RS 125 Project / Restoration

[demon9374]

As requested by some folks, sorry for hi-jacking your thread Hadden haha

Anyhow, I have no idea what the end result will be, street fight, old shape, new shape etc. Can't really decide, would make sense to stick with the old shape seeing as all the fairings & lights are present.

First thing first is to get the Engine running. I have no idea if it runs yet.

Anyhow, luck would have it that someone local was selling a full bike for spares/repair & no one bidded/wanted anything. So I didn't know what to offer at first as I wanted all the bike. After mentioning it, Hadden suggested £300 without Engine, £450 with. So I offered £200 without, £325 with & he took £320 straight away.

The guy mentioned he was riding it and poof, nothing. He said he mentioned it to a mechanic in Hyde that used to race 600's, whom said it would be the main bearings as they sit in a sleeve which eventually gets chewed up & knackered.

I picked her up yesterday. Would seem that all that is missing is a battery, no problem, cheap enough to buy & I have a charger to get started. Just need to get round to buying a battery.

I removed the engine when I got back & took the bike upstairs (live in a small rise flat, so there's no room in the hallway, but I have a spare room to play in lol).

Engine removed, I drained the oil, the drain plug/screw was covered in a thick layer of filings, so I guess he hasn't attempted to check the problem out, he said he didn't & what was revealed suggests he hadn't either.

One of the balance shaft gears has a gap where some teeth have broken off & the other looks to have a crack in it. When pulling the clutch basket out the broken part fell out from behind it. Now if it was just that causing the problem, then I'm laughing, but nothing is ever as simple as that aye? There's also a tiny dent in the clutch push rod? (Pictures to follow).

Today I think I shall remove the top end & insect the piston & cylinder, looking up the exhaust port, the piston looks alright, but I'll get a better look later.

I think I'm going to split the case & replace all bearings, it has 22k on the clock, so it's probably due a bottom end rebuild anyways. Once everything's out I can then clean the casings properly as the outside is covered in black shit/dirt etc. I'm just wondering what way is best to clean it? I came across a thread on google & the guy put it in the dish washer & the washing powder fucked up the metal lol..

Pictures..

Reflective rim tape, ohh shiny. I don't like the front wheel, that needs to go up for sale/swap for a matching 3 spoke.
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/397376_2926441045130_1384021063_33099105_1100086052_n.jpg

Caved in and finally asked next door to help me lift it upstairs.
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/399656_2926451085381_1384021063_33099108_137111696_n.jpg

Mess.
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/386075_2926473965953_1384021063_33099122_1246782727_n.jpg

Mess.
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/399102_2926477206034_1384021063_33099123_847928130_n.jpg

Organised mess.
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/392139_2926447645295_1384021063_33099107_448938316_n.jpg

Dint to the right of the bearing.
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/383040_2927330747372_1384021063_33099681_515684828_n.jpg

Balance shaft gear had been to the dentist.
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/383655_2926973698446_1384021063_33099358_1800502109_n.jpg

This one's been on crack.
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/389918_2926975978503_1384021063_33099360_1772692112_n.jpg

Heart & soul of the party.
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/393213_2926979738597_1384021063_33099367_1263734521_n.jpg

[hadden]

good to see you have joined me on the show and tell.my piston was a right fucking mess when i got mine off.u did well to get all that done yesterday tho dude.looking forward to see the outcome of this one too.let me know if you want some piccies of the headlights if got..i just looked and they have actually got your name all over them
____________________
red bull gives you wing sting!!!
current:aprilia rs 125
previous:honda c90,honda cm 125,yamaha xt 550,2004 suzuki drz 400.(all used for off road back in the day)and a piagio zip 50cc..oooossssshhhh

[demon9374]

[hadden]

well the piston doesn't look too bad but if you can afford it you might aswell change it,the rings are supposed to have a little play in as when they go back into the head it compresses them(i think ).my con rod has play from left to right but i think its if it has any play up or down that you have to worry.looks a bit orange tho?could that be surface rust because mines the same and my head gasket went leaving water/oil surrounding it.im sure that's the 122 have u managed to find where it sais yet??
____________________
red bull gives you wing sting!!!
current:aprilia rs 125
previous:honda c90,honda cm 125,yamaha xt 550,2004 suzuki drz 400.(all used for off road back in the day)and a piagio zip 50cc..oooossssshhhh

[demon9374]

[hadden]

thats look mint.iv never seen one with the af1 swing arm on. and i would say if you change all that and it doesnt fire, but turns over then it will be electrical.so get a multi meter just incase.and make sure the fuel you use when trying to start it is fresh. and as for the back lights there are plenty on flee bay for quiet cheap which might be easier to incorporate into the rear plastics.im going for the double barrel lights off the r6
____________________
red bull gives you wing sting!!!
current:aprilia rs 125
previous:honda c90,honda cm 125,yamaha xt 550,2004 suzuki drz 400.(all used for off road back in the day)and a piagio zip 50cc..oooossssshhhh

[demon9374]

[demon9374]

Forgot to add.

https://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc7/390620_2941580263601_1384021063_33106454_1801807717_n.jpg

Doesn't look good.

