KMX 125 Restoration

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

Lads just bought a beat up old KMX125 89 Model.

Going to be a nut and bolt restoration any tips on mods or any advice ?

Are the barrels on the earlier models plated ?

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

hi

good to hear another kmx project getting started !

Yes all barrels on the kmx 125/200 were Nikasil plated, for all years. Occasionally owners fitted a liner, so bear that in mind when you strip the engine. I bought standard piston for my kmx 200, only to find when I took the cylinder off, it was fitted with a liner - so the piston didn't fit !

Hard to give tips without knowing what you're looking to do exactly & budget etc. would say that if you're going to be selling the bike any time soon, try to keep the bike standard as far as possible. Good standard bikes tend to make better money than modified ones.

if you're going to hold onto it, then originality isn't such an issue, but worth keeping any original parts to convert back to standard if you decide to sell.

There's a few of us on here working on KMX's, so may be able to help with a few things.

Look forward to seeing more on the project !
____________________
1988 Kawasaki KMX 200

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

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

Bike is a keeper for my son just turned 17.

I had a KMX, RD125LC and DT125LC myself in my youth but have forgot so much despite doing engine rebuilds on them all.

Sort of tips i was after as all the brakes forks and engine need a overhaul is there any upgrades i could do rather than overhaul what i have.

Ill post some pics tomorrow its in a sorry state.

Anyone know where to get graphics sets ?

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

In terms of upgrades others would probably be able to advise better than me. One of the guys on here fitted a KDX front end to his KMX125 which had the benefit of a twin piston caliper along with more stability.

As far as the engine goes the 125 engine is pretty tough, as it has the Nikasil bore. They make good power which will be plenty for a 17 year old. There's a range of exhausts available, alternative reeds, air-filters of course. After he's passed his test, a 200cc barrel can be used - this means changing the exhaust, rejecting the carb and some other details.

On the suspension, if it's clapped out, get the later rear shock (has a remote reservoir) this is a good upgrade on the original. Also KMX200 forks and yokes fit straight in, which are beefier than 125 forks and have different internals. Tapered head bearings are better than the cup & cone bearings which are standard fitment.

Im going to be overhauling the brakes on the 200 shortly, using braided hoses, will put some pictures up.

There's a thread of my 200 being slowly rebuilt on here too in the projects section.

Hope that helps - I expect others will be along shortly with tips aswell.
____________________
1988 Kawasaki KMX 200

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

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Also for graphics sets try either Cradley Kawasaki, or online here:

https://www.cmsnl.com/kawasaki-kmx125_model11857/
____________________
1988 Kawasaki KMX 200

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

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

Nice one mate some good info there, yeah ive been looking at your 200 thread im very impressed Thumbs Up

Ive got the bike half stripped today will finish the strip Friday after work and take frame and anything else metal that looks shabby for plastic coating.

Here some pics from its previous owner

Its in a bad way pics make it look better than it is .

https://i56.photobucket.com/albums/g181/Ferret19/kmx1.jpg
https://i56.photobucket.com/albums/g181/Ferret19/kmx7.jpg
https://i56.photobucket.com/albums/g181/Ferret19/kmx6.jpg
https://i56.photobucket.com/albums/g181/Ferret19/kmx41.jpg
https://i56.photobucket.com/albums/g181/Ferret19/kmx31.jpg

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

Again as other's have said it's hard to know what upgrades to suggest without being specific?
Just a few points and they are not common to just KMX's at all but,
1, Check the alloy wheel rims for corrosion inside, as it can happen.
2, The rear shock along with the swing arm bushes and the Unitrack linkage tends to get a battering and will need a proper re-build with all new bearings, and seals etc in most cases.
3, The sidestand cut out switch often gets dirty and corroded causing cutting out problems etc. If it's still there, id remove it personally. also check the wiring under the seat as it can get damaged and frayed.
4,If the OE exhaust is damaged or rotten, then there are 2 common aftermarket pipes that both work well and are much lighter than the std one. Giannelli pipes seem to give a bit more top end power, but thier full system is a bit on the loud side!
5, Definately fit sintered pads front and rear, and use braided lines. I found a world of difference in braking on my 200, with sintered pads and a decent front disc. The std Organic pads don't give enough braking performance for 30bhp!
6, If he's only going to use the bike on the road when it's restored (which would be the best way to keep it looking nice) the fit some decent road tyres with no off road ability at all. You could get Pirelli MT65's in 21/18" sizes, and im sure there's a current equivalent. Road tyres make the bike ride much better IMO, faster, better braked and more stable too!
7, If and when you re-build the motor then look out for broken powervalves. If it's an early bike it's a common KMX problem. There's plenty of people on here who can advise you about what to do about them when the time comes.

Lastly it's well worth looking at the radiator as old abused an heavily off roaded KMX's can end up with damaged radiators which cause cooling and reliability problems. I don't reccomend flushing out crusty old rad's and think for the piece of mind a new rad and thermostat is a wise move on any re-built bike.

dengser · L Plate Warrior Joined: 22 Apr 2012 Karma :

Im going to be overhauling the brakes on the 200 shortly, using braided hoses, will put some pictures up.
https://www.nlmlol.info/g.gif

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Doesn't look too bad in the pictures - at least it is virtually complete.

As with all these bikes when they reach this age, if you expect to overhaul every part, then if some parts are in good order then thats a bonus.

That rear disk looks pretty scored - might be worth having a scout about for a replacement. There's a set for sale here very cheaply:
https://www.bdkraceeng.co.uk/Used%20Parts.html

Also one of the major costs with these bikes is the Nikasil bore so might be worth having the barrel off sooner rather than later to see the condition of that.

