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

Red LED taillight underneath the seat - Suzuki T250J

I purchased a red LED taillight a while ago from ebay. Taillight came with two M4x40 screws, washers and nuts. I had a clear one in my Kawasaki KDX 125 back in the day.

I was going buy a Bates style taillight and mount it to the rear fender but decided to go with this one since they seem to be quite popular these days and I wanted something different. I decided to mount it between the rear fender and seat.

Red LED taillight from ebay.

Back side.

I started by disassembling the seat. Seat cover was attached with a strip to the seat pan. Strip was easy to remove by simply pulling it although you had to be careful not to tear the seat cover with the clips in the strip. 

Disassembled Suzuki GT 250 seat.

Once I removed the foam off the seat pan I drilled two 11 mm holes to the rear end of it. I then welded two hex weld nuts around them with my MAG welder.

I ground the hex weld nuts flat before welding them.

I fastened the weld nut with a screw to keep it in position
while welding. Lip helped with the positioning.

Hex weld nuts welded in place.

Next step was to make a suitable bracket for the taillight. I decided to use 2 mm stainless steel sheet as a material. I used two M8x16 socket head cap screws to mount the bracket underneath the seat. I replaced the two M4x40 screws which came with the taillight since they were a bit too long with two M4x35 socket head cap screws.

Stainless steel brackets and fasteners.

Measurements for the taillight bracket.

Test fitting.

Done.

Some GT parts - Suzuki T250J

I have been scavenging some parts for my Suzuki. I saw an advert for GT550K parts nearby. The guy selling those parts is building a flat tracker out of '73 GT550K and he replaced the old suspension with KTM parts. First time I went to meet him I bought those rear shocks seen in the picture and a tail light. After a while I decided to buy the front fork also. Fuel and oil tanks are from GT250 as well as the seat. I bought the seat from a Finnish auction site and found the fuel tank from a guy from southern Finland. I bought the oil tank from ebay.

The front fork is a bit different than the one in my T250J. I'm going to replace the stock triple clamps with custom made parts and lower the shocks as well. So stay tuned for that. GT250 fuel tank is a bit dinged and is going to need a bit of straightening, bondo and a fresh paint.

Front forks and rear shocks are from '73 GT550K.
Fuel and oil tank as well as the seat are from GT250.