2004 CR125 Budget Brother Build

36Wheeler
Posts
137
Joined
2/15/2018
Location
Hinckley GB
Edited Date/Time 8/2/2021 12:50am
Hi everyone!
Quick backstory on the bike. This was my first proper bike and my dad bought it from a fast local racer here in the south of England back in 2012 for £1500
.

It's been sitting in my garage the last couple of years while I've been riding my 250f and deserves some love. It just so happens my brother is 14 and getting a little large for his 85 so I thought it would only be appropriate to hand it over to him as his first big bike. I really want to pass it over to him in good shape so he has a nice fresh bike to ride so thought I would document the process.
Started on the strip down tonight after work:




Pipe is in decent shape but the bracket has broken, going to get it welded tomorrow and clean it up properly!
3
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36Wheeler
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137
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Location
Hinckley GB
5/26/2021 1:22pm
Last time my friend rode it last September it was making a piston slap noise so gonna put a new top end in it. Before I got my crf250, it had a new cylinder which only has around 10 hours on it.



3
36Wheeler
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137
Joined
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Location
Hinckley GB
5/26/2021 1:29pm
This is as far as I got with it after work tonight:


Will continue to post updates as I make more progress on it. Hoping to make it a bit of a suprise for my brother so want it to look the part and be ready to ride. Going to service the forks and shock, get the wheels vapour blasted and rebuilt, clean/replace all the chassis bearings, chain and sprockets... Etc etc

I'm unsure weather to go with restyle plastics or the OEM look. I'm sure my bro will prefer a more modern look but I do love the clean low hours OEM look of these bikes too.
What do you think?
6
TunaBro
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Lake Stevens, WA US
5/26/2021 1:48pm
Very cool! I'm stoked to follow this one.

The Shop

5/26/2021 11:35pm
36Wheeler wrote:
This is as far as I got with it after work tonight: [img]https://p.vitalmx.com/photos/forums/2021/05/26/495212/s1200_IMG20210526202126.jpg[/img] Will continue to post updates as I make more progress on it. Hoping...
This is as far as I got with it after work tonight:


Will continue to post updates as I make more progress on it. Hoping to make it a bit of a suprise for my brother so want it to look the part and be ready to ride. Going to service the forks and shock, get the wheels vapour blasted and rebuilt, clean/replace all the chassis bearings, chain and sprockets... Etc etc

I'm unsure weather to go with restyle plastics or the OEM look. I'm sure my bro will prefer a more modern look but I do love the clean low hours OEM look of these bikes too.
What do you think?
Oem plastic is much better looking. Make sure to pull the pv cover off and check pv operation. Check tps plug on the carb, the teeth on mine are wore. Check carb slide. I,m on my 2nd 04 cr125. I have a 04 thread under tech section, for info.
2
36Wheeler
Posts
137
Joined
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Location
Hinckley GB
5/27/2021 3:14am
36Wheeler wrote:
This is as far as I got with it after work tonight: [img]https://p.vitalmx.com/photos/forums/2021/05/26/495212/s1200_IMG20210526202126.jpg[/img] Will continue to post updates as I make more progress on it. Hoping...
This is as far as I got with it after work tonight:


Will continue to post updates as I make more progress on it. Hoping to make it a bit of a suprise for my brother so want it to look the part and be ready to ride. Going to service the forks and shock, get the wheels vapour blasted and rebuilt, clean/replace all the chassis bearings, chain and sprockets... Etc etc

I'm unsure weather to go with restyle plastics or the OEM look. I'm sure my bro will prefer a more modern look but I do love the clean low hours OEM look of these bikes too.
What do you think?
Oem plastic is much better looking. Make sure to pull the pv cover off and check pv operation. Check tps plug on the carb, the teeth...
Oem plastic is much better looking. Make sure to pull the pv cover off and check pv operation. Check tps plug on the carb, the teeth on mine are wore. Check carb slide. I,m on my 2nd 04 cr125. I have a 04 thread under tech section, for info.
PV operation is good and luckily I haven't had any issues with the servo thus far.
Biggest issues i had in the past was exhaust bridge cracking. had it welded a couple of times and eventually got a new cylinder. I also tend to run a cast piston over a forged piston as they seem to be prone to nip up even with very careful heat cycles

I know people complain about this year being low on power but its a perfect bike for transitioning over from the 85 and the handling is very fun.
2
5/27/2021 12:46pm
36Wheeler wrote:
This is as far as I got with it after work tonight: [img]https://p.vitalmx.com/photos/forums/2021/05/26/495212/s1200_IMG20210526202126.jpg[/img] Will continue to post updates as I make more progress on it. Hoping...
This is as far as I got with it after work tonight:


