and it begins (99 KX 125 conversion)

[diymirage]

this was her 2 days ago



and this is her after about an hour or so of relaxed wrenching



here are both the bottom tripple clamps soaking to get cleaned so they will be nice and nastynessfree for Ron to work on
(shipping themn out on monday)



and here are the new forks waiting installment



they look like they came from a very low hour bike
one or two scratches on the upper tubes, nothing im concerned about

when i contacted the seller several months ago he still had the fork guards but when i finally got the funds together to pull the trigger and buy them those were gone (anyone have a set to spare?)

what was included in the sale is the front wheel WITH axle and comeplete brake set up
well almost complete, the PO must have dropped the bike once and snapped the brake lever in two

i intend on using the (larger) KDX caliper and everything else from the KX
i will take the caliper in to work on monday to machine it down so the KX line will fit it

any thoughts on which master cylinder would be better ?
or any other suggestion/things to look for?

[rbates9]

Why would you machine the caliper? If you are going to run a headlight on the bike then you will need to run the KDX brake line routing. The KX brake line routing for those years sucked any way. I would start by leaving the brake alone and just mount the KDX caliper to the KX forks and not remove the line from anything.

As far as the fork guards, if you can't find the $25 to buy a new set then you probably shouldn't bother with a fork swap.

[diymirage]

good point on the line
i hadnt thunk about the headlight yet (which i will be running seeing how its really more of a comuter bike then a dirt bike)

as for the forks guards, they werent budgeted in
i had figured 180 for the front end, 35 for the spacer
now i decided to let a profesional do the stem swap instead of piddling around with it myself so that put me over my budget by 40 bucks (money well spend in the long run) but the 25 for fork guards does add up

im sure ill get a set sooner or later but i figured it never hurt to ask

[B737driver]

I've got a set of fork guards for you. PM me and pay the shipping and they are yours.

Don

[diymirage]

I've got a set of fork guards for you. PM me and pay the shipping and they are yours.

Don

thats great Don
could you send me an email at epj777_oost@yahoo.com ?
i dont have PM priveleges yet

thanks

[diymirage]

and....done
mostly, still waiting on the fork gaurds to get here but everything else is done

i had Ron do the stem swap and he suggested i replace the bearings since they were wore out so i did
got the parts back from Ron on friday and everything bolted on on friday

today i did the finishing touches,made the steering stops and a new bracket for the headlight (more on that later)

here are the first pics :)



this is how i dealt with the brake line



i used the KX wheel and disc with the KDX caliper and line BUT i took the banjo bolt of the caliper and turned it around 180 degrees so it loops around the outside of the fork (and hopefully will attach to the fork gaurd in a acceptable manner)

right now it is still looping through both the upper and lower tripple clamp cable guides but im thinking of removing the upper one for a free-er movement



this is the extra lower headlight bracket i made
(it is just temporary, im planning on buying a KX style headlight for this bike and putting this stock unit on the project)



and here are the steering stops
i just drilled and tapped the stock KX stops and put a bolt in each of them





and finally the whole bike again



comments are welcome :)

[rbates9]

looks good!

But, unless you are only going to ride the street then you will want to get the brake line to the inside or it will get caught on stuff and probably lead to a bad day. Also you will need to attach the brake line to the fork guard so it pushes the line up with wheel travel. You will probably want to use the lower KX brake line guide and the lower KDX line guide on the upper T clamp to keep the line going straight.

When I did my fork swap I found that a set of UFO rubber headlight straps worked great for the lower mount of the headlight with the stock upper mounts swaped from side to side made the headlight sit about right.

[diymirage]

Thanks for the advice Roger (wild guess there)
The bike is mainly a comuter bike, id say 90% street use, so i am not too terribly worried a bout snags.
having said that, i do plan on it stradling the fork guard once they get here and i will install the KX line clamp then

As for the headlight straps...i cant see myself paying $25 for a set of straps when i can get a new headligt WITH straps for $35

But that will have to wait till the next paycheck
(I also have a project bike that is missing the headlight all together so thats where the stock unit will end up)

[diymirage]

bump per Juliend's request