Comming Soon
Home > Forum


Author Topic: New Project 04 RM 125 Barn find  (Read 343 times)

0 Members and 1 Guest are viewing this topic.

Offline eprovenzano

  • Professional
  • *****
  • Posts: 500
    • View Profile
New Project 04 RM 125 Barn find
« on: June 29, 2017, 08:09:20 AM »
New Project... Barn fresh 04 RM 125.. My son's girlfriend mentioned to him I know where there's a bike that's been sitting for years (6 years to be exact).  Ex boyfriend's... she called his step mother, it doesn't run... she said please come get it out of the barn, please, you can have it... FREE...

Adam picks it up, said the tires were 3 inches down in the dirt, wheels didn't want to turn.  Was told by the ex that it has a full aftermarket exhaust, bored 40 over....  Adam didn't care, just wanted to collect the bikes and its parts and get out of there... 



So we gave it a much needed bath... found its missing a few small things, but its pretty complete.  As usual I don't take believe what previous owners say they've done to their bikes..  After a quick inspection I see it has the stock exhaust... so I know the PO is full of shit... Before wasting my time I check for spark, yep, got lots of spark.  So with that, let the tear down begin  (the other RM in the pic below is his buddies, just happens to be a 04 RM 125 too)



I drain the rads, it had engine ice in it... nice.  Pull the head, so far good, measures out to a stock bore.  I feel a slight scratch in the bore...  hmmm  I may be able to salvage this with just a top end refresh.  I pull the cylinder... somethings not right.  It takes me a while but then it hits me...  someone resleeved the cylinder but didn't line it up...  it's off 3/8 th's of an inch.  How that hell do you do that...  the ports are partially closed, including the power valve.  It was blocked from being able to open...



I'm dumbfounded as to how stupid some backyard mechanics are...  When I 1st saw the sleeve didn't line up with the casting, I assumed the sleeve or casting was broke... nope.... upon closer inspection, it's just bad work... The crank is tight, no play in the big end bearing, and no play on the clutch or flywheel side...

So we'll have the sleeve replaced and of course put in a new top end.  The bottom end will get washed out with clean diesel fuel. It needs a new chain and sprockets, levers, grips, and the rear fender stitched back together .  Clutch plates are serviceable for now.   It will make a fun track bike.
« Last Edit: June 29, 2017, 02:41:02 PM by eprovenzano »
Eric Provenzano
2001 KTM 380 EXC (mine)
2000 KTM 300 EXC (Son's)
1991 KDX 200... fun play bike
sold 1999 KX250
sold 1999 YZ125 (son's)
Sold 2001 Yamaha TTL 125 (son's 1st bike)
Sold but never forgotten 1974 Honda Elsinore CR250M
Sold 1974 Honda Elsinore CR125

Offline Coop

  • Global Moderator
  • Professional
  • *****
  • Posts: 1740
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #1 on: June 29, 2017, 05:25:40 PM »
Nice. Anytime I got a bike for free it ended up being more to get running than if I just bought one already running lol.
Nobody on their deathbed has ever said "I wish I had spent more time at the office".

Offline beaner

  • Novice
  • *
  • Posts: 19
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #2 on: June 30, 2017, 06:10:41 AM »
I had one of those for 6 or 7 years. It was a good solid reliable bike.
Ontario, Canada

Offline racer x

  • Expert
  • ****
  • Posts: 126
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #3 on: June 30, 2017, 01:12:49 PM »
gonna be good thread epro

Offline Coop

  • Global Moderator
  • Professional
  • *****
  • Posts: 1740
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #4 on: July 01, 2017, 10:11:41 AM »
I keep looking at that sleeve and wondering how anyone thought that was acceptable. It's just baffling.
Nobody on their deathbed has ever said "I wish I had spent more time at the office".

Offline eprovenzano

  • Professional
  • *****
  • Posts: 500
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #5 on: July 02, 2017, 06:45:15 AM »
Coop I keep looking a it and keep laughing...  how could no see something was off...   when I first saw it I thought the sleeve was broken...  even a dumbass back woods mechanic like me can see that's wrong...  wow the mechanical skills of whoever put this together make me cringe.

I need to pull the power valve and look for any damage.  If it tried to open, it would be hitting the sleeve.

« Last Edit: July 07, 2017, 06:52:36 AM by eprovenzano »
Eric Provenzano
2001 KTM 380 EXC (mine)
2000 KTM 300 EXC (Son's)
1991 KDX 200... fun play bike
sold 1999 KX250
sold 1999 YZ125 (son's)
Sold 2001 Yamaha TTL 125 (son's 1st bike)
Sold but never forgotten 1974 Honda Elsinore CR250M
Sold 1974 Honda Elsinore CR125

Offline rsmith

  • Administrator
  • Junior
  • *****
  • Posts: 57
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #6 on: July 07, 2017, 09:55:31 AM »
I'm going to bet it went something like this:

Cylinder hot -- Check!, sleeve cold -- Check!  Now I'll just drop this in here and align it.... Crap, its stuck!  Now what? Uh.... Maybe they won't notice!

