aprillia 125 rebuild

[Nexus Icon]

Wow, what a mess you have taken on! I can see this becoming a very interesting project for us to follow and a very irritating one for you to undertake. Best of luck

On the bright side, according to your gauges you have a free 1/4 tank of fuel
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Greetings from Shitsville!

[mintex]

cheers mate, i can see it being a headache but i like a challenge lol.

I like the idea of free fuel, and to think i thought the tank was empty

[mintex]

Well i finally managed to remove the swing arm/ rear engine bolt only i'm now going to need a new one

It was seized in the bush in the swinging arm, some one had tried to remove it before but had failed and made a mess of it.
One end had been drilled, hit, and a chisel on it so it was knackered so i decided the best way to save any more damage would be to cut the other side off.

I had to do it with a hacksaw blade as there was limited space, it did take a while but at least its off, i just need to try and find a replacement bolt now.

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/P1000761_zpsb0562941.jpg

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/P1000769_zps4f865739.jpg

Its free ............................

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/P1000771_zps86438ceb.jpg

[Kickstart]

Hi

You have some patience!

Part number of the spindle is 8125387 (not the same part as an RS125).

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[mintex]

It did take some patience with that saw blade lol

Thanks Keith, the hunt for a new one begins

[Kickstart]

Hi

Quick look and it appears the spindle is used on a few other Aprilias:-

https://www.apriliagenuineparts.co.uk/part-search.php?txtSearch=ap8125387&btnAction=Go!&hdnSearchMode=Parts

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Phil_B]

Not an easy way to get the bolt out, there certainly isn't a lot of room in there!
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This restoration is ruining my bank balance! Restoration project - 1991 Aprilia AF1 Replica
Yamaha R3

[mintex]

Bit of an update on the wiring loom.
Phil kindly sent me some pictures of his loom, cheers bud ,
I know his is a little different to mine but it gives me an idea of what should be where.

I looks like i have the right loom as the ignition, switch gear, clocks and front and rear lights all plug in, the fuse box is intact, and also there is defiantly no plug for that power valve control unit i have so i can only guess that he was given that in a box of parts.





https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/P1000772_zpsf68b1cdc.jpg

[Kickstart]

Hi

Might be worth checking all the lights on the clocks work (the earth wire is a bit dodgy where multiples join together).

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Phil_B]

glad it helped

if there's anything else I can help with give me a shout
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This restoration is ruining my bank balance! Restoration project - 1991 Aprilia AF1 Replica
Yamaha R3

[mintex]

Ive got myself a new swing arm spindle, thanks kickstart for the heads up, that one you said about fits a treat

I hope to do a bit to it this weekend
I have just been looking at the the engine though and i think the power valve on mines been modified to stay open at all times.
I guess it will run ok like this but im imagine its going to have no bottom end pull and be a flat out or nothing engine if i leave it like this although that does sound like fun lol


https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140402_194946_zps2497c8ef.jpg

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140402_200647_zps740c7602.jpg

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140402_200637_zpsc53685da.jpg

[BravoCharlie]

just spotted this. you have more patience than me for sure! but i look forward to seeing more!
____________________
Current: Kawasaki ZL600 Eliminator
Past: Suzuki GZ125, Kawasaki GT550, Kawasaki GPX600R, Honda vrx400,Kawasaki Zephyr 750, Suzuki SV650 K5
Dream as if you'll live forever, live as if you'll die today.

[Kickstart]

Hi

That is a blanking plate for the power valve, possibly modified to be in the full open position full time. Still have the one for my Futura somewhere (was restricted when new and I ran it in like that before the power valve kit arrived).

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[mintex]

Come across another problem today

I removed the top cover of the cylinder to check inside and found this, its a shame as the barrel looks in good shape with no big sores or anything, even the top of the pistons still silver and not dirty.

Its the outer wall of the water jacket (cylinder walls are fine) and i was wondering if i could get it welded it or something??

