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| Just_James |
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Just_James
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Joined: 29 Aug 2014
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 Posted: 16:24 - 07 Jun 2015  Post subject: Rieju RS2 Tidy Up |
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So it's time to make a start with this one.
As mentioned in the RS1 thread, I won't be making a proper project of this now as I just don't have the time or money so it will be just getting a general tidy up and fresh MOT so I can move it on.
Shame really as I like the styling of this bike and it has great potential but I can't have everything.
I bought this bike the day after I sold my MR2, I wasn't really thinking but just had cash burning a hole in my pocket and possibly needed to cheer myself up from the loss of the car 
I didn't really take any pics of it when I first got it but I do have the potato images from the gumtree listing when I bought it
https://i9.photobucket.com/albums/a75/RS1Rebuild/_863_zpszt81v8o0.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/_86_zpsovuqa9up.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/_861_zpstkabjrtt.jpg
You can sort of get the idea from those that the plastics are in a bad way and the bike is just generally a bit bashed and bruised from the young lad keep falling off it.
He was selling it due to the fact he kept falling off and his Dad was now getting him driving lessons instead  Frightening!
Anyway, it's been sat in the garden under a tarp since last autumn and today I lifted the tarp to give it a quick wash down and have a proper look over it to see just what it needs doing.
I'd already removed the side panels and nose fairing with the intentions of starting repairs on them, they were all held on purely with cable ties!
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1355_zpsgbvqlwr5.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1356_zpsc79oqlva.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1357_zpszzcbhacj.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1358_zpsbvbddrpy.jpg
My initial thoughts were that it needs quite a bit more work than I remember but as I've gone round it things aren't so bad and it is mostly time and labour I need to put into it.
I tried the ignition 'for what it was worth' not even expecting to get dash lights but to my total amazement the battery had enough juice in it to fire the bike into life! Quite incredible considering it's been sat untouched all this time including over winter! So battery is a good one at least!
Bike runs and idles great and all electrics are working fine so that's all good, bike also has nice low miles.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1360_zps5b5mdtiv.jpg
Other good points are -
Both Pirelli tyres are good as new and the wheels are in nice condition, just need a clean up.
Chain and sprockets are hardly worn, chain needs a good clean but should be fine.
Everything feels nice and tight with no play so all bearings and bushes etc seem good.
Brakes are great! The discs need a bit of a clean up from being stood outside but there is hardly any wear on them.
They are awesome compared to ones on the RS1 but not surprising considering the size of the discs and the twin pot caliper on the front.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1367_zpsoukaenzz.jpg
Bad / not so good bits are -
Swinging arm has a lot of corrosion and so it's going to have to come off to be blasted. Bit more involved than I wanted to get but it's beyond a quick tidy up.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1363_zps59lynbae.jpg
Exhaust needs a tidying cosmetically. It's solid and sound but just has some surface rust and road rash on the can, no big deal.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1359_zpsphjthjbx.jpg
Hugger is going to need a bit of repair / tidying where the exhaust has been left to rub and melt into it. It's beyond me why previous owner didn't just bend the hanger back - took me all of 5 seconds just using my hands! 
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1362_zpspqkysdw5.jpg
Front mudguard needs quite a big repair.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1361_zpswdpmewkx.jpg
Rear seat lock has the latch bit snapped off but should be easy enough to sort.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1364_zpsaslpd49j.jpg
Grips need replacing but I already have a new pair that can go on
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1366_zpspcshhzmu.jpg
Choke cable has nothing to connect to, I'm clearly missing a part from the l/h switch gear so I assume thats where it should go. Will try to get a used replacement but otherwise maybe I can just get a spurious lever of some type to connect it to?
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1365_zpsnmtssynv.jpg
Fork seals are well gone so will have to do those.
Other than that it's mostly going to be a case of repairing the fairing panels and respraying it all.
The tail and tank aren't too bad with just minor scuffs and scratches but they've had a previous crappy paint job in black (bike used to be orange) and I need to paint them to match everything else anyway.
Got quite a big repair to do on the l/h side panel
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0817_zpsh5inkmxg.jpg
Pretty nasty but already made a start on that 
The nose has a split in it and is badly scuffed (this was actually the second one he's smashed, he gave me the old one with the bike too that he'd snapped in half on a previous off!).
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0826_zpssklx5fzb.jpg
r/h panel is also badly damaged and as with the left side, all bolt holes have been smashed out!