Will continue to post updates as I make more progress on it. Hoping to make it a bit of a suprise for my brother so want it to look the part and be ready to ride. Going to service the forks and shock, get the wheels vapour blasted and rebuilt, clean/replace all the chassis bearings, chain and sprockets... Etc etc

I'm unsure weather to go with restyle plastics or the OEM look. I'm sure my bro will prefer a more modern look but I do love the clean low hours OEM look of these bikes too.
What do you think?
Oem plastic is much better looking. Make sure to pull the pv cover off and check pv operation. Check tps plug on the carb, the teeth...
Oem plastic is much better looking. Make sure to pull the pv cover off and check pv operation. Check tps plug on the carb, the teeth on mine are wore. Check carb slide. I,m on my 2nd 04 cr125. I have a 04 thread under tech section, for info.
36Wheeler wrote:
PV operation is good and luckily I haven't had any issues with the servo thus far. Biggest issues i had in the past was exhaust bridge...
PV operation is good and luckily I haven't had any issues with the servo thus far.
Biggest issues i had in the past was exhaust bridge cracking. had it welded a couple of times and eventually got a new cylinder. I also tend to run a cast piston over a forged piston as they seem to be prone to nip up even with very careful heat cycles

I know people complain about this year being low on power but its a perfect bike for transitioning over from the 85 and the handling is very fun.
Yeah the 04 probably has more complaints than any other 125. My 1st one JM racing decked, ported cylinder and bored the carb, pc setup, vforce, iKat. Huge improvement aprox 36.5 hp but had a super wide usable mid range. Next was step was 2 mm stroker crank. 2mm ovr bore, 23-24 ft lbs of torque, 40 hp. You still had to carry a lot of momentum to keep it pulling, forces ya to attack everywhere. I ordered a Rad Valve for my 2nd one, that should help it get on the pipe quicker. Rv did that on my 06 cr125. I ordered a 05-07 air boot 26.37 , supposed to help.
2
5/27/2021 12:59pm
36Wheeler wrote:
This is as far as I got with it after work tonight: [img]https://p.vitalmx.com/photos/forums/2021/05/26/495212/s1200_IMG20210526202126.jpg[/img] Will continue to post updates as I make more progress on it. Hoping...
This is as far as I got with it after work tonight:


Will continue to post updates as I make more progress on it. Hoping to make it a bit of a suprise for my brother so want it to look the part and be ready to ride. Going to service the forks and shock, get the wheels vapour blasted and rebuilt, clean/replace all the chassis bearings, chain and sprockets... Etc etc

I'm unsure weather to go with restyle plastics or the OEM look. I'm sure my bro will prefer a more modern look but I do love the clean low hours OEM look of these bikes too.
What do you think?
Oem plastic is much better looking. Make sure to pull the pv cover off and check pv operation. Check tps plug on the carb, the teeth...
Oem plastic is much better looking. Make sure to pull the pv cover off and check pv operation. Check tps plug on the carb, the teeth on mine are wore. Check carb slide. I,m on my 2nd 04 cr125. I have a 04 thread under tech section, for info.
36Wheeler wrote:
PV operation is good and luckily I haven't had any issues with the servo thus far. Biggest issues i had in the past was exhaust bridge...
PV operation is good and luckily I haven't had any issues with the servo thus far.
Biggest issues i had in the past was exhaust bridge cracking. had it welded a couple of times and eventually got a new cylinder. I also tend to run a cast piston over a forged piston as they seem to be prone to nip up even with very careful heat cycles

I know people complain about this year being low on power but its a perfect bike for transitioning over from the 85 and the handling is very fun.
I was told too drill a hole or 2 in the piston, lined up with exhaust bridge. For the 2mm ovr bore. You can run more sag and it will still corner like it’s on rails.
36Wheeler
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137
Joined
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Location
Hinckley GB
5/28/2021 5:52am
Oem plastic is much better looking. Make sure to pull the pv cover off and check pv operation. Check tps plug on the carb, the teeth...
Oem plastic is much better looking. Make sure to pull the pv cover off and check pv operation. Check tps plug on the carb, the teeth on mine are wore. Check carb slide. I,m on my 2nd 04 cr125. I have a 04 thread under tech section, for info.
36Wheeler wrote:
PV operation is good and luckily I haven't had any issues with the servo thus far. Biggest issues i had in the past was exhaust bridge...
PV operation is good and luckily I haven't had any issues with the servo thus far.
Biggest issues i had in the past was exhaust bridge cracking. had it welded a couple of times and eventually got a new cylinder. I also tend to run a cast piston over a forged piston as they seem to be prone to nip up even with very careful heat cycles

