Looks absolutely incredible, better than new 👌🏻...can't wait to see it in the bike ,you have given me such inspiration and ideas 💡for my 02 ktm 125 sx build !keep the awesome videos coming 🙌
Daniel, thank you for making this series, it was instrumental to my rebuild! It's a small world,.. I recently moved from Grand Junction to Mississippi. I hung up my mountain bike and got a 2006 KTM 125sx. Started watching your KTM series, and immediately recognized the Bookcliffs BLM land! Cheers and rip on!
Daniel, thank you so much for taking the time to make this fantastic series! It has been incredibly helpful to me so far. I’ve subscribed and can hardly wait to see your finished result. Your restoration will be much better than a new stock bike. KTM should award you a prize, as you are a first rate brand ambassador. I admire your skills as both a mechanic and now as a videographer. You are obviously a very talented individual. You have inspired me to pull my 2005 KTM 125 SX out of storage for a complete rebuild. Sad to say that it’s probably been 10 years since it’s been run, so I’m looking forward to riding it again. Will restore our 1990 Honda XR250R, as well. With fresh gas, I just got it running again after way too long sitting in the corner. I will have plenty to do over the winter if parts availability hasn’t become a problem with these older bikes. Both KTM, Honda and Yamaha all made a high quality product that really lasts if taken care of. After getting a WR250R with electric start some years back, the oldies fell out of use. It’s time to get them back in the rotation. Thanks for the inspiration. And glad to see that you’re over the illness and doing well again. Keep up the great content. I suspect many of us look forward to seeing you ride the KTM again. All the best to you -
Thanks David, that’s what it’s all about. I’m really just like you and everyone else out there with a passion to ride and wrench. I take pride in my work and try to help others feel more confident in what can seem to be a major hurdle. Building bikes is fun, time consuming, aggravating, and then throw the filming in and talking and it’s tough. I love the challenge but most of all love the interaction with the fans. Thanks for the comment man, and good luck on the build! You got this!!!
Tip if you don't have an adapter for your torque wrench: you can use a spanner at 90 degree to the torque wrench, since you're not adding length the torque value is the same. How do you connect the torque wrench to regular wrench? Fit the same size socket to the torque wrench, then take an old bolt and two nuts the same size as the nuts on the head that you want to torque. Double nut the old bolt to prevent the nuts from moving on the old bolt, so you now have a bolt with two heads essentially. This bolt allows you to connect between torque wrench and rear of the spanner. Hard to articulate in text but I hope it makes some sense
John, this is awesome, and as a matter of fact I did this back in my mechanic days when working on Cat\Ariel compressor packages. Funny, I never thought to use this method on the bike lol thanks for the info and I love these kind of tips and tricks, send some more my way. Btw, your explanation was spot on!!!!
@@DanMX2112 hey no worries at all, im glad it made sense and a small contribution. One other tip, turn the torque wrench upside down so gravity keeps the old bolt captive. Rakes a little bit of the awkwardness away. Snug is likely just fine, but for those with OCD (like me) it can help you sleep at night :)
I recently brought a 03 ktm 125 cheap but needed some work. Im so glad I found your series. Thanks for all the tech help and pro tips, and keeping the older 2 strokes alive. Once it’s up and running, do think you’ll do a carburetor tuning video?
Hey Dan, Great video series,I’ve followed your process step by step rebuilding my 2003. My question is regarding the cylinder head gaskets. 1. My vortex kit comes with 3 different size head gaskets(head to block). I am not sure which one to use. 2. I noticed that you did not install the OEM o-ring style gasket on the cylinder head cap(near spark plug). Are the paper gaskets better?
Hey, thanks for watching and according to KTM, you want to be around .06 mm for cylinder to piston clearance, hope this helps and I appreciate you following!!!
I just got a KTM dirtbike myself. Can't wait to get my hands dirty and get it together. 1985 KTM 125cc 2 stroke. What carburetor are you using on this build?
hello, i fully rebuildt a husqvarna te 125 which has the ktm sx 125 2007-2016 engine. what should the squish be? i have a high compression head and it’s .7mm is this to little?
Yes, you are correct. Those holes correspond with the holes in the head an cylinder to control flow. It looks like it’s bad, but does nothing different that running the O-ring like OEM. I actually swapped that out to the o-ring later on. Just like it better!
Hey Dan.. Congrats on your videos man you’re awesome..I just finished my top end rebuild on my exc 125 ‘01 but it won’t start..I get fuel in the cylinder,I get spark, good compression but it won’t even think of starting..😢any ideas??spark plug is not the recommended one cause I didn’t find a br8es on my local shop so I bought a br6es instead!! You think it might cause the issue??
Your reeds could be stuck closed causing no air and fuel mixture. Other than that if you’re sure on the rest I’m kinda lost. The plug shouldn’t affect it starting and running. If it’s not a strong blue spark, it won’t run either.