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0818_zps68t4mpbm.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0819_zpsfkh828bz.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0820_zpsbcox589f.jpg
.... but other than that it's perfect!
Plan to get this done over the next few weeks and am going to try and keep to a budget of around £100.
So... the fun begins! 
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125 |
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| stevo as b4 |
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stevo as b4
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Posted: 19:30 - 07 Jun 2015  Post subject: |
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Watching with interest! 
Yes it's kind of cool, and trick for a 50cc sports machine with the USD's, fancy discs, Alloy frame etc, but it will never be cool as the original and best (RS1) that you have completed for yourself.
Don't get too interested in this IMO, fix the paint, scuffs, scrapes and Bodges, and get it running with an MOT, and fling it on the bay for 16yr olds to have wet dreams over while asking their dad to lend them some cash.
Every penny you save on this project, and every £ you get from selling it on can only help in making your Mito resto better and more awesome, is how I would view it all the time your working on it. |
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| DRZ4Hunned |
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DRZ4Hunned
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| Just_James |
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Just_James
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| Posted: 20:28 - 07 Jun 2015 Post subject: Re: Rieju RS2 Tidy Up |
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| stevo as b4 wrote: | Watching with interest!
Yes it's kind of cool, and trick for a 50cc sports machine with the USD's, fancy discs, Alloy frame etc, but it will never be cool as the original and best (RS1) that you have completed for yourself.
Don't get too interested in this IMO, fix the paint, scuffs, scrapes and Bodges, and get it running with an MOT, and fling it on the bay for 16yr olds to have wet dreams over while asking their dad to lend them some cash.
Every penny you save on this project, and every £ you get from selling it on can only help in making your Mito resto better and more awesome, is how I would view it all the time your working on it. |
Yeah there are a few bits on this I do prefer over the RS1, I like the fancy dash, the big brakes (they really are good) and the USD forks but in all honesty it doesn't feel quite as well built as the RS1.
Neither are exactly BMW build material but the RS2 does generally feel a bit more flimsy / plastic somehow.
But yes I agree, don't worry, I shall not be getting attached to this one! I couldn't if I wanted to without giving up on the Mito and that's not going to happen!
Just going to do the bit's I've mentioned and move it on - may also load it with LEDs and make it look like something out of Tron!
| DRZ4Hunned wrote: | | Just_James wrote: | keep to a budget of around £100. |
100% more interested now. |
I think that should be fairly realistic unless I come across any nasty surprises.
Shopping list so far consists of fork seals, choke lever and a pair of indicators for the front. Already have pretty much anything I'll need to do the cosmetic side of things so I'm feeling positive / optimistic
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125 |
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Just_James
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Posted: 21:33 - 07 Jun 2015  Post subject: |
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Have finished the big repair on the l/h side panel tonight.
This is how it started off
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0817_zpsh5inkmxg.jpg
It was a mess really, not only is that piece broken off but the whole area is severely melted and warped. The bits I need to meet up are so badly warped that they are curving the wrong way! 
Always up for a challenge though and these kind of repairs are the most fun so set to it
Started by getting the heat gun on the rear (broken off bit) section first and getting it as close to its original shape as I could then gave it a heavy sanding to remove any high spots.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0825_zps2aj7kuyn.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0829_zpsjkpccetv.jpg
I gave the main panel the same treatment with the heatgun followed by a heavy sanding. Then met up the two parts and clamped in place
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0831_zpsfl2dx14a.jpg
I put a couple of plastic weld 'stitches' in just to hold it place while I checked it all lined up back on the bike. Once happy, I plastic welded it front and back
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0832_zpsxewlbnwt.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0833_zpscxloftvv.jpg
Then sanded it back
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0834_zps4ixjqiez.jpg
The plastic weld gives a really good strong repair (you couldn't pull the two bits apart) but I want to reinforce it from the back to minimise flex so cut out some fibreglass matting.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0835_zpsfcztzewy.jpg
Then resin applied, this also helps build up the upper and lower areas where I have lost some of the original plastic
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0837_zpsaypom6ye.jpg
Then a few skims of flexible filler and sanded to shape
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1368_zpsmrr52ux2.jpg
And finally in primer
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1369_zps4kzo1lbp.jpg
Happy enough with that
Still got a few other bits to do on that panel alone but it's the biggest repair out of the way.
