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Had the bug for a while now and I'm about to act on it. Looking at an '04 KX 125 and an '02 KX 125 today. I've done some research and understand most of the nuances between the model years, just curious if anyone would like to chime in on their preference and why. Thx in advance.

I have done an '01 and an '02 hybrid. Kept away from the 2003 and up because in California they get a red sticker, 02 and back are green sticker.
I would prefer the newer model because
1) newer styling
2) suspension upgrades
3) don't have to modify the gas tank
4) I believe that they have a lower seat height
5) easier to find nice graphics for.
6) the newer engine will sell for a little more (both are easy to sell)
The '04 is a good choice because it was the last year that the KX125 was updated. All of the newer models are the same basic bike and use the same parts.
With that said, I have been very happy with with the older L-series chassis I used and parts are easy to find. They also have a slightly larger fuel tank.
Either will make a fine ride. The '02 has the larger front forks that the newer models have.
Good luck with your project. You came to the right place.

What is the price difference between the two?

The "02 is $400 and is a full bike, motor still in, not running. The '04 owner hasn't returned my call to give me a price. Strangely enough the '02 has a black frame hmmm so it's been modified/gone through/paintred at some point.http://dallas.craigslist.org/mdf/mcy/3545375740.html

The '02 is a great price. Pretty clean bike.
Love the chevy graphics, just like on my '01.
You can sell the carb and engine for at least that much.
You are right that it originally had a green frame.

for 400, can't go wrong, check the vin to really be sure it is wha tit says it is.
Be ready to replace all the bearings on that bike...looks like it lived outside it whole life. seen the pipe

Going to look at it now. What should tenth digit on VIN be for an '02?

2

Could be an '01. It looks like the Mukuni carb.
Only difference is the front forks.

$300.00 later. It's an '02.

Still going to look at the '04. If I like, I'll part this one out.

B737driver wrote:$300.00 later. It's an '02.

Nice score - cant go wrong at that price.

Looks a lot like mine! Except the engine. I better check the garage when I get home!

Man, wish one of those deals would fall in my lap. Even if you get the '04, you can make money off parting out the '02.

That thing looks great Doc. Wish I could snap my fingers and swap the motor over. I can already tell that I'm going to like the ergsos.

Gotta figure out what I'm gonna do with it. It's got good compression, Suspension has been tuned by Pro Circuit, carb was full of old gas and the float is not functioning. It's been sitting out for a while. Gonna order a carb kit and try to get it running.

This is my time of the year to ride,so I'm not ready to pull the motor out of the KDX just yet.

Think what you have to look forward to though.

It actually looks a bit different now. That was day one after the build.
I can't leave well enough alone.
I did a speed build on the one above because it was my second go round. Had it together and running in a day with only some scraped knuckles.
Only part you'll need to buy is a KX250 silencer from a 99 - 02. That is why a swap starting with two complete bikes is the way to go.
Sell the extra kdx parts and you'll be in the thing for hardly anything. I paid about $1100 for my low hour donor 2000 KDX and $850 for a clean KX125 and when all was said and done, I was in the hybrid for less than a grand with a kickstand, skid plate, pipe guard and RB head mod. Your starting out for less than I did.
FYI, I tried the Mukuni TM carb off the 125 on my hybrid at first since it fit the KX airbox boot. Amazing low end which surprised me because it is a bigger 38mm carb.
Once I swapped it for the KDX 200 Keihin carb, the bike woke up and the Keihin was sold on ebay. FYI, the Mikuni had to be leaned out quite a bit from the stock jetting.

I really am looking forward to the build process. I went through my KDX (which I bought new in '04) for the first time last summer and had a blast. There's something about doing it yourself, skin in the game as they say.

This 125 is going to take some work. As sheckaet pointed out, it's lived outside for a while. So it will get the full treatment - bearings, bushings, etc. etc. Which I plan on documenting by the way.

Question - Are the forks a different size from the '01 KX? I've got '01 KX forks on my KDX with a Scotts upper T-clamp and steering damper. The forks on the '02 are really plush, but I really like the steering damper.

The '02 went from 46mm to the 48mm forks but you could swap the '01 forks on it if you want. You would just have to use the '01 clamps. I swapped a kx250f triple clamp on mine so I could run the newer style fender/number plate without having to rig it.
The clamp has a different offset. so I had to play with the suspension, i.e. fork height and sag, to get it turning like I wanted it to.
The '02 forks also have the bladders in them which I removed from mine. I didn't think the difference was worth the effort.
I have a steering damper on mine but it attaches to the bar mount so it will work on either year.

Grab the 04 the pipe fits very well on them my 05 fits like factory around the front of the frame,

When I was deciding what year to use I checked dirt riders reviews online, they list all of the new upgrades from year to year in the review. Ended up going with a 2003, can't be happier. From what I read the changes from 02 to 03 were, Revised rear linkage ratio for better action and reduced ride height by 10mm for a lower center of gravity, 48 mm forks with bump rubbers instead of oil lock, no bladders, fork offset increased 3 mm for sharper cornering, steeper rake on frame, tapered aluminum steering stem to save weight, stronger swingarm and frame, more compact chassis, larger rear brake rotor ( thickness and diameter), larger 25 mm rear axle, larger radiator capacity. I believe the 2004 and newer may have made some other changes, but, 2003 was the year of the big change. Bike is a blast to ride, handles great in the woods. Would definetly suggest the 2003 or newer model for a hybrid build, why not use the latest and greatest technology to build the perfect trail bike.

Thx, all good info. Agreed on the latest technology. Wish the guy would get back with me on the '04. Then I would have options. For now, I'm going to get the '02 running which will add value to either selling the bike running, or selling the motor and using the chassis for the hybrid platform.