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Honda XL125 RC (Kit Form)!! Now With Added Sheep Worrying

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Suntan Sid
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PostPosted: 09:10 - 27 Aug 2015    Post subject: Reply with quote

pepperami wrote:
Really enjoyed this thread Thumbs Up
But it`s not over till you legally ride it on the road without any breakdowns Smile Thumbs Up


You're right and I haven't forgotten about it, I've got a couple of problems at the moment though.

Got my new light switch it had more wires coming from the switch than my original, so I took it apart, removed some tiny component parts from the switch mechanism and transferred them to the original.
Fitted the repaired switch and I have the sidelight but no headlight.
I thought this may be because the engine needed to be running to power the the headlight.
Unfortunately I can't manage to start the thing, it catches and fires and sometimes runs for about a second then dies.
I'm going to be looking at this today.
Rather annoying, considering it fired up straight away after a complete engine rebuild!
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Suntan Sid
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PostPosted: 11:31 - 27 Aug 2015    Post subject: Reply with quote

Well, that appears to be sorted, the headlights only work if the engine's running.

Went out to start it about half an hour ago, choke on, kick, kick, kick same as before would run for a second then die.
Started playing around with the idle screw, thought I'd try and get the revs up a bit, this had the opposite affect, just wouldn't fire.
Backing the idle screw off seemed to make firing easier, which got me thinking, maybe too much fuel!
So instead of full choke I used half choke. This setting eventually, just about, got it running, of course by this time I'd forgotten what postion the idle screw was so I had to adjust this just to keep it running.
Took it for a little run up and down the drive, then left it idling for a while, I've got the idle speed a little bit higher than it should be at the moment.

So next job is to align the headlight, got to watch a Utoob vid again and get a flip chart out! Laughing
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Suntan Sid
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PostPosted: 21:32 - 27 Aug 2015    Post subject: Reply with quote

OK, everything seems to be up and running, so MOT has been booked for 4pm on Sunday, yep a bank holiday Sunday! Shocked
Fingers crossed.

The strange thing is the bike's never been anywhere, up and down the drive half a dozen times, no more than a hundred yards in total. Consequently, I've got know idea how well the brakes perform, they haven't had enough use to even bed them in and the garage is only a mile and half away.

While were here, after riding it up an down the drive, in first, it seemed to get a lot easier to start and there seemed to be a lot more compression resistance from the kickstart. Does running the bike in gear, rather than letting it idle in neutral, increase oil pressure, get more oil round the engine?
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Suntan Sid
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PostPosted: 18:48 - 30 Aug 2015    Post subject: Reply with quote

(Smug Mode)

Took the bike for it's MOT, here's the result:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/MOT%2001_zpsn8frqdv1.jpg~original

A pass, one advisory, slight misalignment of front wheel, the forks look slightly twisted in the yokes.  To be honest I put the forks in and clamped them up without bouncing them,  Doh! !

The testing station is about a mile and a half from our house, the bike had never been ridden more than a few yards, previously.
I was well chuffed with the gear selection, very smooth, doesn't even click when selecting first.

Haven't taken it above 6k yet, however, in sixth, 6k is showing just over 45mph, still another 3.5k left, it might touch 60mph when it's run in.

It's running a bit rich, there's no air screw, so I'll have to move the needle clip to adjust this, I'll give it a few miles first though.
Acceleration is a bit sluggish, I'm hoping some fine tuning will cure this.

Just have to tax it, then it's all legal, hurrah!
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Last edited by Suntan Sid on 22:13 - 10 Nov 2017; edited 1 time in total
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System of a Clown
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PostPosted: 19:17 - 30 Aug 2015    Post subject: Reply with quote

That's excellent!

Inspiring stuff Very Happy
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pepperami
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PostPosted: 19:30 - 30 Aug 2015    Post subject: Reply with quote

Suntan Sid wrote:
(Smug Mode)

Took the bike for it's MOT, here's the result:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/MOT%2001_zpsn8frqdv1.jpg



Quality Thumbs Up have some of this Karma
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Howling Terror
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PostPosted: 19:40 - 30 Aug 2015    Post subject: Reply with quote

Good work. Thumbs Up .... and when it's finally fettled you can take it to Harpur hill quarry where I used to take mine.
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Suntan Sid
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PostPosted: 21:26 - 30 Aug 2015    Post subject: Reply with quote

Howling Terror wrote:
Good work. Thumbs Up .... and when it's finally fettled you can take it to Harpur hill quarry where I used to take mine.