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125 |
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| Matt B |
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Matt B
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| Posted: 10:51 - 08 Jun 2015 Post subject: |
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Nice work
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| Pol Anorl |
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Pol Anorl
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| Posted: 19:33 - 08 Jun 2015 Post subject: |
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watching with great interest!
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20:30:37 Pyro.: I don't sort of like men, I take every advantage to choke on dick.
Jewlio Iglesias: You live in Liverpool - Chances are, the front door has already been kicked off the hinges |
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| dolly3900 |
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dolly3900
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| Posted: 10:47 - 09 Jun 2015 Post subject: |
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You Sir, are an artist.
Loved the RS1 resurection and looking forward to this one.
They are great little sports ped, great fun to chuck about (imagine 6'8" of 17 stone loon on one).
____________________
2002 Rieju RS2-50 (Sold, spares or repair), 2010 Suzuki DR-125SM (Traded for ->), 2007 Honda CBF 600 (Sold), 2010 Suzuki V-Strom 1000 (Briefly, now returned), 2007 Suzuki Intruder 1800m (Even More Briefly, traded in for ->), 2014 Suzuki V-Strom 650 |
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| Just_James |
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Just_James
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Posted: 21:28 - 09 Jun 2015  Post subject: |
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Ah, an artist is creative... where as I'm just patching stuff up to make it useable again Thanks for the compliment though
Been on with the side panels tonight and got them in primer.
First thing I wanted to tackle was the missing bolt holes.
Luckily, the top ones for each side were still attached to the bike so I was able to bond these back in place with some resin
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1370_zpszmua73tf.jpg
They then just needed a bit of a repair on the front side.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1372_zpsolq6gcpy.jpg
Then had to figure what to do about the others, blu tack was my initial thought.... so I ran with it
I plunged some clumps of blu tack into each of the holes
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1377_zpsgqrupg9p.jpg
Then smeared some bridging compound over the back.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0836_zpsrwoapy8o.jpg
Once that had gone off I removed the blu tack and smeared some compound on the front side too just to make sure it was all solid.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0840_zpss3yocith.jpg
Then tidied with a little filler before re drilling.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1371_zps3jl96pj5.jpg
Sorted
There were multiple holes around the indicator mount areas
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0842_zpslef35bmy.jpg
Only need the one hole so the rest were just filled with a little bridging compound
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1373_zpsc46xglxb.jpg
The r/h panel was heavily melted and warped at the bottom also
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0841_zpshptavof9.jpg
So just a tidy up with a couple of skims of filler to make the area smooth again
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1374_zps4md4pghk.jpg
Then finally got them both in primer
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1376_zpsbgc1sybg.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1375_zps7ckovhga.jpg
That was quite a bit of messing about but beats buying new panels any day!
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125 |
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| dolly3900 |
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dolly3900
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| Posted: 08:24 - 10 Jun 2015 Post subject: |
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| Quote: | Ah, an artist is creative... where as I'm just patching stuff up to make it useable again Laughing Thanks for the compliment though |
In which case, You Sir are and engineer, a bigger compliment in my book
Keep the pics coming
____________________
2002 Rieju RS2-50 (Sold, spares or repair), 2010 Suzuki DR-125SM (Traded for ->), 2007 Honda CBF 600 (Sold), 2010 Suzuki V-Strom 1000 (Briefly, now returned), 2007 Suzuki Intruder 1800m (Even More Briefly, traded in for ->), 2014 Suzuki V-Strom 650 |
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Just_James
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| Posted: 21:56 - 11 Jun 2015 Post subject: |
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Tackled the front mudguard tonight. Been looking forward to doing this .... but then I have issues 
Anyway, I've basically got a bit broken off (no surprise with the crap flimsy design) and then that fair chunk missing at the front.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1384_zpsuqx0gici.jpg
Started by doing a plastic weld on the split at the top
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1386_zpsy9nywcnl.jpg
Then a weld on the broken off bit and reinforced at the back
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1387_zpskslbefw9.jpg
Then sanded back
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1392_zps8uemfgsl.jpg
Then cut a piece of fibreglass matting. This is much thinner stuff than I'd rather have used but it's what I've got
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1385_zpshttvhjyl.jpg
Then in place and brushed with resin front and back
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1388_zpsynvba8nn.jpg
Once that was hardened I put a skim of bridging compound front and back then roughly sanded to shape
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1390_zpsfyt0bugm.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1389_zpsptaevfbh.jpg
Then a skim of flexible filler and sanded to shape
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1391_zpsh6ujjq6f.jpg
And finally in primer
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1393_zps2l14fe4u.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1394_zpsoq0axapn.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1395_zpslziu7ilq.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1396_zpsiobikccf.jpg
Sorted
Thats another one added to the pile
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1397_zpsozltokzz.jpg
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125 |
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| Pol Anorl |
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Pol Anorl
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| Posted: 19:54 - 12 Jun 2015 Post subject: |
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so ive got a fazer with a broken nosecone..
