1989 Kawasaki KX125 project

[Gazdaman]

Swapping it for my GS500 commuter tomorrow.

1989 Kawasaki KX125, Carbon reeds, USD forks, Freshly powdercoated frame and swingarm.

It's munching gearbox oil at the minute, so I'll strip the engine down and most likely find knackered crank seals. So I ordered a full seal set, and full gasket set.

As far as I'm aware the only thing it's actually missing is the front number board. I might replace the piston ring(s) while it's apart, but part of me thinks I may aswell ride it until it breaks.

So it's just a case of stripping, sorting the engine, rebuilding and getting muddy.

Watch this space.

Gaz

[Gazdaman]

It arrived yesterday.

https://www.gaz-racing.co.uk/images/vehicle_485.JPG

https://www.gaz-racing.co.uk/images/vehicle_486.JPG

https://www.gaz-racing.co.uk/images/vehicle_488.JPG

For a bike that's nearly as old as me, it looks cracking!

Seems like everything's there. On the shopping list is:

New kill switch
New clutch cable

And that's it. I've already bought it the engine seal kit and gasket set. I might buy it some tarty folding levers, but I suppose they can always wait.

The exhaust is a bit scummy and has clearly had a welded repair at some point in the past, but if it aint broke etc...

Stay tuned.

Gaz

[fra-zzr]

is there a front caliper?
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04' Hyosung Comet Gt125
96' zzr600

[Gazdaman]

Yeah, still attached to the master cylinder and hose in the box of bits. Decent condition too.

Gaz

[KLR600]

This will sound mad but I have been wondering about something for about 10 years now and I just need to figure some stuff out.

If you're taking the engine out is there any way you could weigh the bike sans engine? No worries if not. Just the running gear like frame, forks, wheels, bars and brakes. Don't need to know how much it weighs with plastics and the tank on and stuff, maybe without the suframe aswell.

I used to be able to bunnyhop my old DT125 with a full tank of petrol so I'm wondering how heavy a crosser would be without all the engine bits.

Looks like a good project, keep us posted!
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Now: '00 Kawasaki ZRX1100R - Past: '84 Yamaha DT125, '89 Kawasaki KLR600, '97 Yamaha XJ600N
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[Gazdaman]

What a weird request. If I get the engine out and the bike magically falls onto a set of scales then sure, I'll look at the reading and note it down.

Other than that, I wouldn't hold my breath mate

I would have thought it'd be about 60-70kg? Maybe less I suppose.

Gaz

[OssY]

Looks have done a proper job coating that frame matey. Now get it finished..

[Gazdaman]

Bike moved into my garage this week, bought it a full gasket and oil seal set. And an MX stand.

Now it's a case of cutting out some spare time to do the work, I reckon I can have the engine out, seals changed, back together, back in and fully rebuilt in 2 full days.

https://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs040.snc1/2672_140282530227_673425227_6165478_5820361_n.jpg

Gaz

[Gazdaman]

Doris passed its MOT today

Gave me a chance to work on the KX too. According to the timestamps on the camera, it took me 54 minutes to go from this:

https://www.gaz-racing.co.uk/images/vehicle_514.JPG

To:
https://www.gaz-racing.co.uk/images/vehicle_520.JPG

That's seat and tank off, exhaust off, carb off, swingarm off (the pivot is an engine mount), drain coolant, engine out.

The powder coated frame is just a joy to work with. Everything's so clean.

Also found where I think the gearbox oil is going. The previous owner said he thought it crank oil seals. But in fact I think it's leaking where the crank cases join together. Never mind, I'll strip it down and rebuild it anyway.

I love projects!

I think it needs a new exhaust really too, this one is battered to fuck. And has been welded several times already.

https://www.gaz-racing.co.uk/images/vehicle_518.JPG

Gaz

[BenR]

Nice! You not tempted to get it road legal?
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Current bikes: suzuki RG125UN wolf. Yamaha MT-07

[Gazdaman]

Yes and no.

The yes side of me would like the flexibility (and resale value) of it being road legal.

But the no side of me thinks that the frame number's been powdercoated over, the tyres are illegal, and after everything it's a 125 2 stroke, not really suited for the road.

So as long as I find a decent trailer and get my tow bar fitted. I'll be happy with keeping it off-road only. And it doesn't have a battery, so lights etc would be a bit of a pain.