Funnily enough, that's near enough where I took it for the MOT,
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Suntan Sid
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PostPosted: 21:29 - 30 Aug 2015    Post subject: Reply with quote

So, being the nosey sods you are, Wink , I suppose you want to know what all this cost?

THE BILL

The original boxes of bits cost £400.
I reckon I've spent another £650 on it.
However, there were some other bits and pieces, in the boxes, from various other bikes, I've sold a few of these on ebay and recouped £170, there are still a few more bits I will sell.

Within the total spent were a few, specialised, tools, ie. a puller, a clutch tool, new circlip pliers, a multimeter and a cable crimping set, all available to use in the future.  I also bought a reasonable amount of stainless screws, bolts, nuts, washers etc, of which I've used about a third.

The rebore and new piston cost £60.
I bought another engine from a BCFer for £40

My biggest expense was last month, I bought a new set of tyres, inner tubes, rim locks, rim tapes, tyre levers, a foot pump, a new exhaust system, tacho drive cable, a small sheet of aluminium, battery, chain & sprocket kit and a light switch, that little lot, alone cost, £300.

I used 2 rattle cans of paint, 4 of primer and 2 of laquer.
2 small tins of HT paint, 1 small tin of silver paint, 1 small tin of black enamel, 1 small tin of etch primer.  Everything was brush painted apart from the tank and frame.  The frame and shockcer were powder coated when I bought it, so I saved a bit on that.

I used one tin of WD40 and one tin of Duck Oil, 3 litres of deagreaser, (Swarfega), and a couple of litres of diesel.
I've used loads of scotchbrite, plastic, kitchen scourers for cleaning stuff.

I've got enough parts to build, at least, one more good engine.  I also have another good petrol tank, mudguard, swinging arm and handlebars.

What have I still got to do, well I need to do something about re-laquering the tank, I need to waterproof the electrics behind the headlamp.
I will probably repaint and laquer the rack and the sump guard.
I might fit some under bar mirrors.
I will fit one of those foam tube things that go across the handlebars.
I already have an Akront alloy rim for the rear wheel, cost £30, I want an alloy for the front, then I can have a go at relacing them.
If I can get the paint on the tank sorted I'll proably add the correct decals.
I'm going to make an inner mudguard out of a sheet of aluminium.

The most satisfying things about doing this were:-
Starting it for the first time.
Learning how to solder reasonably well and managing to do some minor mods, that worked, to the wiring loom and lightswitch.
I've never had a 4t engine apart before so I was chuffed to get the cam and valve timing correct, at the first attempt.
Making a seat cover from scratch, helped by Mrs Suntan.

The most disappointing:-
Having rubbed down the original paint on the tank, it was a bit of a PITA watching the primer react with it, and then having to take the whole thing down to bare metal.
If that wasn't enough, I then had to wait 3 months for a day sunny enough and dry enough to finish spraying it!

What have I learned:-

You can never have too many cleaning rags!!!!!!!

I've enjoyed doing it all really, as long as you take your time it's all, relatively, easy stuff..
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pepperami
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PostPosted: 12:24 - 31 Aug 2015    Post subject: Reply with quote

YOU know if it`s any good or not... when you buy, you don't know what`s hiding in the bike, waiting to go wrong.
YOU built this, you know what`s good and what might let you down.

Hats of to you , now give it to me Laughing
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Fizzer Thou
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PostPosted: 16:36 - 31 Aug 2015    Post subject: Reply with quote

Well done on the rebuild.It is a really good feeling to hear the engine run nicely after a full rebuild Thumbs Up Very Happy
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Suntan Sid
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PostPosted: 19:24 - 31 Aug 2015    Post subject: Reply with quote

Fizzer Thou wrote:
Well done on the rebuild.It is a really good feeling to hear the engine run nicely after a full rebuild Thumbs Up Very Happy


Rain, again, has stopped play today, however, I did have a look at the plug, it's a good colour now, must have been carbonned up from idling in the back yard.

I've been doing one of the jobs I was going to do, today.
Ran out of time and precipitation free air though, I'll post up some pics when it's finished, hopefully tomorrow.
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Fizzer Thou
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PostPosted: 20:36 - 31 Aug 2015    Post subject: Reply with quote

Tell me about the rain.I cannot move in my shed for the bikes,hence the reason for making the KTM tool.At least I can get to my workbench Very Happy
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Suntan Sid
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PostPosted: 15:50 - 03 Sep 2015    Post subject: Reply with quote

Life in the slow Lane!

