My 04-KX 125 build

[Scream N KX125]

Hey guys i'm new to the forums and i would like to say hi and a pre-thank you to all.

I first got my KX from my brother who lives in maryland and said if i came and got it, it would be mine for free. so i took a honda element and cramed the bike in all the way back to beautiful florida well i noticed the damages immediatly sence he left it in a so called friends trailer(you know how it goes from there).

No air filter
Blown top-end
Kick assembly lever broke off
clutch lever broke
Sprocket and chain need replacement
Rear Tire replacement

....but other than that its a free bike and i cant complain. i got a K&N air filter, rebuilt the top-end with a Wiesco Piston and Gasket kit. got all new levers. after the rebuild we went through the break-in but on the third stage the spark plug fouled out and we called it a day. before we went out the next day we changed the transmission oil to what at the time i didn't know was wrong, Specter gold 10w 40 4stroke! the guy at KAWI gave me the wrong stuff and i was to dumb to look myself. once we got the bikes off the truck i kicked the bike up and it started like a champ. but when i was going through the gears it would go 1st, N, 2,----transition to Neutral almost automatically. no grinding or anything it just feels like i lost 3,4,5,6.

well after being crushed from what i saw as a failed rebuild and then having my son about 3 weeks later i stopped working on the bike.

...I've been doing some reading after i noticed i had the wrong oil and i dumped the transmission oil out a when i tried to go through all the gears
1,N,2,3,4,5,6. i was looking like this i rushed to KAWI and got GearSavers75 got new spark plugs and filled up the tranny.

tried the gears and i only have 1,N,2,-----Neutral!!!!!
Whats wrong and what can i do. i can do some motor work but splitting the case is out of my department.

[KickassKX125]

Unless someone else knows how, i'm afraid your going to have to split the cases or send the engine off for repair.

Are you sure it isn't going 1,N,2 then jumping back into N.

Does it make any crunching like sounds when you try to change through 3,4,5,6?

[KDXGarage]

If it was 10w-40, then I don't see that being a problem. Do you know for sure that it was shifting properly before the nice friend gave it back? I am guessing gear damage is also on the (what he did) list.

Any chance you still have the drained oil? (to check for metal shavings)

[Scream N KX125]

Thanks so much for the replys.

1st queston:
It feels like it just slips into N after trying to shift from 2-3. there is no grinding or noises what so ever. it feels like it was made to do that if you know what i mean. i guess you could say it jumps back to N.

2nd question:For the first two break-in sessions it went through all gears smoothly just like it is supposed to.

i've changed the oil twice no shavings or particles whatsoever. the first time was after the build i put the 10w40 4stroke oil by accident after the two break-in sessions. i know i should have changed it right after the re-build (but i didnt). it still ran very well. after that i put the gear savers 75.

so with oil in it doesnt shift past second but with it out i can go through every gear with no problems at all.

Thanks for all your help. it means alot.

*someone told me the shift fork could have came out of place and all i would have to take the plate off and currect the misplacement. but with my luck so far this cant be it.

[KickassKX125]

Find a long straight and go from 1,N,2 and flick the gear lever up repietedly so that it wouldnt have chance to drop into N, if it does keep getting no propulsion after 2 then i would get the cases split and find out whats going on in there.

If you sent it away for repair it could cost a fair bit, it would be better off doing a bit of D.I.Y.

[Scream N KX125]

I'm thinking of just bringing the motor to KAWI and let them do the work. I'm stuck and the bike is just attracting dust when its begging me to ride.

Does anyone know of a good shop in the Orlando/Central Florida area. I don't really prefer the dealer.

[KickassKX125]

I'm out of my depth there, I'm in UK not US, Sorry, i'll leave you to the US guys

[jandb917]

how does the clutch feel? i mean does it act like its tryin to pull the bike when you sit there idlein and in gear ? does it fell like its tryin to pull ....... i would even adjust you clutch lever so you have a little play in the lever prior to actually engagein the clutch ..... because if there is the slightest bit of drag on the clutch it can make it hard to hit your shifts all the way i went through this a bit with mine ( 03 kx125) and then i adjusted the clutch like i said above ................. promblem solved !!!!!!! but if you cant get it i have the actual kawasaki service manual just let me know and i can send you the parts of the manual you will need to fix it

[Scream N KX125]

so i know its been a while but i now have time and money to put into the bike again....
I know i just put up the " 2004 KX124 spark plug " thread but i thought i would bring the conversation to this one since my problem is with the bike as a whole instead of just the plug.

so i got the correct plug today along with alot of other goodies but all for nothing. gapped it and then put it in. and went to kick it over and nothing. if i pull the choke and kick i get no noise. if i kick it WOT then it makes a sputter sound as if it trying to turn over or as if you ran out of gas(trying to give you guys an example) what i don't understand is why it wont start if it was running perfect after the rebuild. what could it be?

