KMX125 re-build

Roket125 · L Plate Warrior Joined: 10 Oct 2013 Karma :

Hi, totally new on here but I have been reading some of the excellent posts regarding the KMX rebuilds that are and have been done. Few months ago I got myself an A4 1988 F reg bike that was in bits. Bloke sold it to me under the "it's all there all you have to do is put it back together!"

Should have known better but not shy to a challenge the project began.
These are the first pic's.
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Roket125 · L Plate Warrior Joined: 10 Oct 2013 Karma :

Struggling to get the pics up second attempt! :
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bladerunner · World Chat Champion Joined: 09 Sep 2006 Karma :

Looks like a good starting point! What's the motor like?
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Current bikes...cbr929, KDX200's, Rd125lc mk2, RGV250's

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

bit of work left to do but that frame looks great
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1988 Kawasaki KMX 200

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

Roket125 · L Plate Warrior Joined: 10 Oct 2013 Karma :

Thanks guys. I have totally rebuilt the engine, had to put a new left hand crankcase in cos the mounting lugs for the front sprocket cover were broken. Got a brand new one on EBay for £30! All new bearings and oil seals and it went back together a treat.

New piston and rings for the top end and it feels really sweet. Real test will be how ( and if) it runs!

Need a new carb though cos I managed to snap the idle screw which was seized.

Just got to paint up the engine covers and I'll put some pics up.

All the plastics have been re-sprayed and look great, tank now needs some decals, any ideas?
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dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Roket125 · L Plate Warrior Joined: 10 Oct 2013 Karma :

Engine covers painted and it is looking good.

Thanks for the info re decals, I've got most of my parts from Cradley so I'll speak to them.

Might also have a go at painting my own, got some ideas but want to keep it close to standard as I can.

Here are a couple of pictures of the engine and tank awaiting decals.
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Roket125 · L Plate Warrior Joined: 10 Oct 2013 Karma :

Trying again with the photos!
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dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Nice job on the tank - did you spray it yourself?
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1988 Kawasaki KMX 200

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

Roket125 · L Plate Warrior Joined: 10 Oct 2013 Karma :

Yes I did, although the bloke I got it off had sprayed it but it was a shite job.

I've been reading that after painting it should be lacquered. Halfords do a lacquer for motorcycle petrol tanks that is resistant to petrol, have you any experience of it?

I've also had a right job trying to get hold of the correct size rear brake calliper piston and seals. I've tried two separate pattern parts on eBay and both sent me 34mm dia pistons which are not the ones for my bike, they should be 30mm.
Double the price for OEM stuff!
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dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Yes I used the halfords petrol resistant lawyer on mine.

It's worked well, no issues so far
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1988 Kawasaki KMX 200

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

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Strange about the rear brake caliper piston, thought they were all the same size?

I looked up the kmx200 rear caliper piston and that is 34mm
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1988 Kawasaki KMX 200

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

Roket125 · L Plate Warrior Joined: 10 Oct 2013 Karma :

Been busy over the lat month or so but have managed to keep plugging away.
Gutted I dropped the tank last week and have had to respray it but most of the bike is done now just waiting for a new chain, grips and then I'm going to start the beast up! Hopefully! Laughing

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Fladdem · World Chat Champion Joined: 29 Jun 2011 Karma :

Fantastic! Look stunning so far, keep it up.
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Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.

Roket125 · L Plate Warrior Joined: 10 Oct 2013 Karma :

Well here it is, all back together but still not started! Can't get a spark at the plug, looks like the ignition coil has gone. The readings on the ohms meter are miles out from the specs for the primary winding resistance and zero for the secondary. New HT coil on the way. Pleased with how it's turned. Just got to recover the seat.

Then I might get it dirty 😀😂
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Fladdem · World Chat Champion Joined: 29 Jun 2011 Karma :

Very cool. Trail bikes just look wrong when they're clean though. Wink

I love little two strokes, I've never owned one though, apart from the MT5, I missed out due to EU laws on emissions and stuff when I was looking for a 125, so all the old smokers were battered or overpriced when I was looking. I have had a few goes on some and they always get the adrenaline going for me when they step into their powerband, obviously four strokes are more linear so don't give me the rush as much.

If you don't mind, how much did it cost?
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Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.

Roket125 · L Plate Warrior Joined: 10 Oct 2013 Karma :

Got the basic stuff, frame and forks already sprayed and a big box of bits for £600. Told "all you have to do is put it together". Yeah right! Anyone that has ever done a re-build will tell you it is never that simple. I will know for the next time.

Even so I reckon I have spent the same again on new bits. Sourcing stuff in eBay is ok but some stuff you just have to get from original Kawasaki dealers.
I've really enjoyed doing it though, 1st project, not bad for a bloke in his garden shed and limited facilities.

Even the wife want to ride it and she hasn't ridden a bike in 10 years!
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stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

Excellent project, and she looks really nice and spotless now! Thumbs Up

Good luck with trying to take it off road, I've decided that my 125 can't even see a wet road until after the Easter 2014 Stafford CMM show. I'm going to show mine on a stand for the weekend hopefully, and then once it's over I'll start using it properly and enjoying it.

My 200 is going to get a mechanical re-build to a decent and clean std, but I'm going to just re-spray the tank, and throw back on the scuffed and scraped bodywork and plastics and not worry about the cosmetics, so that I'll have at least one KMX that I'm happy to get down and dirty with in the woods! Laughing