125-200cc 2004 165 Build

Well, I have had the parts for a while and it has taken some time to get started but here we go!

A 2004 CR125, now 165, still lot to do but I'm finally making progress.
Taken a few photos along the way, but not as many as i I should have.
View attachment 62701

Swing arm & linkage bearings changed, quite a time consuming job had to wrestle with the main swing arm bolt for some time to free it up Then discovered the chain wear

165 kit & Lectron on, covers painted, dual map ignition fitted, new foot pegs and rad hoses

Nice work.
What pipe are you going to use ?
Watch those hoses like a hawk they like to leak from every joint no mater how much you tighten the hose clips, Had them on two bikes now and confined them to spares bin rather quickly

I have the modded FMF KTM200 pipe from Walt
Not good news about the hoses, I'm gutted! To be honest I was in two minds as they are much bulkier and seem to get in the way a lot more than the standards.

Also having trouble with the positioning of the ignition module, it doesn't have mounting holes like the original so I made an aluminium plate to mount it on which fixes to the rubber mounts............Only to realise that my IMS (or WR) tank wont fit as the ignition module is much wider and it stops the tank seating fully forward, now looking at other options?

Heard that assembly lube in first pic helps things go together a lot smoother

The first weep was from the head spigot after around 10hrs use and after that they all had damp patchs and the ones on my Kwack did the self same thing, The right lower rad fixing was a real pain as well as the hose was squished on the motor on my 165.
Did you look at the squish clearence? Even with Walts lower compression head mine still had a tad of detonation under severe use/load but cleared up completely with the thickest base gasket.
Not sure how your going to mount that unless it will run in line with the back bone some how, Its a big unit, What make is it ??

I have same bike looking to tear down for winter project. I've read bunch of info on 165 upgrade but I love the way the 125 is. Wondering if the 144 or 165 kit makes it a "different" bike. I just got a beta 430 and it handles same trails like a dream so don't need a crazy boost in power. You think upgrade is a necessity while she's apart? Also you know of any places to get parts for 04? I've heard yes but once i give part #'s no response. Thanks

Will keep a close eye on the hoses, thanks for the heads up.
Used the thickest gasket, was either 1 or 1.2mm
The ignition is made by JD Racing, sold by Fast by Ferracci, New old stock 100 dollars.

Ahh man I just ordered some silicone hoses today for 300. Gplus chinga brand. Hope they don't leak like oem one did/does(jus the bottom rad hose with t join rest are fine). What brand are the leakers Johnny?

Bike looks good geezer covers look cool

There is a G Plus thread.
Have had some on for about 40 hours with no problems.

The hoses were / are AS3 items, Not expensive to purchase but for some reason just leaked all the time, The day I locked the 165 solid after a long days riding I blamed myself for not tightning the clips properly now im not so sure if it was my fault, Also Trig fitted his at the exact same time and his weeped from day one.
May of been a dodgy batch because the area around the lower right area on trigs hoses when removed and put back to stock had broken up inside and was blocking the hose off (dodgy) Never heard of anyone else having the same problem but when you leave a bike in a secure container for a week and enter to find a coolent patch on the floor where the hoses have leaked it dosnt fill you with much confidence thats for sure.

Dual map ignition from FBF, just a shame its so much bigger than the original and I have to find somewhere else to mount it

New Zeta levers had to get the Dremel on the brake lever as it was around 0.8mm the thick to fit in to the perch assembly.

I was hoping to see more of the engine build. Looks good though. I love the zeta levers. You inspired me to put my 165 kit on my 08 cr125. Thanks. I'm stumped till I get a new powervalve seal and gasket. Grrr.

Got a little carried away when instilling the 165 kit and didn't think to take photos till afterwards.
Engine was running sweet beforehand so haven't done anything else to it yet, but will be changing crank seals at some point in the near future.

Anyone got any ideas as to mounting the CDI??
It's wider than the original and stops the tank from fitting correctly if mounted horizontally. I have though about just strapping it to the frame with a piece of foam behind it like this but its touching the rad houses top & bottom (is this problem)

or am I better off extending the wiring loom and putting it somewhere else?

Any help greatly appreciated

Will it fit between the head stays ? wouldnt be to much work to fabricate a bracket that bolts behind them.
My cdi is mounted in that area on my 10 model (not a husky cdi or ignition) but is nothing like the size of that monster, I personaly wouldnt be to keen on the heat from the hoses traveling through it but I know nothing about the goings on in your box lol

Cool bike!

Up near headstock ala ktm?