX 125 H2 - this is how it looked when it was retired back in March 1994.
2 smoke juan:
So far i've put new steering / head bearings in along with fully rebuilt linkage.
The stock Kayaba rear shock has been substituted with an Ohlins and the fork springs have been replaced with NOS genuine heavier springs along with a full overhaul of the forks.
Upon disassembly i found the piston had a hairline crack, the barrell was slightly scored and the KIPS valves were broken. Among other things the barrel was recoated by Langcourt, a NOS stock piston was put in, every seal and bearing was replaced and a new clutch assembly was installed too. It had a Boyesen rad valve installed from new and i have a brand new Pro Circuit platinum pipe (although i would much prefer a bare works pipe no one has stock and PC won't make me one) and 304 factory sound silencer to put on.
I'm happy with the build so far and really looing forward to racing it against bikes of a similar age next year.
There is a ton of parts all over the garage and the house waiting to get bolted on - only parts i'm needing is a NOS generator cover as mine is pretty scratched but it's purely for cosmetics and a NOS fuel tank - again purely for appearance.
Here's a couple of pics of the Ohlins - came with a nice new top mount piece which was handy as the original was indicating signs of fatigue......
The Flyin Hawaiian:
Looking good! :-D
2 smoke juan:
Progress has been really slow due to work comitments but thought i'd show some progress pics.....
Got it rolling now on its new wheels, installed new motomaster discs and renthal sprockets. Got a NOS RHS radiator of ebay for 40 quid delivered and sent the LHS rad down to GMX in Essex to be straightened out and pressure tested - really pleased with the results. They're installed with new coolant hoses and got the electrics cleaned and installed too.
I'd been looking for a NOS standard size fuel tank but after a light restoration the original one has come up pretty nice, a few scratches still remain but the faded green has been replaced with a nice glossy finish as a result of plenty of elbow grease! 5 hours polishing - yes i really do lead such a boring life! Mounted the shrouds too just to see and pretty pleased with the colour match! Best stock graphics ever on a KX IMO :mrgreen:
Have rebuilt the carb, which is a Keihin 36mm PJ carb rather than the stock 35mm PWK, am waiting for a replacement rubber boot for my Boyesen rad valve and replacement carbon reeds before i reinstall it.
Last pic is of my new PC exhaust system. Hopefully get a bit more done tomorrow so will post more then.
Friar-Tuck:
That looks great! 8-)
I was trying to find a thread on restoring plastic and keep coming up empty. :?
If you don't mind me asking how did you get that tank looking so good?
What did you use to "Polish" with?
Your doing a fine job, keep it up!
Tuck \o/
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