My daughter asked if we could ditch the ATV's and ride dirt bikes again (Cue angles singing). Wifey likes the idea of an extra 125 play bike floating around too ~ I think she has her eye on this one. I couldn't help but bring it home (Sub $500 and ran well). Ofcourse it needs some love (Hellow EBAY)... And after checking out the RM100 sticky I'm getting the itch to make a few changes.

First off this lovely jewl is a 2003 that has been unloved and just about left for dead. Engine runs great but the rear wheel was shot or so I thought. I made up my mind to replace the wheel upon purchase but the rear wheel was actually Missing ??? This rear wheel was from a YZ85. Yes I bought it in the dark in the rain and it was coverd in mud (intensionally I'm sure) also chain was as tight as a banjo string ~ Hmmm another cover up ~ masking some of the bearing issue. The YZ 85 application was determined by running a search on the DG sprocket part #. The YZ wheel was missing a few spokes / bald tire / No bearings in the wheel at all (&%$#@!).... But like I said it was cheap.

I'm doing research while my Ebay parts on order arrive (Plastic / OE rear wheel / ect).

AS for the project name "Spare tire" It is partially from the shape I'm getting as I now round up to 40yrs old and part from the ideia of having a spare bike around to bring frineds out riding with us.

We chased down a Craigs List ad today ~ 160 mile round trip and came home with a 2002 KX 100 bike in a box for 1/2 price of the DRZ. Unfortunatly I had to dive out of wifey's SUV upon getting back in town and head to work.
Not much info on my new purchase yet. I need to take inventory of hardware.

So far ~ I know I am missing:
1. wheel mounting hardware (2) axles / (2) axle nuts & washers / (4) axle collars / (2) rear axle adjuster blocks / (1) rear caliper holder. I think that covers wheel mounting.
2. rear sprocket + mounting studs & nuts
3. Brake line banjo bolts and brass washers

The Good? 1 1/8 Renthal bars / almost new MX tires front & rear

Swap tips I ran across. Not sure how accurate they are ~ either way... I talked to my machinist today and have him lined up and ready to go.

Smacaroni, on 23 June 2011 - 06:21 AM, said:

Im guessing the previous owner was not trying to hide anything, it just looks like he had no idea how to maintain a bike. The chain looks to be about as tight as a bmx bikes chain would be...How about some pics with the bike cleaned up? Looks like a fun project!

Nothing more picture worthy yet ~ sorry Tom. The fresh Ebay plastic is still in the box.

After washing the bike I stripped it down furthuer. It is on the bike stand still no seat or plastic and now with no rear wheel. It is awaiting the KX axles I just purchased an hr ago to arrive cross country from Calif.

Also working on an order for a KX 100 rear wheel bearing set and 428 conversion sprocket. KX front end is now removed from the KX frame ~ here begins the long tedious hrs of stripping the Wal_mart spray bomb paint and over spray off of the KX parts.

I'm also missing the Wheel bearing spacer that belongs in the KX hub between the bearings. I'm sure that is a dealer oreder only item. Maybe I can have my machinist size up the YZ hub bearing spacer a get a reasonable fit.

Why did they paint the Gold Annodized Easton 1 1/8" bars with Wal-mart gold cream spray paint ~ Yuck

Swing arm is now metal flake black but they didn't get the dirt or ripped up stickers off first. Also Metalic Black frame overspray on the tripple tree and forks.

~ YZ rear wheel bearnigs were not bad, It was the stock 12mm DRZ rear axle thru the larger 14mm YZ bearing races.


WOW ~ Drz 212cc is a very cool build thread http://www.thumperta...ld/page__st__40

tom has another 190 engine for sale - cheap. hit him up or look for the recent thread.

cheers,
gila

Stripper in a can ~
Beneath the black paint on the swing arm was the same creamy gold paint that was on the bars, and beneath that was a stale flat Kawasaki Green, beneath that was the OEM silver grey I am after. Not sure one can of aerasol paint stripper will complete the swing arm. At 3 cans of stripper I'll be getting close to the ebay bottom price of a replacment swing arm. Lets hope i don't need to reshoot the silver grey too.


Thanks Gila, I'm interested but I know I'll need to keep it stock for right now ~ My daughter is still a timid novice. She began at 4 on a PW 50 then a TTR 90 at 7 but switched to atv's at 9. I still want her to ride this one, maybe once she gets comfortable I can step up.

Has anyone stuffed a DRZ 125 into an XR 100. I've got a dead 02 laying around taking up space.

Got the KX front end installed ~ everything went smooth. DRZ 125 front fender just needed a minor adjustment of the mounting holes to fit. Dropped the swing arm off at the machine shop.

Hoping to have it and the parts in hand by next wednesday.

You did get the title for this bike correct? All that paint makes me think its stolen, or somebody is trying to hide it from somebody else...The other option is it was owned by a kid (or adult I guess) who had no clue what they were doing. So far looking good though!


Tom

All the paint was on the KX bike in a box, it didn't have that stolen look.... They stenciled stripper stars on various parts like the shifter. It looked more like a kid with no mechanical knowledge and lots of free time to dream of riding it. The guy I bought it from painted the black over some of the kids work (but still rattle can and over spray).

