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

[Suntan Sid]

Today I bought one of these, a Honda XL125RC, 1982:-

https://www.motorbikespecs.net/images/Honda/XL_125_RC_82/XL_125_RC_82_1.jpg

I'd like it to end up looking similar to this:-

https://i208.photobucket.com/albums/bb117/577450martinihenry/Bikes/xl12509122006a.jpg~original

The bad news, it's in the back of the car, at the moment, in the boxes it came in, fully dismantled.

The good news, is that the frame and a few other bits have already been powder coated and are ready to go.
Frame and engine numbers match, it has a V5 plus the last MOT and is SORNed.
It was last on the road in 2009/10
The engine has done 30k.
Spare engine, forks, handlebars, petrol tank, mudguard.
Plenty of spare carbs.
I have bought one and a half bikes, AFAICS.

The worst thing I can see, at the moment, are the wheels, although straight, they're a bit skanky.

It's the first of the monoshock models, which was also the first to have 12v electrics!

Spares, according to Wemoto, are plentiful, and appear to be very reasonably priced!

Photos, tomorrow, after I've unloaded the car!
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"Everybody needs money, that's why they call it money!"

[Tracey Suntan-King]

So that's what all that stuff is in the back the car. You said you were only popping out for a stamp.
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Whether you think you can, or think you can't, you're probably right

[MattWadz]

looks like a cool bike/project!

what headlight is that on the bottom bike?


Thanks
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Pitbike x2, Mini Moto x4, China Quad, 02' Suzuki AP50 > 03' MBK Nitro > 86' Suzuki GP100 > 02' Yamaha Jog R > 57' Honda Lead 100 > 95' Piaggio ZIP Rst 50 > 51' Suzuki TS50x > 83' Honda CB125TDE Twin > 51' Yamaha Aerox > 98' Kawasaki KX60 > 89' Yamaha DT50MX > 80's Honda QR50 > 05' CG clone > 125cc China Pitbike > 91' Honda MTX125 RW-L > 09' Peugeot Speedfight 2 LC LR > Lucky MX 140cc > Apache Tomahawk 50 Quad (current = 2010 Yamaha WR125R

[waffles]

So you have bought a bike-shaped jigsaw puzzle? Nice!
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Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[Suntan Sid]

[Suntan Sid]

Well this is how I bought the bike, a couple of weeks ago. These are some of the ebay pictures:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XL125RCA_zpsd0e47c2f.jpg

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XL125RCB_zps93f3d47d.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XL125RCC_zps8561e982.jpg~original

I spent some time checking everything is there, there are a few bits missing, front axle, side stand bolt, for starters. The rear brake arm was missing, the new one arrived a couple of days ago.

I'm trying to sort out and identify the, numerous, nuts and bolts. I dumped the lot into a bowl of diesel and I'm cleaning them as I go along.

As you can see the frame, and lower engine mount have already been powder coated.
Unfortunately the powder coating has partially obscured the VIN number on the head stock, it's still visible but once everything is back together it will be unreadable, so I'm going to have to remove some of the powder coating and lacquer over it, I guess.

A few bits drying after painting:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XL125RC01_zpsfb763d72.jpg~original

My only major expense, so far, has been buying another rear wheel, the one that came with the bike was rusted through, on the inside of the rim. £59 inc. P&P!

I've been working on the swinging arm, front and rear brakes.
Cleaned everything, got the knackered bushes out of the swinging arm, going to give that a final clean then paint it.
No problems with the rear brakes, now I've got the new brake arm.
The front brake carrier also houses the speedo drive gear which, inevitably, was seized, couldn't move it a millimeter.

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XL125RC02_zps7045b87c.jpg~original

Left it soaking for 24hours in diesel, still couldn't budge it!
Left it over night in some vinegar! This seemed to shift quite a lot of rusty gunge, the diesel didn't touch.
Still couldn't move it using the drive gear though.
A couple of taps with a drift, on the very end on the worm gear, got it moving, some Duck oil and 5 minutes later it was spinning freely, I've left it soaking in the same.

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XL125RC03_zpsb4b4554f.jpg~original

The only problem I have with it now is that the drive gear doesn't seem to engage with the teeth on the hub. There are two thrust washers underneath the drive gear, they are wafer thin, I might have to add another washer to get the two parts to mesh together.

I have two engines, one, the original, is complete, the other has been partially dismantled.
I'm going to do a top end rebuild on the original, then, when I have time, do a complete rebuild on the other.

Oh yeah, the chain's a bit rusty!
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"Everybody needs money, that's why they call it money!"

[stevo as b4]

That's a nice Honda enduro bike project, it will be brilliant when done. So you brought it as an unfinished project then, the frame coating looks nicely done to me. As for the VIN, it's been completely obscured on my KMX due to a thick powercoating, but I don't see it being an issue or affecting the chance of selling it on, as i have all the paperwork and masses of history for the bike. I personally wouldn't worry about the VIN being covered over by powder coat if it's a legit bike.

