KMX 125 on/off road project.

System of a Clown · Two Stroke Sniffer Joined: 29 Aug 2015 Karma :

I'm still waiting for the back wheel, and I need to clear some time at work so I can get on the lathe/mill and job the front forks (I'm largely content they'll be fine though) so I made a start on the bit I detest - wiring.

I hate auto wiring, it's not complicated, it's just invariably been mucked about with, and this is no exception. I've pulled off lots of vulcanising/masking/electrical/parcel tape and found:

https://i245.photobucket.com/albums/gg63/cpopaul/D61F2B38-866B-42B5-92A3-E8E33FED0464.jpg

https://i245.photobucket.com/albums/gg63/cpopaul/70F6B9E7-A35E-4E92-BA22-A5F1CA387970.jpg

https://i245.photobucket.com/albums/gg63/cpopaul/8710D85A-D944-405D-A8A7-4C9AEE91BB6E.jpg

And joy of joys, a rounded off screw on the pickup Rolling Eyes

https://i245.photobucket.com/albums/gg63/cpopaul/45D081FF-5B19-4F68-AD4D-5626ADBE9299.jpg

I'm going to have to pretty much rewrite this I guess!

And a quick question, does anyone know any aftermarket plastics that will fit this?

I've done a fair bit of research, and so far I've found that I can either a) buy some secondhand KMX plastics and try to restore them b) get my pants pulled down by Kawasaki for a new set or c) aftermarket stuff.

I'd prefer the aftermarket stuff but I've got a sneaking suspicion that I'll need to remove and reweld the plastics mounts on the frame, which I'm not very keen on TBH.

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

some people have fitted plastics from other models but it does need mounts adjusting, not ideal.

best bet is to respray what you have got if you are trying to stay below your budget.
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1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

System of a Clown · Two Stroke Sniffer Joined: 29 Aug 2015 Karma :

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

[quote="System of a Clown"]

Just_James · Could Be A Chat Bot Joined: 29 Aug 2014 Karma :

Some epic wiring you've discovered there! I've done worse myself in the past though Embarassed

Following this with great interest, really liking what you've done so far and am intrigued with the turbo side of things Thumbs Up

My 2p on the plastics, I'd personally be sourcing solid 2nd hand originals in the right colours. Even if they're heavily scuffed and scraped they can be sanded and polished back to a good finish.

I have a pet hate for painted plastics on trail bikes, they are generally a different type of plastic that is 'oily' and are supposed to flex. With all the best prep' in the world you can't expect any paint to stick to them for any length of time other than perhaps for 'show' conditions.

I don't have any personal experience of aftermarket plastics but would expect them to be quite flimsy. Maybe a viable option depending on just what you want to do with the bike and how you want it to look though?
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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

I agree Dave. I also saw those OEM plastics set from Japan for £300, and was in two minds about their value.

Sure it's a lot of cash to lay out on new plastics, probably less though than ordering each piece from a Kawasaki dealer here though.

I guess it depends on how battered or really unusable your old plastics are? if they are smashed/holed or cracked in several places then repair will be time consuming if you can do it yourself, and expensive if you pay someone to do it.

I think having non painted plastics for a pure off road bike is a good bet, but plastics can be painted just as on a road bike I suppose too. All my KMX 125 plastics were re-painted at a car body shop and they came out lovely, but I'm not sure they will be worth it for off road use only?

My 200's black plastics are just all badly scratched and faded, but I will try polishing them and maybe the heat gun trick if required, but then as long as that bike is all the same colour the finish won't matter a bit as I only want to get it really muddy! Smile

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

System of a Clown · Two Stroke Sniffer Joined: 29 Aug 2015 Karma :

Thank you for all the advice on the plastics chaps Smile

I've been doing a fair bit of looking about and I've decided this:

My front mudguard is ok, it's badly painted and there's a small chunk out of the bottom edge (ie at the back of the wheel) I reckon taking 7-8mm off carefully with a dremel and shaping it a bit will be just fine - I can't see anyone noticing! The rad scoop is generally ok, albeit badly painted. The rear mudguard is nasty, it's snapped in half at some point and has been stapled/cable tied back together, so it's bin bound. I want an OG KMX rear mudguard as it's also the mount for the oil tank. I'm watching a couple on eBay right now.

I've found a guy in Japan who is advertising what appears to be NOS left and right side panels for £45 + £19 postage. I've messaged him and if that's the case I'm having them, there's loads of crappy ones for £15-20 plus post and I figure I'll probably break even by the time I've sanded/painted etc.