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140403_113135_zps01518c59.jpg

[Kickstart]

Hi

That should be repairable. Think Langcourt Engineering are one of the main places that others send their barrels to:-

https://www.langcourt.com/Cylinder_repairs_&_replating.htm

Think they can repair cracks (and rechrome if required).

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[mintex]

Hi keith
Thanks for the link .
I did thinking about using a dremel to cut the crack into a v shape and brazing it.

[Kickstart]

Hi

You might get away with it, but not sure I would risk it. There isn't a massive amount of stress on the outer water jacket, but if the top surface isn't pretty flat the cylinder head cover probably wouldn't seal very well.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[mintex]

Ive managed to get hold of a coil/cdi, i missed one the other week because i never had the cash but i found another one and had been watching it for a few days and i got paid today so bought it

I only need a starter motor now but that will have to wait until next pay day lol

[Phil_B]

I've got my original owners manual, I'll try to get it scanned for you and e-mail it over. May take a few weeks as I'm off on holiday on Sunday
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This restoration is ruining my bank balance! Restoration project - 1991 Aprilia AF1 Replica
Yamaha R3

[mintex]

Cheers Phil Have a great Holiday bud

[mintex]

Bit of an update but not much as i've not had much time to do alot to it.

My cdi/coil i ordered arrived so happy i've now got that as they seem quite had to find and expensive.

I've also had some more bits given to me that the previous owner found, its mostly gearbox stuff but there was also a speedo drive and a rev counter drive that i needed.

I cleaned the wheels to take a look at them as i was told they had been powder coated but looking at them im not impressed, unless they were just prepped badly, they look ok if you don't inspect them to close.

I've also started rubbing down the rear subframe ready for its respray

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140410_111911_zpsadcc9799.jpg

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140418_170859_zps6b6272bd.jpg

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140418_170910_zpsa3fc968a.jpg

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140420_143003_zps1e9fb902.jpg

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140420_143025_zps69ae57d1.jpg

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140420_143044_zps19bf554e.jpg

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140420_142946_zpsf31fc8c5.jpg

[Kickstart]

Hi

At a glance that finish looks too thin for powder coating.

But you pile of spares has a stator and rotor in there which is good.

Electrex World have done SEM flywheels and I am trying to persuade them to do some more. Down side is that they don't think they can do the starter motor toothed wheel for a reasonable price. However if they drill the appropriate holes then it should be possible to swap over the toothed ring from a knackered flywheel (in other words, even if all the magnets have fallen off, don't throw it away).

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[mintex]

Ive not done a lot to this build as late, work and lack of cash stops play

Anyway i had a go at brazing the split water jacket on the barrel, im quite pleased with the outcome, it needs a little more cleaning off but i think it should do the trick.

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140403_113135_zps01518c59.jpg

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140522_115828_zps0e9281ac.jpg

https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140522_123538_zpsf65040e3.jpg

[mintex]

Hi all
Its been a while since i've been on and ive done nothing to the af1.
Ive had a few few family problems with my older sister being an idiot and giving me unnecessary hassle and my dad passed and ive had his things and estate to sort so the bike was left.

It also turned out that the frame has been hacked by someone trying to remove the swingarm pivot bolt and they had filled it after with some type of metal filler so that put a stop to the project until now but ive just ordered a new (second hand) frame so once that arrives i hope to get a lot more done to the bike and get it running again

Before i removed the filler


https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/20140501_213446_zpsbe340a2e.jpg


After i removed it


https://i128.photobucket.com/albums/p161/suzuki998/Aprilia%20af1/P1010072_zps0671ff23.jpg

[BravoCharlie]

Sorry to hear about your dad, mate

looking forward to seeing more of it when you've got the frame
____________________
Current: Kawasaki ZL600 Eliminator
Past: Suzuki GZ125, Kawasaki GT550, Kawasaki GPX600R, Honda vrx400,Kawasaki Zephyr 750, Suzuki SV650 K5
Dream as if you'll live forever, live as if you'll die today.