2012 Raptor 125 built into a 96CC 2-stroke

[oscarmayer]

my son has moved up in classes and so got a very nice rapy 125 for a steal. I am going to pull the motor and drop in a YZ85 with BB kit and run that for the class. I'll post photos of the progress.

First order up is stripping the down to the frame for engine removal, gusseting and such. from there will be the new engine mounting designs and radiator mounting and finally swingarm re-enforcements and such.

as i progress, i'll post remarks, photos and info on what I am doing and why.

hope ya'll like my build.

[oldskool83]

when he's ready for a 125 2 stroke let me know, I got a nice RM package I'd like to sell for a good price.

[oscarmayer]

you got it sir!

[oscarmayer]

well here's where we are at.
ATV was torn complete down tot he frame. sold motor and all electrical and exhaust.
I wondered why when we adjusted the suspension it never quite worked how we wanted it. Well we found out why. the previous owner had a bad accident and tweaked the front end of the frame some. $200 later it will be straightened. So I ordered a new gusset kit. I do all my own work, so I'll be welding in the new kit and then having the Frame powder coated Kawi green. (my son likes green so quad colors are green and white.) I'm also going to get the a-arms coated. thank god I took them apart, bearings were failing and both lower ball joints were shot to piss. We just got sponsored by LSR racing. Yes Lone Star Racing. So I am probably going to get him a +2 chromoly swinger and will also get him a new Fox rear shock. The front shocks are custom valve and sprung YFZ450R shocks and work perfectly (Very heavy duty compared to others) but they will need a refresh for this season, so I will have a place do them near me. Cost is $210 for both fronts so very good deal! For an extra $50 they will help set the sag and other settings for my son's riding to center so we have a good middle starting to adjust from.

Motor was shipped off to Lukesracing.com (Awesome 2-stroke shop) to get new HotRod crank, and 96cc BB setup installed.

[oscarmayer]

well stuff is coming in. got the stainless braided rear line for the extended swinger I ordered from LSR. got the gaskets and seals as well.
should have frame back Monday and should have gusset kit either by this weekend or early next week so I can get started on gusseting it.

[briano]

Sounds like a cool project for sure. I'll be peeking in to check on progress.

[oscarmayer]

well lots of stuff being done.
I will pick up straightened frame this evening, i already ordered +2 LSR swinger w/bearing carrier (already got their axle), I will be ordering the fox racing shox as well. main motor was sent off to sponsor's shop for rebuild (Lukesracing.com). He is also going to do a 2nd top end for a "spare" motor I am doing up myself. (Instead of them building it, I will be building it the same way but I will do the labor on the bottom end). hotrod cranks were ordered and should be here this week. one for the sapre and one gets sent to luke's racing.
I still need to look at a clutch setup. for now I will run the stock basket, but I will look at getting a billet wiseco setup in the next 3 months. 1 setup should be fine for the main motor and the spare can stay stocker with new discs, plates and springs. If needed I can awlays swap the billet stuff into the spare later.
I ordered 2 new 28mm carbs from yami. in the box new for an awesome deal! i will polish them out so there are no rough spots and flow is smooth. I Also have a jet kit i will use I am going to start with jets being x2 sizes bigger than stock to start and go from there. that is for both pilot and main jet sets.

I expect the dusset kit to come in this week. Once frame is gussetted, I will take frame, and a-arms over to get blasted and powder coated kawi green. (my son wants it that color)
I will also be ordering green stuff as much as possible and having any parts I decide to be either green or black. our colors are Green and White, but a littler black here or there is ok too.
i will post photos once i egt the frame gussetted and ready for the coater.

[86T3]

This is going to be pretty cool. How did your son do on the kx based quad last year?

[jakep53]

wow this sounds awesome! very lucky kid!

[oscarmayer]

Thanks for asking. He took 6th over all in his class out of 16 riders, so not too bad. The other ATV I sold. It was just too narrow and short. With the kx65 being built and out maxed and it was just way to powerfull for that frame, the guy that baught it is going to have his son do CX racing with it. I kow it will work beautifully for that hands down (I spect his kid to have some wins as he grows in skill). It just doesn't like the mx track when being pushed hard. Trying to corner at high speeds it skipps across the track and causes my son to slow down too much. The old frame was a modified typhoon xtreme.

We ran some practice session with the raptor using the stock 125 and the suspension was night and day difference for him. He is already trying to see how far he can jump it and the limit is the motor. It just can't give him the grunt he needs to clear tables and doubles. The new YZ85-BB to 96cc 2-stroke will do wonders for him. Along with the +2 swinger and fox rear shock(current rear is stock no rebound). I think this year he has a good chance to make it to the podium more often.

[oscarmayer]

frame man called and sais frame is done!
post man emailed sayign i had several packages delivered!! (mmuuwwaahaaaa!!! chrismas #2!!!!)

[oscarmayer]

I Completed the gusset kit install last night and started building new motor mounts. got the rear done (except for the spacers i need to make once I decide side movement). I believe I have a good idea for the front mounts now too. The next thing is I will have to modify an existing pipe to fit with the radiator where it needs to be mounted. I have some photos on my phone and will try to figure out how to upload them later, The pipe is gonna be a booger....

[oscarmayer]

Gere are some photos of the progress.
gusset kit welded on. rear engine mount made and bolted on, photo does not show, but i am working on 3 different designs for front engine mounts trying to decide best before i send frame off to get coated.

The final photo is the first time he rode the raptor he took it jumping. So you can see it needed the gusset kit especially with a much faster engine that is going into it.

[oscarmayer]

I did some more work. Mounted the radiator and test fit the tank and body. I will have to do some small trimming on the body, but it will work good.
We received some more parts, I got the new lower ball joints, all bearings, and some other misc. parts. I also got the LSR bearing carrier in. so they just owe me the swinger. it should be here first week of Feb.

next steps are to install the swinger re-enforcement kit, then mock the front end and take it with everything on it on the front and center
(engine, tank, rad, a-arms, shock, steering and tie rods, the reason is we need the pipe modified to fir properly.) I also need to finish my front engine mount design. I have not finished designing.

[86T3]

Looks good. Do you have any videos of your son racing last year? I'd like to see one of these in action