now....the past problem with it the engaging in third may be resolved but i cant get the bike to even start. a member from this forum had the same problem and you guys will not believe what it was. oil drain plug GASKET wow yes a $2 piece put my transmission out of commission. but i still dont know if that will totally solve my problem since i cant get it to start and test it out.

so heres a list of the rebuild:
Kawasaki Kickstart assembly
Kawasaki Air box assembly
K&N air filter
Wiesco top end
Cometic gasket kit
Renthal grips
all new levers
all fluids refreshed

***Now on hold until the bike is running properly***
Primary Drive Alloy Kit & Gold X-Ring Chain
FMF Gold Series Pipe
FMF Turbine Core II Silencer
Tires

Thanks for all the help you guys have provided me on this forum and hopefully we can jointly fix my problem. Mike.

[Scream N KX125]

took the carb off last night and took pics of the intake and exhaust. it looked clean if that means anything. took the bolt off the bottom and fuel was in there, it was also clean.

do you guys think the jetting could keep the bike from starting?

[05kx125]

if its not starting and you dont know what to do, then just push it and jump start it if it doesnt run (which it should even if it had 1 year old fuel) then something is up. thats what my buddy did. didnt start his bike for a year and hid little gas in so i pushed it and he jump started in 2nd gear thing started up pretty easy but ran like crap cuz the gas was like 80-1 becuase it was old...

[stevied645]

now....the past problem with it the engaging in third may be resolved but i cant get the bike to even start. a member from this forum had the same problem and you guys will not believe what it was. oil drain plug GASKET wow yes a $2 piece put my transmission out of commission. but i still dont know if that will totally solve my problem since i cant get it to start and test it out.

What do you mean, i just dont get why that would stop it going up the gears. Or can it??

[Scream N KX125]

What do you mean, i just dont get why that would stop it going up the gears. Or can it??

first: its not that it wouldnt go up in gears its that it wouldnt engage third therefore not allowing access to 3,4,5,6.

its not a fact that it fixed my problem since i haven't got the bike to start and try it out. but his symptom's were identical to mine with the exact same bike and i happened to be missing the same part the he described as what fixed his bike.
also when i was changing oil to figure out what was wrong the bike i would go through every gear smoothly with no problems with out oil. but with oil it wont engage third. No oil no gasket or plug. with oil = just a plug since i misplaced the gasket. assuming the drain plug was in just enough to obstruct 3rd from engaging. Mike.

*now that i think of it i can see if it worked by just pushing and shifting. i'll keep you up to date. gotta wait till my toddler takes a nap so i can work on the bike once again.

[SixFiveOh]

That would indicate that the oil plug was long enough without the gasket to interact with a moving part in the transmission. The interaction causing the trans to bind. Not sure I'm convinced this would be the case, but if it works, it works.

[Scream N KX125]

That would indicate that the oil plug was long enough without the gasket to interact with a moving part in the transmission. The interaction causing the trans to bind. Not sure I'm convinced this would be the case, but if it works, it works.

i can only hope.

but, if not once i get the carburetor back together if its not running like the champ i know it to be its going in the shop and i'll fork over the cash. i need to ride.

[Scream N KX125]

so when i was i was removing a screw from the float bowl i stripped it. it just keeps getting worse.

[stevied645]

That would indicate that the oil plug was long enough without the gasket to interact with a moving part in the transmission. The interaction causing the trans to bind. Not sure I'm convinced this would be the case, but if it works, it works.

+1 cant see it myself but if it works it works

[alyssakx]

The same problem occured with my bike a while ago. Only 1 2 & N were there. After 2 it would simply lock up. After splitting the engine completely... we discovered I must have cranked the drain plug too hard & over time it stretched, preventing 3rd & up to click in. I had never heard of that occuring before and neither had the guys at the shop I go to. After having to put the engine back together ..ugh and replacing the drain plug it worked great... yeah it does happen so make sure your not cranking too hard on that plug. I learned the hard way.

[Scream N KX125]

It's been a while since I touched the dirt bike. I cant get it to start and after buying a '05 zx6r I've had little time. I plan on working on it soon. i get spark but the bike just wont start. I need to read and just try everything i can.

*Nothings Free*

[gaz]

If you are going to split the case, you can save heaps by stripping the motor down to the stage where you are about to split the case then take it to the shop. I did this when I needed a new crank. They only charged me 100 bucks to install the crank/bearings and seals that I supplied and reseal the case. Also when taking the clutch hub off you can see the gear ratchet assembly and you can make it go through the gears and see whats happening. This is a last resort if nothing else works.