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Author Topic: 2004 KX 125 Rebuild  (Read 41649 times)

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Offline DP3601

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Re: 2004 KX 125 Rebuild
« Reply #30 on: April 18, 2016, 01:36:13 PM »
Quote from: Foxx4Beaver on April 18, 2016, 12:37:05 PM
if it's "jetted right on", it shouldn't be smoking a lot.
there is a seal on the KIPS shaft...part number 92049-1238, and if it's worn/leaking, then it will show a little more black oil than normal when you pull the cover.

you could have a bad clutch side crank seal too...which would allow it to suck tranny fluid and burn it, causing the excessive smoking...a possibility.
and if it does have a bad crank seal, you'll never get it jetted correctly.
[/quote

There is a lot of oil. It poured out when I pulled the cover. I have been lucky not to pull the cases apart but I think its time to just do it.]
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Offline Foxx4Beaver

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Re: 2004 KX 125 Rebuild
« Reply #31 on: April 18, 2016, 08:46:22 PM »
Quote from: DP3601 on April 18, 2016, 01:36:13 PM
I have been lucky not to pull the cases apart but I think its time to just do it.

yup...then you'll know what you have, and can start fresh with a tight motor.
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Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ

Offline DP3601

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Re: 2004 KX 125 Rebuild
« Reply #32 on: May 03, 2016, 12:26:46 PM »
When I pulled the exhaust valve cover this is what poured out... Not good! 


Ive been putting off splitting the cases so I decided it was time to replace the bearings and seals through out the engine so I know it would be nice and tight.
« Last Edit: May 03, 2016, 12:28:42 PM by DP3601 »
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Offline DP3601

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Re: 2004 KX 125 Rebuild
« Reply #33 on: May 03, 2016, 12:33:45 PM »

Motor pulled, trying to decide if I want to powder coat the frame while she's apart.


Motor pulled and it begins..



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Offline DP3601

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Re: 2004 KX 125 Rebuild
« Reply #34 on: May 03, 2016, 12:35:00 PM »

Pulled the cover off and they had no gasket, so there is a little bit of a mess I need to clean up.
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Offline DP3601

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Re: 2004 KX 125 Rebuild
« Reply #35 on: May 03, 2016, 12:36:41 PM »

I hope I remember how to put this all back together.  Good thing for a service manual..
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Offline DP3601

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Re: 2004 KX 125 Rebuild
« Reply #36 on: May 03, 2016, 12:59:49 PM »

The cases are looking pretty rough on the outside.  I planned to send these to member sandblaster to have these done but unexpected expenses causes me to save that till another time.

So I have been working on these with scotch brite and some elbow grease.  My fingers are sore!
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Offline DP3601

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Re: 2004 KX 125 Rebuild
« Reply #37 on: May 03, 2016, 01:00:53 PM »

The assembly begins
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Offline DP3601

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Re: 2004 KX 125 Rebuild
« Reply #38 on: May 09, 2016, 10:12:31 AM »
Has anyone had experience with power coating their frame?  How lone does it last and is it durable?

I have always repainted with color rite paint and it of course doesnt last to long.  I am debating going with the green frame as I was never a big fan of the gray frame that came on this originally.
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Offline Foxx4Beaver

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Re: 2004 KX 125 Rebuild
« Reply #39 on: May 09, 2016, 10:18:25 AM »
powder coating is the only way!...very durable. 8-)
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Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ

Offline DP3601

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Re: 2004 KX 125 Rebuild
« Reply #40 on: May 10, 2016, 11:10:47 AM »
Quote from: Foxx4Beaver on May 09, 2016, 10:18:25 AM
powder coating is the only way!...very durable. 8-)


Looks like that will be the next project on this bike maybe for the winter.  Time to get it all back together and ride for now!
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Offline DP3601

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Re: 2004 KX 125 Rebuild
« Reply #41 on: May 10, 2016, 11:14:52 AM »




Got it back together ready to drop back into the frame.
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Offline Foxx4Beaver

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Re: 2004 KX 125 Rebuild
« Reply #42 on: May 11, 2016, 07:24:00 AM »
lookin good....
the cases didn't come out too bad for doing it the old fashioned way..(Man-u-el labor) :mrgreen:
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Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ

Offline DP3601

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Re: 2004 KX 125 Rebuild
« Reply #43 on: May 11, 2016, 01:38:31 PM »
Quote from: Foxx4Beaver on May 11, 2016, 07:24:00 AM
lookin good....
the cases didn't come out too bad for doing it the old fashioned way..(Man-u-el labor) :mrgreen:

Im pretty happy with it, lots of hours of that manual labor...  I had picked up a few add ons as you can see that made it look better than stock.  I am just waiting on a couple motor mount bolts that needed replaced and she will be back in action! :-D
« Last Edit: May 11, 2016, 09:56:54 PM by DP3601 »
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Offline DP3601

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Re: 2004 KX 125 Rebuild
« Reply #44 on: May 27, 2016, 12:51:02 AM »
I have searched for this all over but cant find the offset for the triple clamps on my 2004 KX 125.  Does anyone know where I can find this or know what it is?
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