fancy fixing for me
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20:30:37 Pyro.: I don't sort of like men, I take every advantage to choke on dick.
Jewlio Iglesias: You live in Liverpool - Chances are, the front door has already been kicked off the hinges |
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Just_James
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| Posted: 20:51 - 12 Jun 2015 Post subject: |
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Not really, I've got a broken nosecone of my own to fix
If you want to have a go at it yourself I'd be more than happy to help you out with it though, you don't learn if you don't have a go
Only self taught myself and am still learning new stuff all the time from playing at it
I've stripped the back end off tonight to get that swinging arm done
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1403_zpsy2ozjksu.jpg
While the chain was off I d̶u̶m̶p̶e̶d̶ ̶i̶t̶ ̶i̶n̶ ̶a̶ ̶l̶i̶t̶t̶e̶r̶ ̶t̶r̶a̶y̶ placed it in the parts cleaning vessel and left it to soak in some white spirit for a couple of hours
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1398_zps2bqyz0lw.jpg
Then removed and dried
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1399_zpstxlmhbvx.jpg
Then b̶a̶c̶k̶ ̶i̶n̶ ̶t̶h̶e̶ ̶c̶l̶e̶a̶n̶e̶d̶ ̶l̶i̶t̶t̶e̶r̶ ̶t̶r̶a̶y̶ over to the parts lubrication vessel for a soak in oil before hung to drip dry
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1400_zpsegs0bbwj.jpg
Good as new
Shit, rusty swinging arm is shit and rusty!
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1401_zpsljrm7gjb.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1402_zps0fsqkwol.jpg
I can't believe how rusty it is for a 7 year old bike
My weedy blaster will take for ever to do all that so set to it with a flap wheel
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1404_zpswhcm1qm7.jpg
That's as far as I got with it tonight because warm evening and beers in fridge
Will get it in the blast cabinet tomorrow to get to all the nooks and crannies then see what I'm left with
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125 |
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| aceofhearts |
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aceofhearts
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| Just_James |
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Just_James
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| Posted: 00:22 - 13 Jun 2015 Post subject: |
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| aceofhearts wrote: | Awesome job! I will have to have a go at panel repairs one day |
Thanks mate
Yeah, have a play!
If you've got a panel you'd have binned otherwise you've absolutely nothing to lose other than maybe the cost of a beer or two in materials.
It's no dark art and once you get a basic understanding of how materials work, it's all pretty simple really. Slap stuff on and sand it, if it's not right... slap more on and sand it again
One of my nephews has taught himself to carve wood, now THAT is an art and incredibly impressive! He is currently carving himself an electric guitar body with an intricate design from a solid block of wood using basic hand tools!
That, I can't get my head around! You can't make a mistake then add filler or lace in primer to sort it, you get one shot! Unreal level of patience as a minimum and awesome skill!
Brings repairing a bit of plastic right down into perspective
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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125 |
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Just_James
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ride_to_die
Crazy Courier
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| Posted: 13:19 - 15 Jun 2015 Post subject: |
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Fork seal bodge is something I wouldn't put past Paddy
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Just_James
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| Posted: 20:59 - 15 Jun 2015 Post subject: |
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| ride_to_die wrote: | Fork seal bodge is something I wouldn't put past Paddy |
I wouldn't mind if it was in any way effective but oil was still pissing out and that had just been left stuffed in there!
I was relieved to see there was actually still a seal behind it and that paper hadn't been put there as a replacement
Bit of progress today.
Postie left a couple of bits for me this morning, a cam lock bar and a universal choke lever
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1412_zpsvamtzu5w.jpg
I want to have a go at sorting the rear seat lock first.