Not my first ride, I put 50 miles on it yesterday, I'm still trying to keep it below 6.5k, so no high speed thrills. I did hit 50mph in top, on the flat at 6k so it's looking good. It does seem to get a little bit faster each time I take it out.
Restricting it to 6k means there's naff all acceleration going uphill, the exhaust sounds nice though!

The video starts in the Goyt valley dropping down to Errwood reservoir and finishes joining the Cat and Fiddle!

Low speed thrills here!
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Suntan Sid
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PostPosted: 21:50 - 03 Sep 2015    Post subject: Reply with quote

The nearest bike, parts wise, I can find to this one is an XL200R.
On the parts fiche for that bike it shows an inner rear mudguard.
There is a gaping hole on my bike, instead:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%2001_zpse0rpsqew.jpg~original

There are two mounting holes in the plastic tailpiece, so I decided to have a go at making something to plug that hole.

First thing I did was cut out a cardboard template, mark out and cut a sheet of 1.2mm aluminium:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%2002_zpsb64pza4s.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%2003_zpshk5urwex.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%2004_zpseajqlr7y.jpg~original

Next job, bend the aluminium into the correct shape, I made a little template to get the angle of bend correct:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%2005_zpshqscvyfq.jpg~original

Test fitting, to mark up the position of mounting points on the back of the airbox, there are two fins sticking out of the back to drill through.

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%2006_zpsvk48hbm7.jpg~original

In place after drilling the required holes:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%2007_zps1legca2h.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%2008_zpsxpuz1dvj.jpg~original

I had to make a smaller panel to fill the gaps I had to leave to fit it.
It isn't green, that's just a reflection from the cheap ass gazeebo!
I'll fill in some of the gaps with draft excluder tape,  the holes at the edges allow the seat to fit correctly.

Fitted this handlebar pad thing, it used to be red, but it's faded in the sun, LOL, adds a bit of authenticity and, in tight wad mode, I refuse to pay a tenner for a bit of foam and plastic!

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%2012_zpsgn9eunhd.jpg~original

Some random photos:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%2009_zpsmj5p9wqk.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%2010_zpsbjypz5a3.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%2011_zpshltxvgcj.jpg~original


I fitted this camera mount to the handlebars, it's just one of those gorilla things wraped around the bar and cable tied to within an inch of its life:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%20CAM%2013_zpsmestlcxl.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/GAP%20CAM%2014_zpsynqpnfdt.jpg~original

That's it for today!
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Last edited by Suntan Sid on 22:16 - 10 Nov 2017; edited 1 time in total
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Just_James
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PostPosted: 23:08 - 03 Sep 2015    Post subject: Reply with quote

You've done a stunning job of this and it's sounding really good on the road Thumbs Up

Watching that vid I was half hoping you'd suddenly take a detour off into the fields for some off road action.... but then it'd be a shame for it to get dirty! Laughing

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stevo as b4
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PostPosted: 23:15 - 03 Sep 2015    Post subject: Reply with quote

I love the standard of work and finish on this! Thumbs Up

The paint looks superb too! Well done on a brilliant project bike build too! I'm sure once it's run in, it'll be an awesome little bike to ride!

We need to get a BCF mass gathering/picture off all the small trail bikes together ASAP I reckon!
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Suntan Sid
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PostPosted: 14:38 - 05 Sep 2015    Post subject: Reply with quote

Racked up my first 100 miles yesterday, so changed the oil.
There were a few fillings in the strainer and some paint flakes, oops Embarassed , not sure how they got in. Anyway with the new oil in, the engine sounds a lot quieter.

While I've been trying to put a few miles on this, I've noticed that the foot pegs are, shall we say, a bit insubstantial.  They're not long enough or wide enough and my, booted, foot easily slides off them.

Having looked at some aftermarket pegs, firstly, there are none specifically for this bike so if I bought some they'd have to be modified to fit.  Secondly they range in price from £20+ up to £60+! Shocked FFS!
There was no way I was paying that for something that had no guarantee of fitting.

So, yesterday, I bought myself this:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/PEG%2001_zpscd1owtmp.jpg~original
A 1m length of 20mm wide aluminium strip, total cost £3.98.