I know people complain about this year being low on power but its a perfect bike for transitioning over from the 85 and the handling is very fun.
Yeah the 04 probably has more complaints than any other 125. My 1st one JM racing decked, ported cylinder and bored the carb, pc setup, vforce...
Yeah the 04 probably has more complaints than any other 125. My 1st one JM racing decked, ported cylinder and bored the carb, pc setup, vforce, iKat. Huge improvement aprox 36.5 hp but had a super wide usable mid range. Next was step was 2 mm stroker crank. 2mm ovr bore, 23-24 ft lbs of torque, 40 hp. You still had to carry a lot of momentum to keep it pulling, forces ya to attack everywhere. I ordered a Rad Valve for my 2nd one, that should help it get on the pipe quicker. Rv did that on my 06 cr125. I ordered a 05-07 air boot 26.37 , supposed to help.
some good stuff there, thanks! We do always drill the piston. A couple of years ago I had the small locator pin for the piston rings fall out while riding and destroy the cylinder, that was the last time i ever used a namura piston...

The bike had on it the vforce 3 reeds, DEP pipe and few other bits when we got it.
Ive also gone for the 07 air boot. Im reluctant to play around with decking, porting etc for reliability. The likelihood is that this bike will continue to be used as a practice bike so we arent too worried about peak hp numbers but it is fun to liven it up a bit

1
Zesiger 112
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Pink Hill, NC US
Fantasy
2309th
5/28/2021 8:29am Edited Date/Time 5/28/2021 8:38am
Here is a CR me and my friend did. Wasn’t a fan of the fitment of the restyle kits so opted to go with front fender and number plate and designed the graphics to mimic the restyled rear fender and plates.

You are right about it being a very slow power, this one is last year, 06-07? I was amazed when I took a spin on it. I never understood “125 is hard to ride” until I rode a CR. It’s night and day difference from a YZ. Yz was never lacking, twist and go. These bikes are slow to get into the powerband, short window of acceleration, then fall off quickly. It takes a very dedicated rider to figure this bike out. Does handle like its on rails though!




4
36Wheeler
Posts
137
Joined
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Hinckley GB
5/28/2021 11:22pm
Here is a CR me and my friend did. Wasn’t a fan of the fitment of the restyle kits so opted to go with front fender...
Here is a CR me and my friend did. Wasn’t a fan of the fitment of the restyle kits so opted to go with front fender and number plate and designed the graphics to mimic the restyled rear fender and plates.

You are right about it being a very slow power, this one is last year, 06-07? I was amazed when I took a spin on it. I never understood “125 is hard to ride” until I rode a CR. It’s night and day difference from a YZ. Yz was never lacking, twist and go. These bikes are slow to get into the powerband, short window of acceleration, then fall off quickly. It takes a very dedicated rider to figure this bike out. Does handle like its on rails though!




That looks great! Will definitely be taking some inspiration from you on the graphics side.

Would you agree that this bike is a good bike to transition to and develop your riding on? I found that even though it is not an easy bike to go fast on, once you learn to ride it aggressively and keep it on the pipe, but then most other bikes feel easy in comparison Laughing
2
Zesiger 112
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5/29/2021 9:38am
Absolutely a great transition bike will teach the fundamentals to make other bikes easy.
1
Rickyisms
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FL US
5/29/2021 10:06pm
My first big bike was a bone stock 2006 CR125, I stopped riding the last year I was eligible for superminis and took a year and a half off, got a good deal on the bike with a fresh OEM rebuild so I was stoked for a friend to hook me up with it. The first time I went out on it I thought I sucked at riding and had lost every bit of technique from when I was younger. That bike seriously hated to get out of its own way, but I started to ride it like I was trying to blow it up and was able to get rid of it. When I rode my mod build KTM 125 for the first time after I sold my Honda I felt like I was on a rocket ship.
2
36Wheeler
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137
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Location
Hinckley GB
5/30/2021 11:09am
Took wheels to my local shop for them to vapour blast the hubs and rebuild with new spokes.


I'm thinking of aiming for the 2004 team honda look. Close to OEM with some nice factory touches.

