Thanks a lot for sharing that information.

The ineffectiveness of the Resonator in KB125 was not because of the resonator itself but due to wrong size of it...Which is why I posted that the resonators are engine specific.A resonator meant for a 100cc cannot be fitted into a 125cc...The resonator basically stops standing waves in inlet and aids in better volumetric efficiency where the engine needs. By changing the size,shape and mouth length and dia the resonator can be tuned for any specific engine ...
In my Lancer the stock inlet Resonator was tuned for a higher RPM...I had designed and fitted a resonator which gives better low to mid response and fuel efficiency...But the process is slow, and time consuming.
In your 125 or Prowler this would mean making appropriate holes in right side top of crankcase to fit the metal duct and opening the right crankcase to fit the resonator feed through pipe and "O" ring..
A custom Expansion chamber exhaust or even the old KB 100 Megaphone silencer will make the 125 or prowler quicker..I remember doing 120 with the expansion chamber..But look out for low 2T oil feed through Autolube..I had many seizures in stock KB 100 due to this one single problem, when I upgraded it to 110cc with KN /KH 110 piston...Pre-mix at 30ml per liter in city and 45ml for highway riding solved the problem...
I think the 125 comes with 14 teeth front sprocket and 38 rear..Try changing the front to 15 from Yam RX 100 or Suzuki AX 100..will give you better and smooth top end.

Top end speed is not a problem with Prowler, I have crossed 120 Km/h (maximum available on console) with ease, the needle in fact was over the Bajaj logo on the meter, it could be 130 / 135 km/h but no markings available to measure the exact speed.

My main interest to add Resonator is to add some punch at low RPM. Although it is not necessary for the Prowler, cause it has a very good power. You need to ride it to believe it. Is it possible to replace resonator case from KB 100 to 125 or Prowler ? I can have one scrap condition KB100 for this purpose. Please advice.

Today after almost 3 years I took the bike out on road, WOW it is still doing like as it is taken out of a Showroom. There was hardly any air pressure left, but still manage to drive without any hassle, Thanks to brand new Dunlop Tires (Were replaced on the last day) My first visit was straight to the Tirewala to check and maintain the air pressure. I drove for some kms. and found no issues with the power but certainly there was a bearing noise. I have to replace all bearings asap. If I replace these bearings My Thunderbird will sit in the parking, and I will be enjoying 2 Stroke Beauty again !

120+ on a Prowler? Is it stock? Whats the HP @ crank?

Your bike seems to be faster than the RX135 5-Speed!!!!

The Delta 100cc Resonator is not a match for the 125...I had already expressed this on my previous post....plus the amount of engineering work you need to do needs precision and time consuming...also Vitamin " M ".

The Yamaha RX135 YEIS can be tried with due work to fit it..

My Prowler is Stock and, Yes 120 + (On Chakan-Shikrapur Newly build highway in 2002) and that too with ease. Company claimed Top Speed is 110 Km/H. How much is the company claimed top speed for 5 Speed RX 135 ?

One of my friend had 5 speed RX 135 and for sure it was no where close to prowler in any way Power, Torque, Top Speed, Fuel efficiency, etc. On several occasions we tried these bikes and there was not even a single incident that RX had ever created any challenge to the Prowler. Undoubtedly Prowler is faster, and way better than RX 135 (5 Speed). You need to ride it to believe it !

Actually my friend was lighter by at least 20 Kgs than me and his RX too was lighter than Prowler by @ 12-15 Kgs, but Prowler didn't bother it at all....

Certainly Prowler was the best bike of that time. (even these days as well) Bajaj should have continued this bike. But to make a way to Pulsar (Pulsar was on the way to launch) and due to strengthen emission norms they stopped producing 2 Stroke vehicles. Otherwise Prowler could have been one of the most successful 2 Stroke bike for sure.

KB 100 Case with resonator outlet would be a ready fit for KB 125? If that is the case, I can try RX135 resonator box for R & D.

it might be a direct fit as i found the only difference between the kb100 and kb125 to be the width of the crankcases and the pcd of the studs

The KB100 crankcase will not fit into KB125 ..I had already mentioned in my earlier posts ...the KB125 has larger ,wider crankshaft,the bore is bigger with the stud bolts positioned wider etc.,so no way KB100 crank can be fitted on to 125.

Yes, 125 has a larger case. Idea Dropped.

Planning to replace all bearings soon. Any suggestions and advice please.

S K F and TATA bearings are supposed to be good...Don't buy sealed ones which cannot have proper lube circulation inside engine.

the kb100 and kb125 has the same crank shaft width , the kb125 crank is a direct fit to kb100 crank case however the gudgeon pin of the kb125 and hence the small end is much larger than the kb100 , how do i know this , believe me you dont wanna know......, ms ranade was referring to grafting the kb100 clutch cover to the kb125 clutch side so that he can go for the resonator set up.

as for bearings go for skf or nrb both are said to be extremely good , as for tata heard complaints of humming sounds from them, youy will need to replace total of 4 bearings (not incuding the shifter drum one) total cost will be under 1k

Can the Prowler still pull 120 today, in 2011? OR has there been a loss in bhp. I would be very interested to know this as I have a KB-100 from '87.

When I had gone to Khivraj Motors Chennai looking for upgrading my KB100 to 125 The head of Engineering brought out the ,Crank shaft with conrod,piston, L and R crankcase,gear lay shaft ,Head etc., to show how they were all different....all of them were bigger than stock KB100...so dropped the plan.At that time the Engineer did clarify that i cannot use the stock KB100 crank with conrod,to fit into the 125, or the other items I had mentioned earlier.(was trying to see what all I can save cost on).
I think they were right because with increased crankcase depth the support bearings for crankshaft will also be at different distance ,which means the crankshaft must have corresponding difference in it's dimension.

Yes, I believe so,

There is only a bearing noise, but no issue with power at all.