A previous repair attempt of some form has left this glue / epoxy stuff which I need to get out.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1413_zps4qyuoe2v.jpg
I manage to get an old little self tapper in there
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1414_zpsdqo8q7ab.jpg
Pulled out nice and clean in one go
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1416_zps8s3knlth.jpg
I was expecting / hoping this would reveal a thread but it would appear another previous repair attempt has involved solder. I can see the thread at the bottom but all the top is covered in solder
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1415_zpsqqfnm7kl.jpg
So I drilled and re tapped it to take an M6 bolt
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1417_zps3emu4ibw.jpg
Then bar fitted with washer and bolt
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1418_zpsapefcwdb.jpg
I'd taken a punt / rough guess on what bar length and offset I'd need based on an image I found on t'internet, I figured if I made sure it was on the long side it didn't really matter as I could bend it to fit and cut off any excess if need be.
So went for a trial run to see what adjustments need be made
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1432_zps2jncqgii.jpg
It worked 'straight out the box', perfect fit!
Purely luck, but... BONUS!
Sorted
Cost of bodge £1.40
Onto the choke lever next. I had no luck getting a used replacement so went for this as it looked quite neat.
First thing that was immediately obvious was that I need to remove a lot of outer cable to make it fit.
Next thing was, it is clearly designed to take the smaller nipple
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1419_zpsxrnjeczl.jpg
I don't want to mess around getting a new cable or nipple (in fact I want to try and do it all in situ without removing the cable at all and avoid removing the nipple if I can).
So, out with the drill and bored a bigger hole right through so it will accept the nipple
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1420_zpsbyup3tp1.jpg
Looks like that will do the job.
Next need to figure how much outer cable I need to remove so I thread some wire through and mark where the outer cable needs to end.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1421_zpsrknbptym.jpg
Then transferred to my cable and marked with tape
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1422_zpsoy8xxvlu.jpg
Then trimmed off the plastic sheath
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1423_zpswkopynxx.jpg
Got the cutting disc on the ferrule so I could split it and remove it
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1424_zpssctlfymf.jpg
Then carefully cut around the outer cable with the cutting disc
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1425_zpsmu9enol4.jpg
Was really proud I managed to cut through that all the way around without going through the inner plastic sheath
Then stretched the outer so I could thread the inner cable from it
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1426_zpsaefkoh6x.jpg
Then trimmed off the plastic to leave me with just the cable (I'm not bothered about having any kind of ferrule on this for the little and occasional movement the choke lever has - obviously wouldn't do it on a throttle or clutch cable!)
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1427_zpsy9t68vto.jpg
Then assemble it all and hope it works
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1428_zpsh2xrcopx.jpg
It works, and works well!
Struggled for a while trying to find the best place to mount it. Wanted it on the l/h bar really but no matter what configuration I tried it just wasn't going to fit.
Decided best / only spot was going to be on the r/h bar between the brake and throttle.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1429_zpsdkiuvsv2.jpg
Can't live with that rust there but don't want to get over involved so quick rattle can tidy up on the bar first
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1430_zpsctxjupuf.jpg
Then fitted in place and held tightly with a cable tie / motorcycle assembly strap
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1431_zps1doturgs.jpg
Works great and doesn't look too out of place, I happy
Cost of bodge £9.86
So spend counter so far is at £11.26
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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125 |
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Just_James
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| Posted: 20:05 - 16 Jun 2015 Post subject: |
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Little update.
Managed to get the swinging arm, hangers and stand painted tonight.
Just a quick rattle can job on the hangers and side stand.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1433_zps9ukh3d9u.jpg
And the swinging arm in 2k
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1436_zps8uriydjv.jpg
I can start building the back end from tomorrow but first need to at least have a good clean up here
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1437_zpskf5nfo9w.jpg
Absolutely not getting involved in spraying the frame but need to at least make a gesture of something with that rust while I've got access to it.
I am going to tidy up the visible rust on the bottom frame sections at the sides but it will just be a quick rattle can job in satin black.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1434_zpstckdzp4s.jpg
Also, if you didn't notice from that pic
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1435_zps3ezhxory.jpg
Looks like one of the offs the lad had may have been side stand related
So, yeah, need to borrow a mig
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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125 |
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| Pol Anorl |
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Pol Anorl
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| Posted: 17:20 - 17 Jun 2015 Post subject: |
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looking good!!
i like your lubricating tray, i have one that looks similar from poundland 
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bandit_engineer
Borekit Bruiser
Joined: 01 Oct 2006
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| Posted: 19:52 - 17 Jun 2015 Post subject: |
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Really enjoy reading the progress of this project and the RS1.