After cutting off two 150mm lengths, bending them around a suitable piece of pipe, drilling a few holes and fixing then to the existing foot pegs I ended up with a pair of these:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/PEG%2002_zps31jzmsow.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/PEG%2003_zpsvhg4teda.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/PEG%2004_zps4ebyv0r0.jpg~original

Easy peasy, total cost, if you add in the stainless nuts, bolts and washers, is about £4.50, more importantly my feet don't slip off the foot rests anymore!
I need to do something with the gear change as well, the toe of my boot seems to slide off it very easily.
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Suntan Sid
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PostPosted: 21:37 - 12 Oct 2015    Post subject: Reply with quote

Quick update.

I added this fairing last week, more to protect the rats nest of wiring lurking behind the headlight than anything else.
The bike should have a fairing but this one is from a later model, an XLR I think. It came in the box of bits I had so didn't cost anything. The original bracketry didn't fit So I butchered it and made it fit!

[img]https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/COWL%2002_zpstp9wrlwp.jpg[~original/img]

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/COWL%2001_zpsleknhsfh.jpg~original

Still running it in at the moment, done about 320 miles so far, no real problems, other than it being a wheezy 125.
I'm not maxing the revs out yet but given a long enough straight it'll hit 60 on the flat, hills absolutely kill it though.
The only real niggle I have at the moment is chain adjustment, it has snail cams on the adjusters so you can get to a position were the chain is either to loose or too tight.
It's a bit tight at the moment which seems to be causing front sprocket vibes at a particularly annoying part of the rev range.
Just have to wait until the chain stretches a bit.

Anyway, as promised, here's some sheep worrying action from today, it's a,short, ride around the Hollinsclough area near Buxton, starting at Buxton speedway track. There was more but the sound was crap due to wind noise.


Buxton UCR

https://youtu.be/a5YnTktOEeE
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Howling Terror
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PostPosted: 22:00 - 12 Oct 2015    Post subject: Reply with quote

Used to regularly go to Sheffield on mine....They don't do long hills.

Nice little run that. Thumbs Up
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RyanTZR125
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PostPosted: 12:43 - 14 Oct 2015    Post subject: Reply with quote

Just read the whole tread, what an absolute banger of a project, and a spanking job done, you should be proud of that bike Cool

Loved the last video clip of you blasting the lanes, spot on Thumbs Up
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Suntan Sid
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PostPosted: 18:32 - 14 Oct 2015    Post subject: Reply with quote

Ryan AKA H100A1980 wrote:
Just read the whole tread, what an absolute banger of a project, and a spanking job done, you should be proud of that bike Cool

Loved the last video clip of you blasting the lanes, spot on Thumbs Up


Dunno about blasting, still running it in, hopefully it will be a bit more sprightly, once it's done.

The thing I'm most proud of is the fact it was a box of bits when I bought it and I made a bike!

Thanks for the comment! Thumbs Up
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stevo as b4
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PostPosted: 20:33 - 14 Oct 2015    Post subject: Reply with quote

It's the most awesome 125 off roader build I've seen since Mugenseki's DTR re-build a few years ago!

+1 to the comments about being proud, and it looks brilliant and sounded really good on the road too! Was fidgeting in my seat when you hit the loose gravel though. Laughing

I'd love to see this bike sometime, and maybe even one day if there's a BCF small bike/trailbike meet up, I could have a little spin on it if your happy to take my KMX for a blast?

I'd just really like a go on a cool trail bike that does not make you stink like a heavy plant mechanic that's been working in an oily smoky scrap yard all day, after every ride. Thumbs Down Laughing
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Suntan Sid
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PostPosted: 21:05 - 14 Oct 2015    Post subject: Reply with quote

stevo as b4 wrote:
It's the most awesome 125 off roader build I've seen since Mugenseki's DTR re-build a few years ago!

+1 to the comments about being proud, and it looks brilliant and sounded really good on the road too! Was fidgeting in my seat when you hit the loose gravel though. Laughing

I'd love to see this bike sometime, and maybe even one day if there's a BCF small bike/trailbike meet up, I could have a little spin on it if your happy to take my KMX for a blast?

I'd just really like a go on a cool trail bike that does not make you stink like a heavy plant mechanic that's been working in an oily smoky scrap yard all day, after every ride. Thumbs Down Laughing


You're not that far from me, if you're ever in or around Buxton you're welcome to take it for a ride around the countryside.

I've got a KMX cylinder head hanging around if you're interested, for a very small consideration.
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