Gaz

[freko]

Hi

I'm working on the same bike(though -88). My engine got totally trashed when it cut. The piston broke into pieces, that fell down into the crankshaft...
I'm going to open it up tomorrow and check the damage, but it doesn't look good...

I have some pics here if you are interested, https://www.bikepics.com/members/freko/88kx125/
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You do what you can, I do what I wan't.

[Gazdaman]

Nice project mate!

I would offer you spares, but I hardly have any, think I've got a petrol tank and that's it.

Was the engine difficult to take apart? And at least your barrel looks like it got away fairly unscathed.

Gaz

[freko]

I've been busy this weekend working on the engine...

I had some problems with the generator, but it gave in after I found fitting tools. I don't think the engine has been opened like this in the last ten years(if ever), so things where tight stuck. The electrical coils where fitted with cross-head screws, so they got a beating when i tried to get them loose. After some hammering, some foul language and a bit of violence I got them loose though. When I put the coils back to place i will be using hex-socket screws, not that original crap. I also had the same problem with the screw that held the exhaust valve rod in place. Now I'm having some problems with the bearings that need to be replaced, but I try in couple of weeks again if I get the proper tools. The bike is at my parents house, so I only work on it when I'm visiting.
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You do what you can, I do what I wan't.

[Gazdaman]

God knows when I'm gonna find the time to work on my beast.

Might try and do some this weekend.

Gaz

[Gazdaman]

Had a small go at it today:

https://www.gaz-racing.co.uk/images/vehicle_541.JPG

Turns out there's about 1mm of sideways play (each way) in the con-rod.

So what do I need to replace? Just the big end bearing? Or the cod-rod et al? A kit is about £40, which I suppose isn't too bad.

But I'm guessing I have have the crank split and pressed back together.

Gaz

[BenR]

Movement side to side should be there, it's if you have movement up & down that you have a problem?
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Current bikes: suzuki RG125UN wolf. Yamaha MT-07

[Gazdaman]

There's no up and down. I thought side to side was bad...

Gaz

[element]

1mm side to side is fine.. theres meant to be a tiny bit of play.. its up and down play that means a crank rebuild so all is good
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04' DT125RE (run-a-bout) // 89' DT125R (rebuilt + supermoto conversion)
SPARES FOR SALE. 2RK TZR // 82 DR125 // DT125R/E .... PM ME...

[Gazdaman]

Sweet, that means I can crack on with the rebuild tomorrow.

Gaz

[Gazdaman]

First step, piston off, couple of little side covers:

https://www.gaz-racing.co.uk/images/vehicle_550.JPG
Found out the sprocket wasn't held on by anything. Will have to look into that.

https://www.gaz-racing.co.uk/images/vehicle_551.JPG
Alternator side off. Got the bolt out, but couldn't pull it off the crank, didn't have the right size puller.

https://www.gaz-racing.co.uk/images/vehicle_552.JPG

Mmmm Carbon fibre reeds.

https://www.gaz-racing.co.uk/images/vehicle_553.JPG

Clutch side, I couldn't get the clutch basket bolt off for love nor money. Didn't help that the engine moved around.

Anyway, I think I found the source of the leak. I drained the gearbox oil to take the clutch cover off. And when I went to put the drain plug back in, it wouldn't fully tighten. So my diagnosis is a threaded sump plug. What a bastard.

So that means splitting the cases, and getting it helicoiled. Never mind.

I did look at just replacing the cases, but they're very expensive on eBay!

I also put a towbar on my car ready for trackday season:
https://www.gaz-racing.co.uk/images/vehicle_548.JPG

Gaz

[Welshd1k]

loving the chav mobile
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Current >Cb600fx hornet, ns125rk90 21.7bhp@wheel<
Sold >,zxr400 h2 (33bhp kit) rd350 n1 rd350 lc2<

[Gazdaman]

I love my car. Granted it is quite chavvy.

https://www.gaz-racing.co.uk/images/vehicle_532.JPG

I bought it a present recently:

https://www.gaz-racing.co.uk/images/vehicle_542.JPG
2L engine ftw.

Gaz

[Welshd1k]

even with 2ltr engine = chav . i mean the seats LOL
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Current >Cb600fx hornet, ns125rk90 21.7bhp@wheel<
Sold >,zxr400 h2 (33bhp kit) rd350 n1 rd350 lc2<

[Gazdaman]

Each to their own, I love my little car personally.

Gaz