@@DanMX2112 update: it was the plug.. I put a BR9ES and it started on the 2nd kick..maybe the first one was clogged with all the 2t oil I used while assembling the cylinder and all the stuff.. anyway thanks for the reply..greetings from Greece my friend!!
Hi, love your videos! Just bought the exact same bike myself. It needs a lot of work, and watching your videos helps me a lot with planning my project. Unfortunately one day after riding my piston broke (i think), and I hope theres no damage in the motor. It starts but it makes a metallic clacking noise that i assume comes from the piston. Do you know what might be the problem? Regards from Norway🇳🇴
Oh boy, that sounds bad. Take the top end apart and do some investigations but I be you broke some rings or maybe the bottom skirt of the piston. Sorry to hear my man! The videos are for guys like yourself that are doing builds and repairs, so please let me know if I missed anything or have any questions!!!
@@DanMX2112 Took the cylinder and piston out yesterday. They both looked fine, but I might change out the piston. What i noticed was that there were some metal fragments down by the crankshaft and a lot of play on the crank. I am assuming a crankshaft part got smashed, probably a bearing or something. Fingers crossed I get the bike up and running for next season.
How long did the bottom end on this bike last doing a bottom end rebuild on a 03 model but can't find how long it will last because I struggle to believe it will last 120-160 hours as said in the internet
The internet is full of garbage and truth. I would do your top end rebuilds as recommended about every 20-40 hours or when compression starts to fall off. While in there, check the crank play and that will be the sign you need a bottom end.
Looks absolutely incredible, better than new 👌🏻...can't wait to see it in the bike ,you have given me such inspiration and ideas 💡for my 02 ktm 125 sx build !keep the awesome videos coming 🙌
Thanks dude, I have to agree it’s much better thank stock! I say go for the build and don’t look back. There is so much satisfaction in it!
Daniel, thank you for making this series, it was instrumental to my rebuild! It's a small world,.. I recently moved from Grand Junction to Mississippi. I hung up my mountain bike and got a 2006 KTM 125sx. Started watching your KTM series, and immediately recognized the Bookcliffs BLM land! Cheers and rip on!
Thanks for comment bro, I bet you love the 125. Glad to hear you dominated the rebuild. Take care man, and visit Utah again sometime.
Daniel, thank you so much for taking the time to make this fantastic series! It has been incredibly helpful to me so far. I’ve subscribed and can hardly wait to see your finished result. Your restoration will be much better than a new stock bike. KTM should award you a prize, as you are a first rate brand ambassador. I admire your skills as both a mechanic and now as a videographer. You are obviously a very talented individual. You have inspired me to pull my 2005 KTM 125 SX out of storage for a complete rebuild. Sad to say that it’s probably been 10 years since it’s been run, so I’m looking forward to riding it again. Will restore our 1990 Honda XR250R, as well. With fresh gas, I just got it running again after way too long sitting in the corner. I will have plenty to do over the winter if parts availability hasn’t become a problem with these older bikes. Both KTM, Honda and Yamaha all made a high quality product that really lasts if taken care of. After getting a WR250R with electric start some years back, the oldies fell out of use. It’s time to get them back in the rotation. Thanks for the inspiration. And glad to see that you’re over the illness and doing well again. Keep up the great content. I suspect many of us look forward to seeing you ride the KTM again. All the best to you -
Thanks David, that’s what it’s all about. I’m really just like you and everyone else out there with a passion to ride and wrench. I take pride in my work and try to help others feel more confident in what can seem to be a major hurdle. Building bikes is fun, time consuming, aggravating, and then throw the filming in and talking and it’s tough. I love the challenge but most of all love the interaction with the fans. Thanks for the comment man, and good luck on the build! You got this!!!
Tip if you don't have an adapter for your torque wrench: you can use a spanner at 90 degree to the torque wrench, since you're not adding length the torque value is the same. How do you connect the torque wrench to regular wrench? Fit the same size socket to the torque wrench, then take an old bolt and two nuts the same size as the nuts on the head that you want to torque. Double nut the old bolt to prevent the nuts from moving on the old bolt, so you now have a bolt with two heads essentially. This bolt allows you to connect between torque wrench and rear of the spanner. Hard to articulate in text but I hope it makes some sense
John, this is awesome, and as a matter of fact I did this back in my mechanic days when working on Cat\Ariel compressor packages. Funny, I never thought to use this method on the bike lol thanks for the info and I love these kind of tips and tricks, send some more my way. Btw, your explanation was spot on!!!!
@@DanMX2112 hey no worries at all, im glad it made sense and a small contribution. One other tip, turn the torque wrench upside down so gravity keeps the old bolt captive. Rakes a little bit of the awkwardness away. Snug is likely just fine, but for those with OCD (like me) it can help you sleep at night :)
Great work
Thanks again!
Hey is does this head gasket also fit on ktm exc 125 2005
Pretty sure it’s exactly the same, no changes from 04-05
I recently brought a 03 ktm 125 cheap but needed some work. Im so glad I found your series. Thanks for all the tech help and pro tips, and keeping the older 2 strokes alive. Once it’s up and running, do think you’ll do a carburetor tuning video?
