My 97 YZ 125 Complete Rebuild

[JohnN]

PowerPlayMotorSports AWESOME rebuild!!

Thank you so much for sharing your process of rebuilding the bike.

Welcome to the forum!

[Charles Owens]

Thanks Guys!

The gas tank, yes it is the horrible 97 Navy blue, I have been trying to squeeze out a reflex blue tank.. but little required parts keep dipping into my 'want' fund
I would assume I will have a new tank by the time it is done, will have to see how this week goes. I know it will be replaced before I get the graphics.
Some new wheels/triples/bars are on the list as well, but that will have to wait til after Sep 15th when we close on the new property.
It is a standard bore kit, got it for $500ish delivered.

Thanks for the comments!

[Charles Owens]

Ok got a quick update, I've been busy and waiting on parts.
I got in my wrist pin bearing yesterday, so I started assembly on the top end.
The final OEM power valve parts should be here Tuesday or Wednesday to finish up the bike. Also trying to get a new fuel tank ordered today maybe.

These first few pics I'm checking for casting flaws and burrs in the valve/exhaust port. Thought the pics looked pretty neat.
As you can see there were a few burrs in the exhaust port I had to take care of





...

Got a little bored and brushed/polished both Valve covers and the Boyesen Stator Cover, came out pretty good.

[Charles Owens]

Just ordered a new Reflex Blue fuel Tank, and some Renthal bars.
They will be here Tuesday, the rest of the OEM parts to complete the build will be here Tuesday or Wednesday. 
Hopefully my wallet can cool off now til we move.

[Super Trucker]

Wow great work man,is it a 144 cylinder. I had  Jeff Wiloh,s 97 YZ125 Noleen national bike.

[Charles Owens]

No, it is the standard bore.

[Coop]

Nice work on those covers!

[Charles Owens]

Thanks! I think on the next project (coming in a few months) I will be polishing out all of the alluminum, cases included.

[scotty dog]

Thanks! I think on the next project (coming in a few months) I will be polishing out all of the alluminum, cases included.

That would look sweet!

Nice job though, its lookin a treat!!

[Charles Owens]

Quick Update.
Got in a few more parts.
New Clarke tank, getting rid of my 97 Navy Blue tank.
Works Connection skid plate.
Got in my '99 Pro Circuit Platinum today as well.
Renthal bars.
I also got in an 03 YZ 125 for part out, which dontaed a few parts to my 97.
Not that I need any more of a tuning challenge, but I pulled, and rebuilt the 03 38mm carb, getting rid of my flat side 36mm. This will probably = a jetting nightmare, but maybe not. We'll see.
I'm still waiting on my power valve parts..   
I also bought some Universal Engineering adjustable triples today, got a good deal on them, so I figured I would try them out. I'm hoping the quality is as good as it looks.. I will let you guys know.
..

[riffraff]

Damn that looks pretty 

[Coop]

Looks great!

My only suggestion, NOT complaint, is next project put a wire wheel in your drill press (or drill) and use it to clean up nuts and bolts. Little details like that really make a  project.

[Charles Owens]

I completely agree, and usually I do. But we are getting ready to move, 326459255 things going on, and I have already packed up most of my shop including my bench grinder w/ wire wheel.
I'm sure it will come apart again after I get in my new shop for detail work.. After I ride the Shat out of it anyway.

[Hondacrrider]

That is so sweet, sorta like what I did to my cr125, except I only redid the engine, this looks amazing.

[Charles Owens]

ITS DONE!!%$($*%$%$*%$*%$ For now anyway, my triples will be here Tuesday, and some new wheels after I move on the 15th.

Pics this evening!