Of all the off-road bikes I've bought and sold over the last 25 yrs I've only gotten two with papers (a certificate of origin). Off road bikes are not titled or registered around here. I get a signed bill of sale from the seller just in case.

dude looking way better then in the 2nd pic then the 1st!!! still id like to see more lol

i need to jump on some fork upgrades soon! looking great man, Cant wait to see it put together!

Looks like I'm missing a few parts

I have this: (2002 KX 100 front axle)



Can anyone here tell me what else I'm missing.

Looks like there has got to be another spacer or two, but they are not listed on the microfiche.

Interchange says the hub spacers I need can come from 33 differnt bikes.

KX 80 / 85 1998 thru 2010
KX 100 1998 thru 2009
KLX 140 2008 thru 2009


My axles and spacers were said to be from a 2000 model which should fit... Hmmmm.

Kawasaki's parts interchange is very good, compared to say Yamaha's which is very bad, at least from my experience. If it's on the list, it should work. That's assuming the guy before you didn't just grab something out of his parts bin to make it work of course.
Also, you can add Suzuki to your list of possibilities if you search their parts exchange for 2003-2006 RM100 for the same part, although it's probably going to be listed as K followed by Kawasaki's part number. Suzuki seems to be a cheaper source of Kawasaki parts when they match.

Think I have found the problem ~ :poop:

First:

My Ebay OEM DRZ rear wheel came in yesterday (Great condition / Ready to ride) but had 5 broken spokes on the sprocket side.









At least the seller was cool about it and offered a FULL REFUND + return shipping. Full refund on a $150 wheel (with bald tire and worn sprocket) that I didn't think I need sounded great.

This afternoon I rewrapped the DRZ wheel and sent back out for refund. Then arrived at home to find new KX 100 my rear wheel bearing set and 428 conversion sprocket in the mail box. Woo Hoo!!!!

Began bearing install to find disk side bearing did not fit. Checked sprocket and it did not fit either. Getting suspicious I brought the wheel inside to the computer and began the hunt to match it up by matching up the hub casting disk side. That was when i found that out....

The KX 100 bike in a box came with a CR 85 Wheel set

3rd rear wheel this month and still no dice...


While not the end of the world this wheel set is worth about what is KX 100 wheel set is worth

~ but unless I can find the 6002-2rs bearing, a CR rear sprocket, + inner hub bearing spacer, then riding this weekend might be out of the question.

I might just have to try and set up the YZ 85 wheel that originally came on my DRZ.

Atleast now I understand why the front wheel spacers that should have worked did not....


In othe news...


My machinist called this evening and my swingarm is read for pick up in the morning.

[size=4]CONVERSION PERVERSION[/size]

[size=3]SO I've come to the conclusion that I need a replacment KX 100 wheel set. But that will not let me ride this weekend. So weighing my options carefully I've decided to pool my resources and give the CR 85 Big Wheel set ago. [/size]

I ordered NEW KX 100 rear wheel bearing set and inner hub sleve spacer since these items were missing. Now I see I need Honda stuff ~ OR do I?

[size=4][size=3]Honda CR 85 wheel hub converted (plunge milled) to accept KX 100 style double row bearings on the sprocket side and the new KX 100 inner hub spacer. [/size][/size]

[size=4][size=3]Kawasaki KX 100 428 Conversion sprocket CONVERTED to fit a Honda CR 85 rear wheel. [/size][/size]


[size=4][size=3][/size][/size]



[size=4][size=3]KX 100 rear swing arm converted to DRZ bushings and surface prepped with 400 grit ~ more on polishing later. [/size][/size]
[size=4][size=3]Thought I rear that the KX 100 swingarm was 1 inch longer then the DRZ... Hopefully I do not have a KX 80 swing arm.[/size][/size]
[size=4][size=3]I'm in deep and beginning to question everything. Truely suffering the rath of the Cheap Deal. I now regret having bought the $250 KX100 instead of the $600 one. [/size][/size]

[size=4][size=3][/size][/size]

Wet Sand with mild soap and water (400 grit - 600 grit - 1000grit) by hand. Then polish with rubbing compound and then polishing compound, followed up with a coat of Mothers California Gold. It needs a little more work with the 600 & 1k to get a true imperfection mirror ~ but this will do for what it is.

Custom wheel spacer made and chain line is now correct. We drilled out the ID and cut down over all legnth of DRZ rear wheel spacer to match the unknown spacer that came with the YZ wheel (YZ spacer maybe???). Oddly enough I think the Honda CR 85 wheel takes (2) YZ 85 spacers to fit the KX axle and swingarm. Also looks like the KX rear brake will work on the CR wheel with some minor trimming to the inside brake pad (Hub clearance)


So far that is Honda / Kawasaki / Suzuki / Yamaha parts all on the rear wheel. Also discovered that the KX 100 front outer spoke I ordered (cause my front wheel was missing a spoke) fits perfectly in the Honda CR85 front wheel.



Now if I can only find some KTM pieces ~ Might have to throw on some Husqvarna take offs just to make a a true Mutt bike.

mbwhitfi, on 27 January 2012 - 09:26 AM, said:

thats crazy!!!