Throwback - *EX* '92 Kawasaki KDX 125 SR - Part II - Fitment and installation of '03 Kawasaki KX125 fuel tank, seat, rear subframe, air box, radiators and plastic kit

Let's continue the story of my ex '92 Kawasaki KDX 125 SR with how I fitted and installed bunch of parts from '03 Kawasaki KX125 motocross bike to it. I had no idea in the beginning how all of those parts would actually fit to my KDX 125 but I decided to take that risk and order them from overseas dismantler. My thought process was that since Kawasaki had used frames with similar style in KDX and KX models over the years they would have similar proportions and dimensioning. 

In the end the fitment was fairly straigthforward and I was very happy with the result which you can see below. Intake of the air box was the only thing I could not get properly aligned. Either way I had to place battery and other electrical components somewhere inside the KX125 subframe so they found a new place for themself inside the air box. That meant that I had to use an external air filter.

In the next and last part I will show you how I also fitted an exhaust pipe from '03 Kawasaki KX125 to this bike. Stay tuned for that soon 😎

Bunch of '03 Kawasaki KX125 parts for my KDX125

Starting point

Dissassembly

Test fitting '03 Kawasaki KX125 fuel tank

Hump had to be reformed with hot air gun

Test fitting of fuel tank, seat and rear subframe

Old radiator and rear subframe brackets removed

Templates for new rear subframe brackets

New rear subframe brackets cut and prepped for welding

Test fitting of rear subframe brackets

Right side

Right side bottom brackets from front

Right side bottom brackets from back

Left side

Left side bottom brackets from front

Left side bottom brackets from back

Rear subframe and radiator brackets welded

Simple radiator brackets

Right side

Left side

Top view

Bottom view

Frame after sand blasting and powder coating

Only picture I have from putting things back on

Done for now

Petrol Circus Custom Bike Show @ MP 24 Motorcycle Expo - Part II - Street & Classic Racing - 4th of February 2024 - Helsinki, Finland

 Here's second set of photos from this year's Petrol Circus Custom Bike Show. Check it out 😎

Kawasaki Z1000 Turbo

Throwback - *EX* '92 Kawasaki KDX 125 SR - Part I - Introduction of the build

Here's a story about my first motorcycle build that happened over ten years ago little bit before I started to write this blog. When I first bought the bike it was in original condition. Over the years I did basic maintenance and made smaller mods to it (check first photo). 

At the end of my ownership I wound up converting the look of the bike to resemble '03-'08 Kawasaki KX125/250 motocross bikes. In the upcoming parts of this series I will show you that transformation (check last photo).

List of modifications to chassis and frame...

• Fuel tank, seat, air box and rear subframe from '03 Kawasaki KX125
• Radiator covers, side panels and rear fender from '03 Kawasaki KX125
• Headlight from Derbi Senda R Extreme
  
• Supermoto front fender from '08-'13 KTM SMC (#77308210000XX)
  
• Aluminium swingarm from '91 Kawasaki KX125
• Rear shock from Derbi Senda
  
• Shorter dog bones
• Fatbar handlebar and risers from KTM EXC
• Stainless steel braded brake hoses
  

...and engine

• Cylinder head and piston from '89 Kawasaki KX125
• Reed valve system from '91 Kawasaki KX125
• Keihin PJ36 carburetor
• Motorex air filter
  
• Radiators, exhaust pipe and muffler from '03 Kawasaki KX125
• 520 chain and sprockets
  

Before...

...and after

Petrol Circus Custom Bike Show @ MP 24 Motorcycle Expo - Part I - Custom & Classic - 4th of February 2024 - Helsinki, Finland

Let's kick off the year with photos from last weekend! I will start with Custom and Classic classes and continue with Street and Racing in my next post. Take a look and stay tuned 😎

Husqvarna 1668