I'd prefer the right coloured plastics and I've also decided that aftermarket is out the window (I want it looking like a KMX) so I'm going to see what turns up and decide the colour scheme from there (both my mudguard and rad scoop are red)

I've also had the rear wheel arrive and once again Lady Luck is smiling at me.

It's got the same size wheel bearing, the caliper lines up a treat (I've got to get the pickup out of the motor) but after that I'll be throwing it back in to check for chain alignment. Looks like I'll need to machine down a spacer but that's it!!

I guess it's officially a Supermoto now Very Happy

https://i245.photobucket.com/albums/gg63/cpopaul/D4EAD06F-2F07-4834-A38F-2D88196DC511.jpg

https://i245.photobucket.com/albums/gg63/cpopaul/C906DB58-7E07-4843-B51D-6130A8459A37.jpg

https://i245.photobucket.com/albums/gg63/cpopaul/D362BCAE-10D8-4CB0-9B53-7EFBF8BA679E.jpg

https://i245.photobucket.com/albums/gg63/cpopaul/9971A00C-AF98-447B-92E4-EEDAC199ED5B.jpg

https://i245.photobucket.com/albums/gg63/cpopaul/DDD76BA1-1FC1-4C59-A07D-BE0C5817C76D.jpg

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

looking good!!
____________________
1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

Nice work! Thumbs Up

I've got to say I think that sits much better with the 17"wheels and the Pulse forks than I thought it would. Yeah sure it will be lower, but it does not look drastically so, which is what I think it would if you just fit 17" wheels to a KMX with std forks.

I like KMX's to look like KMX's too! Smile

If the front mudguard is intact and only scuffed or scratched, then it's still good to re-use and re-paint I'd say. The tank and tank shroud along with that front fender could be prepped and sprayed to look very nice indeed IMO. If all you need is a new/good used rear guard and two side panels then you've got off lightly I'd say on a 24year old KMX.

Also if you go with painting the existing plastics you can have the option of easily masking for different colours or stripes to make a 2 or 3 colour paint scheme or just even to add some pin stripes etc?

Your KMX will be a nice tidy Supermoto, and so that's why I think paint is right for your bike, as it's not going to get all muddy and scuffed up (I hope not anyway!) Laughing

Oh and a reasonably smart paintjob is almost essential if you want to really show off the boosted frankenstien technical goings on inside the frame rails! Wink

System of a Clown · Two Stroke Sniffer Joined: 29 Aug 2015 Karma :

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

It's a cool looking bike in green TBH. The red seat suits it brilliantly, and maybe with a matching red frame as well that would be enough red to off-set the rest of the bike being proper Kawasaki green. You could maybe tape a line down the tank and rad shroud to make a red and a white stripe into the green to break it up a bit and give it a nice look?

Or a tricolour tank with red/white/green could look cool too?

If you keep any graphics white or red to go with the theme then even better IMO!

But you should have a think and do whatever you want with it, as your bike your way is the best rules with any special!

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

System of a Clown · Two Stroke Sniffer Joined: 29 Aug 2015 Karma :

System of a Clown · Two Stroke Sniffer Joined: 29 Aug 2015 Karma :

System of a Clown · Two Stroke Sniffer Joined: 29 Aug 2015 Karma :

Done bugger all on the bike apart from source a good used suspension linkage - lack of work has been due to to troublesome vintage Volkswagens and their resistance to working Sad

However I have received a reply from the DVLA, not the V5 I was hoping for, but I'm guessing it's legit?

https://i245.photobucket.com/albums/gg63/cpopaul/image.jpg1_1.jpg

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

By the sound of the letter it looks promising.

If you have the reg number it may avoid the hassle of it being inspected.

If no reg number then sounds like they will have to inspect the machine. bear in mind if an inspection is needed then the machine will need to be made up of more than 50% of the original parts, otherwise it may throw its age/ identity into question.

For example if the engine isn't the one noted in the v5c, and forks and wheels are different, then could be under 50% original parts.
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1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

System of a Clown · Two Stroke Sniffer Joined: 29 Aug 2015 Karma :

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Sean.S · Trackday Trickster Joined: 20 May 2015 Karma :

after all the effort your going to, why have you put cheap chinese wheels and chinese forks on? Rolling Eyes

by the way chinese tyres are lethal, change em mate or be careful out there when it starts to rain

System of a Clown · Two Stroke Sniffer Joined: 29 Aug 2015 Karma :

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

any luck with the registration?
____________________
1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50