KMX 125 KIPS O RINGS

GREEN KMX · Derestricted Danger Joined: 28 Aug 2009 Karma :

I removed the power valves from my Kawasaki KMX125 and chucked them in a box when I stripped down the head.
Rebuilding the new head and reading through the Haynes manual I now see there was supposed to be O- rings above the guides.
I do remember when I removed the guides from the head they were the other way round, upside down to what the book says, with no O-rings in there at all. (not me).

Will any old O-ring work in here or does it have to be some special heat proof type Confused

Now the next job is to split the crank case and check for any debris from the busted piston rings. Not looking forward to it.

Oh ! here's another thing I'm stuck with.
The choke plunger is seized in the carb, anyone had this problem? I need to change the cable and the thing is solid. WD40 has been squirted in and left for a day or two but no joy.
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baldy · World Chat Champion Joined: 15 Feb 2004 Karma :

I just used any o rings. I got a kit with different sizes in from machine mart. As for the the positioning, they go above the silver guides.

Splitting the cases is easy, it took me about 15 minutes to strip and rebuild the gearbox.
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baldy · World Chat Champion Joined: 15 Feb 2004 Karma :

You may be able to free the choke plunger by stripping the carb and boiling it for a bit. It should get it moving.

You can look at the parts fiche for kmx here

They cover all the models but they are nearly all the same.
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One day i will rule the world, just not today.

bandit · Two Stroke Sniffer Joined: 19 Aug 2009 Karma :

Hi

The Haynes manual can be a bit pants Sad

on some bike i have found a parts manual the best as it shows where every parts fits...

I have used gen manuals as well but they can be lacking.... Sad

Instead of putting bits in box, get hold of old bits of card and tape bits to them how came apart/ take pics of what your doing they speak a thousand words and can make up for the time you spent taking them.. Very Happy

If you not good with gear boxs make sure they stay in one part when you split cranks cases... Dont forget any thin washers that may stick to the other bearings as you split cases...

The choke plunger take the black nob of and unscrew brass nut then leave it to soak in a sealed container of petrol for day or 2 it should free it self.. Becarfull of WD40 etc it makes rubber swell..

Please tell me that you are rebuilding with Gen rings you can just about get away with pattern piston.. Do not use patern rings as they just break up in under 2k Crying or Very sad

Best of luck Thumbs Up

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b12 cg125 gt250 kh125 ss50 cg150 CG250cc

GREEN KMX · Derestricted Danger Joined: 28 Aug 2009 Karma :

Thanks for the tip on WD40 i forgot about that Bandit.
Busted rings is the reason I have this bike. I will follow your advice and ask the man at Kawasaki for the geyooine article. Cool

And Ok on the O-rings Baldy. I have a couple which are the right size in my tool box just thought it would be good to ask. Smile

I am not looking forward to the crankcase and will be extra carefull when srtipping down for checking, every days a new adventure just now. Mr. Green

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she's alive!!!!

GREEN KMX · Derestricted Danger Joined: 28 Aug 2009 Karma :

I soaked the entire carb in a tub of petrol for the whole day.
I went out tonight and it was still solid.
Seeing red I hauled at it with all the might of the HULK not caring if it broke, and pop out she came......jeez. Mr. Green

I stripped down the back end today for something to do.
The dog bones were cut and extended not shortened as I thought which is mebbe coz the shocker was knackered.
Going to give everything a pressure wash tomorrow.
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she's alive!!!!

GREEN KMX · Derestricted Danger Joined: 28 Aug 2009 Karma :

Next problem was removing the flywheel to look inside the crankcase to check for debris. I sent off for a flywheel puller. It arrived next day only £11 including postage. I had the 1/2 drive long bar on it and my big adjustable spanner. Boy it was on tight. It gave out a heck of a crack and i thought i had broken something.
Nope it was off and all ok, so removed the woodruff key and had a go at the stator. All three cross head screws were solid and the impact driver just rounded out the centres. I drilled down through the 3 screws and chapped in the square tapered stud extractor. And bugger me it didnt slip or break off, but took them all out easily.
I had the same scenario on the other side with a screw that holds on a cog.
This 20 year old bike is fighting me all the way. Twisted Evil

Hats off to those dude's, who fix up 60's bikes.
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she's alive!!!!