[haroman666]

That's just asking to be Streetfightered!
Renthals, funky front light, jack up kit etc etc.
Looking forward to seeing the progress of this
____________________
The mistresses: 2000 Honda CBR600f, 2000 Honda VTR1000

[Beelzebob]

[demon9374]

Not much progress today. Just took 3 of the bearings out after putting the casing in the oven.

Started to chew up the screw holding the washer over the other bearing, so can't get that out for now, will have to get gramps to extract it, my fault, I have shite posi drives.

Time to price them up off a bearing site, main bearings I'm probably best getting them off PJME with seals for 338 rather than the one's I've found at £15 Exc. VAT, 2 will come to £30 then plus VAT then plus seals. Others should be straight forward & cheaper elsewhere.

[demon9374]

No pictures yet, got some Gunk degreaser. Works a charm, engine looking clean & tidy.

Ordered full set of bearings & seals, also got a flywheel puller on the way aswell.

Just need balance shaft gears & after it's all cleaned, lubed & put back together (god help me) I bet it doesn't start haha.

Reminds me, need to order a full gasket & o-ring set.

[demon9374]

https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/403962_2979705856717_1384021063_33133054_1182917353_n.jpg

https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/373802_2979702416631_1384021063_33133053_739791381_n.jpg

Tool came today, which was a load of shite, none of the bolts fitted the flywheel, used bolts lying round with smaller washers so they didn't fall through the tools holes & after some feat of strenth, pop goes the flywheel.

Will have to oven the crankshaft another time & get that blasted bearing off, got the rest of the bearings out.

My eyes and throat have never hurt so much from opening the oven door with an engine in.. lol

Degreased everything engine side now, I think.. Got frame & shizzle to clean, but that's for another time.

Got some parts coming from Damon

Watch this space.

[Kickstart]

[demon9374]

Cheers Keith

Well I was thinking of freezing the bearings (if needed, hopefully not damage them?) and heating the cases to get everything back in, same with the crankshaft (as I understand, you put one of the mains on the flywheel side, before putting it into the case).

The bearings feel oiled/greased up already, do I need to add further lubrication when they are fitted? I guess the same for the piston refitted, I drop a smidge of 2t onto the piston head?

[Kickstart]

Hi

I would add a drop of 2 stroke oil (well, more than a drop as it smells nice).

Paraphrasing the manual:-

Heat the clutch side crankcase half to 60-100 degrees C and press in the main bearing (closed side of the bearing cage has to point outwards).

Once the crank has been checked to be true, heat the magneto side main bearing to 80 degrees C and slide it onto the crank.

Determine the axial clearance of the crankshaft and place suitable shims into the magneto side crankcase half.

Heat the crankcases to 90-100 degrees C. Push the crankshaft into the hot crankcase magneto side crankcase.

Heat the clutch side crankcase half to 50-60 degrees C, join it to the magneto side one and bolt the crankcase halves together.

If you can heat them up to these amounts so that things slot together) then you need a special tool which bolts to the magneto side case and to the crank and then draws the crank into the crankcase.

All the best

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

[hadden]

keep up the good work dude
____________________
red bull gives you wing sting!!!
current:aprilia rs 125
previous:honda c90,honda cm 125,yamaha xt 550,2004 suzuki drz 400.(all used for off road back in the day)and a piagio zip 50cc..oooossssshhhh

[demon9374]

Well that's a fucker, just compared the new mains to the old mains, new one's don't have a closed side. It would seem all the new bearings are the same in regards to the closed side..

https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s320x320/391933_2981355857966_1384021063_33134340_1557349597_n.jpg

Same on both sides ^

Old main on the right..

https://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/393896_2981358298027_1384021063_33134341_314694506_n.jpg

/sigh, give up.

[hadden]

is that picture of the old one with the closed side up?cause they look pretty much the same apart from the new ones dont have those rail type things above that actual bearings..i would post that on the workshop to see if they would still be ok
____________________
red bull gives you wing sting!!!
current:aprilia rs 125
previous:honda c90,honda cm 125,yamaha xt 550,2004 suzuki drz 400.(all used for off road back in the day)and a piagio zip 50cc..oooossssshhhh

[hadden]

[demon9374]

The rim tape is awesome, when I get matching wheels, they'll be getting powder coated & some new rim tape ordered for sure!

That would be the balance shaft I think, comparing it to someone elses rebuild it's got the same mark on it, so there's no reason to be concerned there.

Yeah, the one on the right is the old one, the new ones don't have that rail type thing lol

[Beelzebob]

[Gazdaman]

Those new bearings look fine to me. They're not sealed so it's all good.

And if you're close enough to inspect bearings in your crank cases, then replace them. Because when the eventually go, it's a bitch to change them. Bearings are cheap, bearing failure isn't.

I agree with Keith, that bit that 'doesn't look good' just looks like a crudely tidied casting mark, I'd have no issues putting that back in.
Personally I'd put the bike back to standard, with finishing touches that you like.

And good god, buy some good tools. Having good quality tools and the right tool for a job makes it a million times easier!

Gaz

[demon9374]

[Kickstart]

Hi

Some might, but not all. And not sure which ones would have the skills to press apart a 2 stroke crank.

Plenty of places around that can do it though. Whereabouts are you? Someone might be able to suggest somewhere local

All the best

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