89 KX125 - Possible restoration

[queen of spodes]

Obsolete 13140-1070 FORK-SHIFT,2ND&3RD fits 82-91 kx125
Obsolete 13140-1123 FORK-SHIFT,5TH&TOP fits 85-91 kx125
Obsolete 13140-1124 FORK-SHIFT,LOW&4TH fits 85-91 kx125
I would keep my eyes open on eBay for a NOS set.

Will do - thanks for the part #s.

[queen of spodes]

I finally had a little more time to comb over the bike this evening.   If the welded on sprocket wasn't enough proof, this bike is in sad shape.




 
Shift mechanism is boogered - no spring action. 




Crusty intake boot


Left side peg mount:


Right side peg mount:


Looks like I'll be needing some new linkage components.  Bearing completely gone on the lower shock joint:


Front wheel off of a 85-87 KX - note the black (not spray painted) hub:


TUF Racing "TUF II TWIST" handlebar stabilizer.. woohoo!


Radiator is damaged and bent.  I'm sending pics & dimensions to a Chinese manufacturer in hopes they have cores long enough to reproduce this one.


But hey, cylinder has 155psi compression!



I haven't ordered any parts yet, and may sit on it another month before deciding what to do.

[Foxx4Beaver]

Honestly...it's not that bad...it's all there.
I would try to spend some time searching for the parts it needs before giving up too quickly.
You can soda blast most of the aluminum parts to give them a new look, same with the engine cases...most of the cosmetics you can still get, such as plastics, new seat cover, fork boots...etc

Yeah, it'll be a job finding the obsolete parts...but not impossible...do what Sandblaster suggested and search e-bay on a daily basis.

[queen of spodes]

Started disassembly this afternoon.   Have a couple questions a little further down.



Tell-tale signs of orange silicone:


I try not to think too hard about the things I find on this motorcycle:



First question - were these rear brake line bracket studs originally bolts? Or is this how it's supposed to be?   



Second question - WTF is the white powder and why is it here?   Best way to clean it off the stator?








That's it for now!

[queen of spodes]

Bump for my two questions in the post above (white stuff & rear brake hose hardware).

Also a third question.  Will newer brake calipers fit on the '89 legs?  guessing the answer is no due to the switch from conventional to USD but worth asking!

[sandblaster]

The front brake caliper mount holes are 78mm.
The newer forks use 60.5 and 102mm.

http://www.oem-cycle.com/KX125KAWASAKIBIKEID.shtml
Scroll to the right to my fork dimensions.

[queen of spodes]

The front brake caliper mount holes are 78mm.
The newer forks use 60.5 and 102mm.

http://www.oem-cycle.com/KX125KAWASAKIBIKEID.shtml
Scroll to the right to my fork dimensions.

Thanks - very useful site.  Bookmarked.

[queen of spodes]

Any input on the other two questions a couple posts above?

[sandblaster]

I didn't want to hog all the fun... 
The fasteners that hold the rear brake hoses holders in place are usually a hex head fastener.

The white powder is aluminum oxide from water getting into the stator area and sitting there.
I would test the stator and see if it is still in spec.
If so, I would remove the flywheel and the stator.
Then I would use a dremel with a small wire wheel and clean off all the oxide from the cases.
I would also clean any rust off the flywheel.
You can spray the raw aluminum with WD-40.
For that matter spraying WD-40 on everything else including the stator does not hurt.
Inspect closely, wipe it all dry, reassemble, and double check the ohm specs before putting the stator cover on.

[Goat]

On 88 and 89 the studs in the swingarm for the brake line are factory. Not sure about any other years. I owned both years when I was younger. I'm surprised both studs are still intact. They tend to snap off flush with the top of the swingarm so be gentle with them.

[sandblaster]

On 88 and 89 the studs in the swingarm for the brake line are factory. Not sure about any other years. I owned both years when I was younger. I'm surprised both studs are still intact. They tend to snap off flush with the top of the swingarm so be gentle with them.

+1
I checked some pics I have from 88 and 89's we have parted and sure enough they used studs in those years.
Good catch Goat 

[motopunk]

Bump for my two questions in the post above (white stuff & rear brake hose hardware).

Also a third question.  Will newer brake calipers fit on the '89 legs?  guessing the answer is no due to the switch from conventional to USD but worth asking!

my 83 kx250 with 1991 brake caliper on 88 fork legs with my handmade adapter...  you´ll see its possible to make it...


and the full build report with some more pics:
http://der-motopunk.de.tl/kx250c1_1983-die-wiedergeburt-.htm

[motopunk]

the white powder on your statorplate is aluminiumoxid caused of always wet behind the cover over years...  there is also good to see the rust on the flywheel...

this weld on sprocket is awesome hillbilly-repair very rare to see pics ...  ... i´m just wondering if the seal behind is not melted by welding ...