I'm just gonna leave this here

[lizardfungus200]

Some of the finest jb weld money can buy

[KDXGarage]

Sorry to hear about your wrist! I cracked mine once. I recovered and raced MX a bunch afterwards.

Congratulations on getting it going!

Where did you get the stickers? Was the seat cover from Thailand / eBay? I really like the 1993 graphics, might be the best looking ones ever made (KDX-wise).

[lizardfungus200]

Thanks man, The seat cover is from thailand, they sent it for no charge because I sent them my old seat cover. Some guys say the 93 graphics are too corny which they might be, but i agree with you that they are some of the best, that‘s why I bought them. The stickers are from china, i got them for like $18 shipped. The color is not the best, but I plan on touching it up with an airbrush, so its a bright yellow, fade to bright orange/pink, and im thinking about using a gold paint marker somewhere in the mix. Maybe add some flames? My father was a big time surfboard and boat painter in the 80s and 90s, so we might do something cool with it, who knows. I dont want to go too far out and maintain the clean look



https://www.ebay.com/itm/Decals-Fuel-Ta ... 3384939769

https://www.ebay.com/itm/KAWASAKI-KX125 ... SwsY1dG0bM

[KDXGarage]

Thanks for the info, and thank you for the donation!

[kdxsully]

I wish I sent them my Yamaha of Troy yz cover. They seem desirable and it looked cool

[SS109]

Keep us posted!

[lizardfungus200]

I will be updating and posting pics as I chip away at it. Recently I started to repaint the swingarm, I wanted to go with the bare aluminum look, but not bad enough to put in the work. A few thick coats of primer and paint covered up the scars I made with a wire wheel. I took the cylinder off to do some more porting since my new tool came in. This is still a budget build, so Im always looking for deals on anything i can do to my bike, for example, I picked up a set of like new asv levers for $25, some xr400 fork springs for $20, a free 35w hid bulb and ballast, cheap graphics, a used trail tech vapor I traded, and an 02 rm125 shock

Ive heard the flywheel can strip threads when trying to get it off, does anyone have a preferred puller?

Ss109, I saw you had an rm shock on your bike. I read somewhere it fits with a little grinding, but it makes the bike higher. Would you know if it possible to mitigate the height difference with just a lowering link?

[KDXGarage]

Put grease on the crankshaft end and various threads. I have used OEM, but think others would do well, like Dennis Stubblefield Sales.

[lizardfungus200]

I got a problem, the clutch pin does not stick out far enough, so that the actuator arm thingy on the top of the case needs to be pulled/turned more than it used to before it starts to operate the clutch, more than 90 degrees relative to the clutch cable. Am I missing something?

I have the clutch nut, washer, and springs not pictured.

[SS109]

Double check the placement of the washers. In what order do you have everything installed?

[lizardfungus200]

All the parts shown are installed in the order they appear

[bufftester]

Check the washer stack up inside the clutch basket as well, sounds as if you're missing a washer somewhere

[KDXGarage]

How many threads are on here about missing / misaligned clutch washers? It does seem to be a common concern during reassembly.

[SS109]

Do you have the washer the red arrow is pointing to installed?

Clutch basket washer.jpg (102.14 KiB) Viewed 4695 times

[lizardfungus200]

Hmm, I think I put that washer right underneath the nut

[lizardfungus200]

Wait no, i lost that washer. If anyone reading this is changing out their clutch right now, could you please send me the thickness of this washer?

[bufftester]

That would give you issues with clutch actuation. That washer is p/n 92200-1238 which is a washer with the following dimensions 20.3IDX30ODX2.3 Thickness

[lizardfungus200]

Thank you ao much buffteater

[lizardfungus200]

Even after I found a replacement washer, I was still having the same issue. Upon further inspection, with the clutch springs tightened, the clutch disk was separated from the cluch plates, basically the clutch was disengaged and not grabbing. The inner clutch disk caught on a tooth from the plates when i tightened it up. This may explain why it is a common problem when people service their clutch. Anyway Finished that up and tested out my new asv levers and they made pulling the clutch a lot easier. I used a washer that was .2mm smaller, so that may have made a small difference. I was planning on lengthening the clutch arm, but not anymore.

Here’s a few pics of the porting. Mostly just smoothed things out and matched the exhaust to my pipe. I did raise the transfers and exhaust just a hair, just a little closer on the bevel.

[lizardfungus200]

New wiseco piston. I was having trouble with the one kips rack with the o ring sticking and not moving easily. Honed and polished both tubes and now its like butter, however the central valve that slides in and out sticks where the acuator arm moves it with that little pin. Don’t know if its normal or not, there may be excessive play in that valve, but it doesn’t seem like it would be a problem at all when the engine is vibrating.