my '99 honda cr125 project + 02-07 plastics conversion

[JonKTM]

Hi all, from England!

Currently on with a fun (and bloody expensive ) project.

The bike is a '99 Honda cr125, i bought it several months ago as a non runner due to electrical fault with no spark.

Heres a pic of it at work on the day i got it:



Was so greasy, dirty, oily and shabby it was un-beliavable. First thing i did was put it in the van and take it home, then strip it down and de-grease and clean everything




Once that was done, i concentrated on getting it sparking.
Was told by the person i got it from, that it had a faulty CDI and a new one would fix it. Got one ordered but no luck, not even a weak spark.
Took readings with a multimeter from the stator, and it was giving really poor readings, much lower than usual so i got an aftermarket stator and fitted it, still nothing! I then left the bike for a month or 2 as i didnt want to spend any more money on it for the time being.

Came across a cr125 of the same year being broken on eBay, so i got the only other bits i havnt yet replaced - killswitch, flywheel and coil.

Fitted everything, still nothing! was like WTF HOW IS THIS NOT WORKING!!

Was about ready to throw the thing off a cliff, but in a last effort i quickly swapped the stators round again and put the old one on...kicked it over...STRONG BLUE SPARK! YESSS!! Couldnt belive it, quickly put the fuel tank back on and put some fuel in, kicked it over and it fired right up, first kick! brilliant for a bike thats been stood months and months

Heres a video of it on the day i got it running, although it ran crisp and responsive it refused to idle well


Now that i had got it running, i focused on the cosmetics

Bolted on some new pro-taper bars with new grips



Got some 02-07 style plastics ordered up which came yesterday, they are all test fitted on the 99 frame at the moment.

Front mudguard was a direct fit
Front number board fitted perfect with a nut and bolt holding it at the bottom, and i made a bracket for the top mount
Rad shrouds line up on the 99 tank but are in the wrong position when fitted as they dont sit flush at all under the seat or with radiator
Side boards line up on the subframe, but definately dont work with the standard airbox.
Rear mudguard is way out! 2 bolt holes are the same but it doesnt fit properly in the subframe and the front of it hits on the 99 airbox






Got a tank, rear subframe, seat and airbox+ rubber boot from an 02 bike due to arrive early next week, so everything should fit perfect and flush without the need to start welding, bending, grinding and fabricating things! Some people heat the 02 airbox to get it to fit in the 99 subframe, but im just going to replace the whole subframe, this way the airbox and plastics fit perfect without the need for brackets and modifications.

Exhaust is coming off in the morning and im going to blow the dents out of it, then sand and spray VHT black.
Re-stripping the bike down again also tomorrow, ready for the new parts so i can get them banged on soon as they arrive.

If the weathers poor tomorrow and theres nothing else to do, ill get on with draining the gearbox oil and coolant and putting fresh in, and change the pads if i can get the damn siezed in retaining pins out!

Let me know what you think so far guys!

[JonKTM]

**** me this forum is dead!

[AJ_YFZ]

Looks good when its degreased....Cool pics

[Kev_CR]

Looks like a fun project! The newer style plastics look unique on the '99 frame, I like it. I'm anxious to see how your build goes, so please keep us updated.

I might have to start looking for a fixer-upper CR125..

[JonKTM]

Originally Posted by Kev_CR

Looks like a fun project! The newer style plastics look unique on the '99 frame, I like it. I'm anxious to see how your build goes, so please keep us updated.

I might have to start looking for a fixer-upper CR125..

Yeah having alot of fun doing this project, going to be an awesome bike when its done!

---------- Post added at 01:46 PM ---------- Previous post was at 01:43 PM ----------

Carb removed and cleaned, new coloured fuel and breather piping added






Transmission oil changed, bike held upright with bungee cords wrapped around the roof and fridge

[Tonk]

what did your use to de-grease and give the bike a proper good clean? im stripping my bike in the next few weeks and getting frame powder coated so would be nice to know what you used

[JonKTM]

something called D-CLEAN

Its a homebrand motocross bike cleaner and de-greaser made by the KTM shop in town, most likely very simial to muc-off, but its more friendly on plastics

And for getting really tough muck off i use a special foaming de-greaser, and pressure wash it off (mainly on the frame, gotsa be carefull with using pressure washer near components and seals)

---------- Post added at 08:59 PM ---------- Previous post was at 08:56 PM ----------

HOPEFULLY the rest of the parts i need to finish off the bike will be coming tomorrow, providing parcelforce can be arsed :P

[Tonk]

i got a 1990 cr250 im going to be putting 96 plastics on and alot of engine work so any tips you can give me on stripping and building the bike cleaning anything would be of great help.

i cant pm you as i have not made enough posts yet.

[gsxrdude15]

looks sweet so far and your Priller sure looks nice too! Wish we could buy 2 Stroke street bikes here in the states! Keep us up to date with pics!

John

[Woody_393]

Looks awesome so far! I love the newer plastic, and good job on cleaning it up. I do love a good rebuild thread.

Keep up the good work and thanks for sharing.

[Tonk]

hows the project coming along now? not heard nuthing from jonktm in just over a week...

[mrcribbs]

cool thread. Nice bike and awesome story!

[ClosedCasket]

Updates man ! We need updates

[JonKTM]

Hi guys

sorry havnt updated in a while, been extremely busy with work

right, here goes..what a mess up!

The rear subframe wasnt a direct fit, it would fit if you forced it on, but it definately wasnt right.

The 2002+ tank wouldnt fit at all, completely wrong shape to fit in the frame

Front mudguard and numberplate went on perfect

Airbox was a doddle to fit, no need for heat guns or anything.

Spent several days fitting things and trying different things, and after alot of work i eventually got everything fitted, and to be honest, it looked terrible. The plastics were on, but even with brackets made, most things didnt sit flush and how they should.

In the end i got sick of it, stripped it back down and bought a brand new 99 plastics kit, fitted it, everything went on perfect, even though the 99 plastics look alot worse than the newer ones, everything is fitted originally, flush, and properly. so overall the bike is much better quality.

Still got all the conversion parts in my garage, when its a rainy day i might attempt the conversion again but overall its been a waste of money

[Woody_393]

I'm sorry to hear that. It sucks when you invest time and money and don't actually go anywhere.

[JonKTM]

when iv got a weekend free sometime ill attempt it again probably, but for now i need it all in one piece to ride in this sunny weather

[Woody_393]

Can't argue with that!

[ClosedCasket]

You could get a 00'/01' or 02'+ frame and rads on ebay for cheap, everything else should bolt up fine

[surewhynot]

so the 2002 airbox will fit in the 1999 no problem???