LOL

--Ron.

Offline eprovenzano

  • Professional
  • *****
  • Posts: 500
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #7 on: July 10, 2017, 09:43:09 AM »
Where's the LIKE button...   ;D ;D ;D ;D ;D
Eric Provenzano
2001 KTM 380 EXC (mine)
2000 KTM 300 EXC (Son's)
1991 KDX 200... fun play bike
sold 1999 KX250
sold 1999 YZ125 (son's)
Sold 2001 Yamaha TTL 125 (son's 1st bike)
Sold but never forgotten 1974 Honda Elsinore CR250M
Sold 1974 Honda Elsinore CR125

Offline eprovenzano

  • Professional
  • *****
  • Posts: 500
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #8 on: July 10, 2017, 09:48:42 AM »
I pulled the power valve... luckily its not damaged...  :o... 

so at this point, the sleeve gets replaced, new piston / ring and we're good to go. 

Now my question...  should I just go ahead and go with a 134 kit?  If I do does the Power Valve need to be adjusted?

Nevermind...   ;D  I researched the requirements, and yes the power needs to be adjusted.  I'll keep it at the stock bore... 
« Last Edit: July 10, 2017, 09:58:06 AM by eprovenzano »
Eric Provenzano
2001 KTM 380 EXC (mine)
2000 KTM 300 EXC (Son's)
1991 KDX 200... fun play bike
sold 1999 KX250
sold 1999 YZ125 (son's)
Sold 2001 Yamaha TTL 125 (son's 1st bike)
Sold but never forgotten 1974 Honda Elsinore CR250M
Sold 1974 Honda Elsinore CR125

Offline racer x

  • Expert
  • ****
  • Posts: 126
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #9 on: July 10, 2017, 02:07:46 PM »
I do believe this is a fast 125 motor so stock should be good enough. I have heard and experienced numerous horror stories about tuning and reliability of the 134-144 big bores.

Offline eprovenzano

  • Professional
  • *****
  • Posts: 500
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #10 on: July 11, 2017, 05:20:13 AM »
Racer X I agree...  I only considered it as a new sleeve is required...  but I do prefer stock... plus parts are readily available.  If my son decides to flip it, I'll rest easier knowing it was built to the factory specs.
« Last Edit: July 12, 2017, 09:56:12 AM by eprovenzano »
Eric Provenzano
2001 KTM 380 EXC (mine)
2000 KTM 300 EXC (Son's)
1991 KDX 200... fun play bike
sold 1999 KX250
sold 1999 YZ125 (son's)
Sold 2001 Yamaha TTL 125 (son's 1st bike)
Sold but never forgotten 1974 Honda Elsinore CR250M
Sold 1974 Honda Elsinore CR125

Offline eprovenzano

  • Professional
  • *****
  • Posts: 500
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #11 on: July 11, 2017, 07:45:04 AM »
Quick pic of the power valve prior to disassembly.  I pulled the power valve and all is in working order...  Other then needing a good cleaning, all is good so far... oh and you got to love the lack of a gasket used on the power valve cover... 

Eric Provenzano
2001 KTM 380 EXC (mine)
2000 KTM 300 EXC (Son's)
1991 KDX 200... fun play bike
sold 1999 KX250
sold 1999 YZ125 (son's)
Sold 2001 Yamaha TTL 125 (son's 1st bike)
Sold but never forgotten 1974 Honda Elsinore CR250M
Sold 1974 Honda Elsinore CR125

Offline Coop

  • Global Moderator
  • Professional
  • *****
  • Posts: 1740
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #12 on: July 13, 2017, 04:10:53 AM »
... oh and you got to love the lack of a gasket used on the power valve cover... 


I am surprised it wasn't smeared up with red silicone.
Nobody on their deathbed has ever said "I wish I had spent more time at the office".

Offline beaner

  • Novice
  • *
  • Posts: 19
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #13 on: July 14, 2017, 10:06:20 AM »
They are really good motors. Probably the best thing on the bike.
Ontario, Canada

Offline eprovenzano

  • Professional
  • *****
  • Posts: 500
    • View Profile
Re: New Project 04 RM 125 Barn find
« Reply #14 on: July 16, 2017, 06:26:41 PM »
My son and I was taking inventory of whats needed to put the bike back together.  We noticed the rear wheel was difficult to spin...  a missing wheel spacer may be the cause...

Parts list so far

New sleeve, piston and ring.
Air filter
Right rear wheel spacer
Front brake lever
Handle bars
Grips
Rear Sprocket
Rear Fender
Rear tire
Kill switch
Gas Cap


Eric Provenzano
2001 KTM 380 EXC (mine)
2000 KTM 300 EXC (Son's)
1991 KDX 200... fun play bike
sold 1999 KX250
sold 1999 YZ125 (son's)
Sold 2001 Yamaha TTL 125 (son's 1st bike)
Sold but never forgotten 1974 Honda Elsinore CR250M
Sold 1974 Honda Elsinore CR125