2000 KTM 125sx Complete Rebuild.. With Pictures!

So i bought a 2000 KTM 125sx parts bike for 350 bucks. It needs work and a fair share of it for sure. I would love anyones help and input on this, making my life a little easyer is always welcome lol. I need new crank assembly, the crank i have now is right next to worthless.. I think, It doesnt move smooth so maybe i can replace the bearings that attatch the push rod to the other things? The carb is non-existant, frame has a little bit of rust, besides that it looks in pretty good condition.

My main concern with this bike is that it has a front end off of a 1988 KTM 250.

With plastics removed




I believe this is rust








WHat do i do to make this shiny again? lol


This is the engine....


So should I completely dissasemble the frame and clean it up? I was thinking of powdercoating it or something. Once i get the manual i will start assembling the gears and stuff in the engine. Then work on getting a new crank assembly (or fixing it), i know the top end needs some work cylynder wise but thats for another day.

My E.T.A for the bike is middle of the summer, If i had money =/
Stay tuned.  

Why on earth would they put that old ass supention on that bike and what did they do with the forks that should be on it? You got your hands full on this rebuild! That is actually an understatement! Good luck with this project and keep us informed on your progress.  
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"These are the things that condition the man, seldom shown the ways to understand"

Get a set of forks off ebay.  
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2001 KTM 520MXC

I was going to say I didn't think they looked like 2000 forks!  
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The King Of Crumpets - Crumpet Boy!

- 1991 RM125

RidingTheRockies:
Why on earth would they put that old ass supention on that bike and what did they do with the forks that should be on it? You got your hands full on this rebuild! That is actually an understatement! Good luck with this project and keep us informed on your progress.

They took the forks off of the bike to replace their broken forks. Replacing them is a definite MUST right? I think so these dont seem like they will preform well.

Ill keep you guys posted with pics along the way. I cant wait to see it done.  

Allen_D:
Get a set of forks off ebay.

I dont know why i didnt think of that before.. I just looked i saw a few of them. I dont believe they have to be from the same year right? I think ill be fine as long as they are newer then a 99ish. Found a 2003 250 front forks for 350 with free shipping. Awesome, thats how much the bike was lol.  

So anyone have any input on the crankshaft? Repair or replace?  

92rm125:
I was going to say I didn't think they looked like 2000 forks!

Maybe if i took those stupid purple things off ill trick ya lol.  

Forks:

The 2003 units should work, I'd get some measurements to make sure though.  Heck, the 2003 forks would probably be a significant improvement over 2000 units.

Crank:

If you can find a replacement crank, it is probably the easier route.  Otherwise, talk to your local shops about crank rebuilds, I doubt it will cost too much.  
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2001 KTM 520MXC

Allen_D:
Forks:

The 2003 units should work, I'd get some measurements to make sure though.  Heck, the 2003 forks would probably be a significant improvement over 2000 units.

Crank:

If you can find a replacement crank, it is probably the easier route.  Otherwise, talk to your local shops about crank rebuilds, I doubt it will cost too much.

Yea i guess the newer the better. Just.. which years bearing would I use? the 2003 right?

Ill see what needs to be done with the crank to make it run right because besides the pushrod bearings it looks fine. I cant seem to find a complete assembly for the 2000 model.  

haha i sold you that ktm, hows it coming along?  

As for the frame, you could get it polished or do it yourself, it is rather difficult I have heard, but it will look pretty sweet. I can't wait to see the finished product!  
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My feet start coming off the pegs and I feel like I'm going really fast.
NC

It was coming a long really well untill i bought myself a subaru for 300 bucks. It was a steal so now im working on making it a gc8 w/jdm ej207 swap.

Had to abandon ship on this one, i need the garage room lol.  

aw crap eh u never got er done?  
RIP old dirtrider

Nope, its all over ebay right now lol.

I need the garage room (and money) to work on my subaru now.

I told myself ill never be that guy on a forum that starts something and never finishes haha but at least its for a good reason.