Good to see a standard pipe on it - could indicate the bike has had an easier life. If its still restricted (plates welded into the exhaust) then this is a good sign as wont have been able to be over-revved.
____________________
1988 Kawasaki KMX 200

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

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

Never had so much good advise can tell these bikes are still as popular as when i rode a nearly new one in my early twenties.

Yes i was pretty pleased regarding the front pipe it does look solid so ill take it for some gently blasting with the frame and stuff if it survives then its will be VHT painted and used the rear is a DEP and surprisingly quiet

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

Lads just ordering some must have bit prior to its strip down and transformation.

Need i need for mudguard and im struggling to source one seen plenty of KDX and KX mudguards on ebay.

Anyone know if they will fit some are not drilled so that is not a issue but the width of the of it bettween the yokes could be a issue.

Any help ?

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Yes, am sure the KX + KDX mudguards will fit - may need modify slightly where they mount on the yokes.
____________________
1988 Kawasaki KMX 200

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

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

Cheers Dave

What do you mean by modify i notice the KX has i slight hump infront of the yoke do you mean this or the mounting holes.

Ive seen a KX 250 one that is almost a match to the original apart from the hump in fornt of the yokes, i want to try keep the overall look as original as poss to be honest.

Thanks your experiance has come in useful to me.

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

Any one have any experiance with the KMX Shock linkage ?

https://i56.photobucket.com/albums/g181/Ferret19/Photo046.jpg

Just stripped the bike for plastic coating but the spindle going through the frame and linkage wont come out the spindle turns and moves in and out of the frame side but something is seized to the spindle inside the linkage.

Is this a bearing ?

Ive tried soaking and heat it wont budge . Any ideas ?

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

That was stuborn even a hydrualic press could no puch it out, ended up hack sawing the bolt both sides of the linkage.

£38 for a replacment bolt/spindle Shocked

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

For those that have a interest in old 2 strokes here is a bit of a update on the restoration of this heap of junk lol

For some reason the colors don't look right but pics taken with a camera phone so maybe thats it, the green is a good Kwak Green and the blue is electric blue.

https://i56.photobucket.com/albums/g181/Ferret19/Photo055.jpg

https://i56.photobucket.com/albums/g181/Ferret19/Photo053.jpg

https://i56.photobucket.com/albums/g181/Ferret19/Photo056.jpg

Also had the front pipe blasted

https://i56.photobucket.com/albums/g181/Ferret19/Photo057.jpg

So now the rebuild starts.

What do you think ?

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

Fantastic job they have done on the frame and cycle parts mate, very smart! I'm really liking the blue green combination you've gone for as well, and it will be interesting to see how it looks all assembled, as im not sure i'd be brave enough to coat a swinging arm blue? I think it will work great when the whole bike is together and with contrasting graphics etc.

Did you make up those two plates to stop the powdercoat getting into the frame where the rear suspension rocker arm mounts to the frame, or did your powdercoater mask them for you?

lastly it looks like great work, so are you going to spill the beans on the name of the firm? Thumbs Up

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

I just plated them up with a bit of ali to protect the bearing surfaces the bearings were all out.

Yeah did have my doubts regarding the blue swinger but my lad will have to live with it.

The company was LSN coatings at Castleford, great bunch of lads used them on a epic Honda XL185 restore now that thing was mint when i finished it.

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

Thats a great job they've done on the frame there. If the work so far is anything to go by this bike is going to look mint when complete.

By the way is there a welded in washer in the exhaust header pipe ? This is how they used to restrict them, by limiting the gas flow out of the cylinder. If there's still one in there (unlikely after all these years though), that can be knocked out to give some easy horse-power.
____________________
1988 Kawasaki KMX 200

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

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

No mate no washer there it was the first thing i looked for when i took the pipe off.

Anyone got ant ideas regarding Graphics/Decals ? Phoned Cradley and checked CMSL can not get the original graphics for this year a 89.

Have some Kwak green paint coming through the post this week but really need Decals.

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

I know you've checked CMSNL but looking at it, it just seems to be the 1989 tank decals which are out of stock (but not necessarily unavailable).

https://www.cmsnl.com/kawasaki-1989-a4-kmx125_model11861/partslist/F2861.html#results

I've ordered a few bits for my 200 from them, sometimes it can take a while for them to get the parts in but they haven't let me down yet.
____________________
1988 Kawasaki KMX 200

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

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

I know you've checked CMSNL but looking at it, it just seems to be the 1989 tank decals which are out of stock (but not necessarily unavailable).

https://www.cmsnl.com/kawasaki-1989-a4-kmx125_model11861/partslist/F2861.html#results

I've ordered a few bits for my 200 from them, sometimes it can take a while for them to get the parts in but they haven't let me down yet.
____________________
1988 Kawasaki KMX 200

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

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

Thanks mate

Did check CMSL for the B4 graphics it let me order but then i got a out of stock email.

I guess i could try the A4 ones but the decal backing can differ for the colour of the bike they were made for say Decals for a Black will be different to what i want for the green.

Scares me ill have a good dig around on there.

thanks

Compo · Nova Slayer Joined: 02 Jan 2006 Karma :

Finally got around to sorting the suspension linkage out today.

For those thinking about putting a KMX field back back on the road should really thing about the cost of overhauling the linkage £125 covers it . The Bearings and seals are specials and are only available from Kawasaki or Koyo and the bushes only from Kawasaki.

Pic has a old bearing and bush at the front to show you the state they where in the bushes were seized in the bearings and the bolts seized in the bushes the rollers in the bearing were worn flat. Linkage now has the new bearings pressed home.

https://i56.photobucket.com/albums/g181/Ferret19/Photo060.jpg
https://i56.photobucket.com/albums/g181/Ferret19/Photo062.jpg

MOT will be a piece of cake now Very Happy