6
36Wheeler
Posts
137
Joined
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Location
Hinckley GB
5/31/2021 9:11am
Clean frame:


Opted for soap, scotch brite and elbow grease. Satisfying result Smile
6
5/31/2021 9:27am
Use the hrc method for pv adjustment, demystifying the rc valve video on yt. Clean polish Rc valves and shaft, for smooth operation. This 04 is similar to my 1st one. One valve likes to rub on the exhaust bridge, take it apart and reassemble. I think the seller reused the head gasket, base gasket was a aftermarket cheapo. Was leaking smooge from the head. Cleaned pv valves, polished head, exhaust port, etc. throttle response is excellent, rolling in 3rd gear snap it , the bike is hard to keep the front wheel down for 150 feet. Odd that it’s stonger than my 1st 04 stock, it has 4 replates on cylinder tho. Pro series reeds, stock pipe with a dent, silencer never repacked. I thought the 06 was pretty good stock with maybe 10 hrs on it. It had reed flutter, iKat, Rad vale, 03 kx Budd hgs pipe. Real quick off idle much stonger mid range with 1,500 more rpm on top, never stopped pulling. Perfect power band. Much quicker than a yz or Ktm, with 38 hp. Dirt rider 06 test cr vs yz , there about even. Yz edged the cr out because of the finicky jetting.
1
36Wheeler
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6/2/2021 10:30am
Was just torquing up the last nut on the cylinder head after putting the new top end in and realised I had forgotten to drill the piston at the exhaust bridge area. All apart again now and ready to do another day haha
Gotta have something like that happen every once in a while to remind you you're not so smart Laughing
2
6/2/2021 4:30pm
36Wheeler wrote:
Was just torquing up the last nut on the cylinder head after putting the new top end in and realised I had forgotten to drill the...
Was just torquing up the last nut on the cylinder head after putting the new top end in and realised I had forgotten to drill the piston at the exhaust bridge area. All apart again now and ready to do another day haha
Gotta have something like that happen every once in a while to remind you you're not so smart Laughing
Oh man. Did you clean the power valves and spray them with Pam? It’s a non stick spray in the USA, for food not sticking to a pan. Did you find that video, demistifing the rc valve on yt ? The last way to adjust the rc valve, is the way team Honda used. I used this socket put tape on it, so it stayed in the exhaust port. Scotch bright pad and polish the pv shaft, for smooth operation. I think it’s easier to put the front cable on then the rear. Make sure not to get the cables too tight, takes the servo motor gears out. I installed a new coil and a iKat I had, throttle response is extremely snappy. This is how it looks, using the hrc adjustment method. I could be a little off, on my adjustment. The hit is strong and quick getting on the pipe, higher rpm,s it’s pretty flat. I think it would be a great AX bike, just short shift it. will be dropping a tooth on the rear, lessen the hit and carry a gear further.

36Wheeler
Posts
137
Joined
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Location
Hinckley GB
6/6/2021 1:25am
36Wheeler wrote:
Was just torquing up the last nut on the cylinder head after putting the new top end in and realised I had forgotten to drill the...
Was just torquing up the last nut on the cylinder head after putting the new top end in and realised I had forgotten to drill the piston at the exhaust bridge area. All apart again now and ready to do another day haha
Gotta have something like that happen every once in a while to remind you you're not so smart Laughing
Oh man. Did you clean the power valves and spray them with Pam? It’s a non stick spray in the USA, for food not sticking to...
Oh man. Did you clean the power valves and spray them with Pam? It’s a non stick spray in the USA, for food not sticking to a pan. Did you find that video, demistifing the rc valve on yt ? The last way to adjust the rc valve, is the way team Honda used. I used this socket put tape on it, so it stayed in the exhaust port. Scotch bright pad and polish the pv shaft, for smooth operation. I think it’s easier to put the front cable on then the rear. Make sure not to get the cables too tight, takes the servo motor gears out. I installed a new coil and a iKat I had, throttle response is extremely snappy. This is how it looks, using the hrc adjustment method. I could be a little off, on my adjustment. The hit is strong and quick getting on the pipe, higher rpm,s it’s pretty flat. I think it would be a great AX bike, just short shift it. will be dropping a tooth on the rear, lessen the hit and carry a gear further.

I was quite happy with power delivery last time I rode it so I made sure to take some measurements of the adjustment when I removed the PV cables from the cylinder
1
36Wheeler
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Location
Hinckley GB
6/6/2021 1:28am
Put in some new swing arm bearings yesterday as well as finished the top end.