I will once I get it started up, so stayed tuned for that! Thanks for watching!!!
Thank you!!
🙏 thanks for watching!
Hey Dan,
Great video series,I’ve followed your process step by step rebuilding my 2003.
My question is regarding the cylinder head gaskets.
1. My vortex kit comes with 3 different size head gaskets(head to block). I am not sure which one to use.
2. I noticed that you did not install the OEM o-ring style gasket on the cylinder head cap(near spark plug). Are the paper gaskets better?
I went back to the oring style gasket later on. Didn’t like the paper gasket fitment. I would run OEM orings.
hello, thank you for your video which will help me a lot. What cylinder piston clearance do you recommend ? Thank’s
Hey, thanks for watching and according to KTM, you want to be around .06 mm for cylinder to piston clearance, hope this helps and I appreciate you following!!!
hi! do you have to buy new head gaskets/rings for a rebuild? can't I just use the old ones? thanks for the video!!!
You must replace the gaskets every time.
I just got a KTM dirtbike myself. Can't wait to get my hands dirty and get it together. 1985 KTM 125cc 2 stroke. What carburetor are you using on this build?
The OEM PWK 38. That’s awesome you have a bike! Rebuild are fun and frustrating lol take your time and be patient!
hello, i fully rebuildt a husqvarna te 125 which has the ktm sx 125 2007-2016 engine.
what should the squish be? i have a high compression head and it’s .7mm is this to little?
how are you cleaning the exterior of the calendar. I cannot get the deep grunge off.
Simple green and hot water 50/50 mix. The use aluminum cleaner and a course bristle brush!
Hello so i have a question, the top gasket only has small holes for the water to flow and restricts the full flow is that how it is supposed to be?
Yes, you are correct. Those holes correspond with the holes in the head an cylinder to control flow. It looks like it’s bad, but does nothing different that running the O-ring like OEM. I actually swapped that out to the o-ring later on. Just like it better!
Hey Dan.. Congrats on your videos man you’re awesome..I just finished my top end rebuild on my exc 125 ‘01 but it won’t start..I get fuel in the cylinder,I get spark, good compression but it won’t even think of starting..😢any ideas??spark plug is not the recommended one cause I didn’t find a br8es on my local shop so I bought a br6es instead!! You think it might cause the issue??
Your reeds could be stuck closed causing no air and fuel mixture. Other than that if you’re sure on the rest I’m kinda lost. The plug shouldn’t affect it starting and running. If it’s not a strong blue spark, it won’t run either.
@@DanMX2112 update: it was the plug.. I put a BR9ES and it started on the 2nd kick..maybe the first one was clogged with all the 2t oil I used while assembling the cylinder and all the stuff.. anyway thanks for the reply..greetings from Greece my friend!!
@KostasItea91 good to know my guy, glad you got it figured out!
Hi, love your videos! Just bought the exact same bike myself. It needs a lot of work, and watching your videos helps me a lot with planning my project. Unfortunately one day after riding my piston broke (i think), and I hope theres no damage in the motor. It starts but it makes a metallic clacking noise that i assume comes from the piston. Do you know what might be the problem? Regards from Norway🇳🇴
Oh boy, that sounds bad. Take the top end apart and do some investigations but I be you broke some rings or maybe the bottom skirt of the piston. Sorry to hear my man! The videos are for guys like yourself that are doing builds and repairs, so please let me know if I missed anything or have any questions!!!
@@DanMX2112 Took the cylinder and piston out yesterday. They both looked fine, but I might change out the piston. What i noticed was that there were some metal fragments down by the crankshaft and a lot of play on the crank. I am assuming a crankshaft part got smashed, probably a bearing or something. Fingers crossed I get the bike up and running for
next season.
@@hallvardeggen7575 sounds like a full motor rebuild on that one. It happens and these bikes with old pistons and cranks can’t last forever.
How long did the bottom end on this bike last doing a bottom end rebuild on a 03 model but can't find how long it will last because I struggle to believe it will last 120-160 hours as said in the internet
The internet is full of garbage and truth. I would do your top end rebuilds as recommended about every 20-40 hours or when compression starts to fall off. While in there, check the crank play and that will be the sign you need a bottom end.
Hey I have a ktm engine similar to that one how can u tell exactly what cc is it if it’s a 125 or 200cc
So bolt fastener kit doesn’t include head bolts?
Correct! I wish it did, I’m not sure why they wouldn’t throw them in.
@@DanMX2112 probably because it’s too complicated for mass production. Head bolts are m7 and have weird shape.
Liability also, different specs for different bikes.
Is this the motor that is on the Husqvarna te 125? If not, wich motor is it? Do husqvarna have an own 125 twostroke engine?
It’s not, it’s on a 04 KTM 125SX.
Ok thank you for answer. Really cool resault of the bike!
Thanks man, I appreciate you watching!!!