Keep up the good work
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Previous: 2002 Speedfight 50, 2000 RS125, 2002 RS125, 1997 Bandit 600N, 2003 SV1000S
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| Posted: 20:26 - 17 Jun 2015 Post subject: |
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| PaulFzs wrote: | i like your lubricating tray, i have one that looks similar from poundland |
Beware of those cheap imitations 
Yours may look similar but I can assure you mine is the real deal, it was very expensive!
I've had some time at home this afternoon so was planning on tidying that bit of the frame and getting on with getting the back end built back up but it's been pissing down all day
Bit limited with what I could do so decided I'd give that exhaust I tidy up, mainly wanted to just sort the rash on the can.
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1359_zpsphjthjbx.jpg
I'm not getting over involved with this, just a tidy up so have a go at just reshaping with a flap disk
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1440_zpsju0myer1.jpg
It's not far off but just need a slither of chemical metal on the expansion chamber side
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1441_zpsey5lr0it.jpg
That will do, it's all going matt black so just give the rest of the can a sand down - not getting involved in fillers or primers.
Gave the expansion chamber a quick going over with the flap disc and wire brush to get any of the loose flaky rust off
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1442_zpskgv3kwc0.jpg
Then gave the whole thing a few coats of matt black - and treated it to some shiny new nuts
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1444_zpscu6rfk9f.jpg
Came out better than I was expecting for a quick tidy up tbh. Kinda wish I'd gone that bit further and sanded out those other little scuffs on it now... I may revisit it
Wasn't much else I could get on with so decided I'd clean a few bits up. Rear footrests need a clean up before I put them back on the hangers
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1438_zpsreq9e72i.jpg
I got a bit carried away 
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1439_zpstiom3k6p.jpg
I just hope they don't make the front ones look odd now because I sure as hell can't be arsed doing those ones too!
Other than that, indicators have arrived
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1443_zpsuqnvik2k.jpg
£9.95
Spend counter now at £21.21
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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125 |
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Just_James
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| Posted: 20:09 - 18 Jun 2015 Post subject: |
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Not had much time to spend on this tonight but I did manage borrow a mig
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1445_zpsjczcdchb.jpg
Obviously assured him I knew what I was doing, no need for any tuition etc.
I've no experience of welding whatsoever but I've seen it done and figure it can't be difficult
Anyway, I set to it.... and some events happened
Fusion of metal took place, that's all that matters and that's the last that shall be said about it! 
Soo we skip conveniently to the 'weld' after a tiny tidy up
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1446_zps77mag3zi.jpg
Sorted
Just need to get rid of all that gunk at the back of the frame now, pretty nasty behind the sprocket cover too
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1447_zpskqwz2zhs.jpg
So, out with the murky white spirit I saved after cleaning the chain my state of the art nano technology degreaser
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1448_zpsyjdmu1vz.jpg
Transferred that to a spray bottle and gave it all a good dowsing and left to soak a while.
I dragged the power washer into the garden and, as I've got the exhaust off the bike, I fit my motorcycle exhaust port plug as a precaution
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1449_zpsjb4s7xgd.jpg
Then gave it all a blast off
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1450_zps2iermq2z.jpg
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1451_zps1enussbp.jpg
Sorted
Need to let that all dry off overnight then can just give a quick tidy up of that rust before I rebuild.
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125 |
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| BravoCharlie |
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BravoCharlie
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Joined: 06 Jun 2012
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| Posted: 23:03 - 18 Jun 2015 Post subject: |
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I'm yet to attempt my first ever project bike, but I spend an insane amount of time looking through the show and tell thread on here, and I am in total awe at your work everyone on here makes it seem so easy!
looking forward to more!
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Past: Suzuki GZ125, Kawasaki GT550, Kawasaki GPX600R, Honda vrx400,Kawasaki Zephyr 750, Suzuki SV650 K5
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ride_to_die
Crazy Courier
Joined: 13 Nov 2005
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| Posted: 10:58 - 19 Jun 2015 Post subject: |
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For someone who hasn't had experience welding you've got some balls to just go for it! I suppose sometimes it's best to just have a crack and see where it takes you. Although I would like to know what happened with the welder?
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Old Thread Alert!
The last post was made 9 years, 147 days ago. Instead of replying here, would creating a new thread be more useful? |
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