Planning to tidy up and reinstall the wiring harness today as well as clean and regrease the linkage bearings which all look ok
2
36Wheeler
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137
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Location
Hinckley GB
6/6/2021 10:30am
Shock and wiring all clean and back in place.


While the paint chips on the shock spring bug me a bit I have to draw the line somewhere so that this build doesn't cost me thousands. I'm opting for a "if it ain't broke don't fix it" attitude. Otherwise I get carried away and it's ends up being a full restoration.

One thing I am going to have to fix is these aluminium footpegs.


I hate the look of anodised after market parts and luckily grabbed some originals in good enough condition for £10. A sharpen up with a file and they'll be good to go.

Next up on the list is rebuilding the forks as the seals have gone.

3
6/6/2021 6:09pm
36Wheeler wrote:
Was just torquing up the last nut on the cylinder head after putting the new top end in and realised I had forgotten to drill the...
Was just torquing up the last nut on the cylinder head after putting the new top end in and realised I had forgotten to drill the piston at the exhaust bridge area. All apart again now and ready to do another day haha
Gotta have something like that happen every once in a while to remind you you're not so smart Laughing
Oh man. Did you clean the power valves and spray them with Pam? It’s a non stick spray in the USA, for food not sticking to...
Oh man. Did you clean the power valves and spray them with Pam? It’s a non stick spray in the USA, for food not sticking to a pan. Did you find that video, demistifing the rc valve on yt ? The last way to adjust the rc valve, is the way team Honda used. I used this socket put tape on it, so it stayed in the exhaust port. Scotch bright pad and polish the pv shaft, for smooth operation. I think it’s easier to put the front cable on then the rear. Make sure not to get the cables too tight, takes the servo motor gears out. I installed a new coil and a iKat I had, throttle response is extremely snappy. This is how it looks, using the hrc adjustment method. I could be a little off, on my adjustment. The hit is strong and quick getting on the pipe, higher rpm,s it’s pretty flat. I think it would be a great AX bike, just short shift it. will be dropping a tooth on the rear, lessen the hit and carry a gear further.

36Wheeler wrote:
I was quite happy with power delivery last time I rode it so I made sure to take some measurements of the adjustment when I removed...
I was quite happy with power delivery last time I rode it so I made sure to take some measurements of the adjustment when I removed the PV cables from the cylinder
Measurements good idea, you could put marks lining up with the flapper on the inside also. I played around with different pv adjustments on my 1st 04. You can get it, to run different. Forgot to mention my transfers are polished smooth, that’s why it probably runs stronger than my other stock 04.
1
36Wheeler
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137
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Location
Hinckley GB
7/26/2021 1:18pm Edited Date/Time 7/27/2021 12:52am
Apologies for lack of updates, been very busy with work and working on other bikes. I got the wheels back from being rebuilt with vapour blasted hubs and new spokes. I also finally got around to rebuilding the forks with new seals and bushings.




I spent a few hours tonight getting it out back together. Another few nights in the garage and it would be ready for my brother to try on Saturday.


For now it'll be mechanically 100%. And then over the next few weeks we will look and freshening up the plastic etc.

One thing I found very satisfying is getting the carb all cleaned and putting this fresh pink vent hose on it. The original hose had gone brown and hard




Will update again with it all finished and ready to rip Woohoo
2
36Wheeler
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Hinckley GB
7/27/2021 2:21pm
It lives! Fired it up and it sounds super crisp



I used a vertex piston and opted for the "race" option which has no window in the back of the piston. Can anyone explain how this affects performance?

First ride honours go to my 14 year old brother this Saturday. I will first do a few heat cycles on it to run the new top end in before he gets too excited at the track.

Will post a pic with the plastic on tomorrow
4
36Wheeler
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Hinckley GB
7/30/2021 1:41pm
It's done and it's safe to say he's very pleased with it and excited to ride it for the first time tomorrow.





It ended up costing me £700 in total and most of that was the wheels and tyres. New vertex top end, new seals and bushings in the forks, some new OEM bits and bobs here and there like bolts and rubber bits. Managed to pick up some used but decent plastic for £30.

I hope that he enjoys riding it as much as I did and hopefully it will be a good transition for him between the CR85 and eventually moving to a 250f.

Enjoyed seeing this come together. Cheers!
15
Rickyisms
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7/30/2021 8:54pm
You're a good brother! Bike looks great, update us after his first ride!
soggy
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UT US
Fantasy
4355th
7/31/2021 2:58pm
Nice build! You can use oven cleaner (i think) to strip the anodizing off those pegs if you aren’t into it

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