[Suntan Sid]

I'm not worried about the VIN for selling purposes, more for MOTing it.
I've seen a few stories where the MOT was refused because the tester couldn't read the VIN.
You can see some of the numbers if you shine a torch on it, from the right direction!
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"Everybody needs money, that's why they call it money!"

[Pol Anorl]

I often wonder why people sell kit bikes like this with the chain they had on it for about 50,000 miles then stored under the sea for 18 years.
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GOOD GAME BODYGUARD: https://i.imgur.com/8WePGgf.jpg
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

[Minty]

I learnt how to ride a bike with gears on one of those, on a trading estate where I lived.

Is this the first bit of action your workbench has seen?
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My fingers smell of your mum.

[Suntan Sid]

Unfortunately I had to leave my last mancave behind!
I'm reduced to a leaky shed and a, new, workmate at the mo.
Hopefully going to have a cellar soon!
____________________
"Everybody needs money, that's why they call it money!"

[Minty]

[Suntan Sid]

I've got two sets of forks to have ago at, so I had a go at cleaning one set.
I gave 'em a good scrub with some plastic kitchen scourers, polished them with Autosol by hand, then gave them a, final, buffing with my homemade polishing mop!
I'm hoping to use this bike, so I'm not going for a better than new look, came out good enough, though!
I got a set of, new, genuine Honda, fork seals with the bike, I'll change the fork oil and see how it goes, they're not leaking at all, at the moment.
There are some, very tiny, rust spots at the top of the fork legs, but no pitting at all on the important bits.

Some before and afters:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XL125RC07_zpsc72debea.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XL125RC08_zps821bd8cc.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XL125RC09_zpsccf2b253.jpg~original

I needed to get the bottom bearing race off the steering stem.
I haven't got any workshop facilities at the moment, just a, knackered, shed and a workmate type thingy, which means brute force, ignorance and a large hammer weren't going to solve my problem.
I decided to get the Dremel out!
It was a lot easier than I thought it was going to be, took less than 10 mins.
I made a diagonal cut into the race, just deep enough to get a flat blade screwdriver into the slot.
A halfhearted twist of the screw driver and the bearing race cracked and came off them stem with finger pressure, didn't mark the stem at all, result!

Sorry about the photo but you get the idea.

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XL125RC10_zps57c31992.jpg~original
____________________
"Everybody needs money, that's why they call it money!"

[Suntan Sid]

Update!

After some head scratching, I found out that the forks I have for this bike are from an MTX125, they are a slightly larger diameter but, annoyingly, use a 15mm diameter axle, rather than the 12mm on the XL. I, eventually, managed to get an MTX front drum, so I'll need to overhaul them next.

We're in limbo at the moment, waiting to move house, hopefully.
My dilemma is, if I build up a rolling chassis I'll have to dismantle it to move it, secondly I've got no flat area outside the house, no garage, only a small, leaky, shed so I've just been going through all the ancillaries, cleaning and painting them, then packing them away.

Thought I'd have a go at recovering the seat.
Got some vinyl, they were selling it by weight, got it for £13 there's enough to make 5 or 6 covers!

Here's a how to!

Remove your knackered seat cover, carefully!
You'll need this to make a pattern for the new cover.
Turn the seat over and remove all the staples from the plastic seat base then remove the cover:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/SEAT01_zpscdf1d9b1.jpg~original

This seat was made up of 4 different components, the main seat top, front panel, back panel and a strip for a hem, around the bottom of the cover.
You need to separate the panels to make the patterns for the new ones.

I used one of these to cut through the stitching, a "seam ripper", apparently!

https://quinncreative.files.wordpress.com/2011/07/scseamrippersmall.jpg~original

Here are the separated seat panels:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/SEAT02_zpsac4c1487.jpg~original

You now need top cut out the new panels.
Because this seat is nearly 30 years old the seams needed to be flattened out, some of them fell apart!
You will be able to see where the stitching was, this line of stitching will give you the correct shape for the new panel, however, you need to allow a further 10mm offset from the old stitching line so you have enough material to sew together!!!!!
If you simply draw around the old panels your new seat cover will be too small!!!!!!!!!!!

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/SEAT03_zps95d38269.jpg~original

Here are the new panels:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/SEAT04_zps77f82eb1.jpg~original

For the next stage you need access to a sewing machine, fortunately the, marvelous, Mrs Suntan has such an item and made a fantastic job of sewing the new panels together.
If you have access to a sewing machine, we had to buy a needle capable of sewing through thin leather, we also used slightly thicker thread than you would use for tailoring!

Here it is ready to be stapled onto the seat:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/SEAT05_zpscb9206ad.jpg~original

Now comes the fun bit, stretching the new cover onto the seat and stapling it in place.
We started at either end but found the sides difficult to stretch into place.
We started again from the middle of each side, stapling about 4 inches, then doing the same on the opposite side. The difficult bits were the corners, but they eventually got stapled into place.

Here's the finished item:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/SEAT06_zpse1be6a0c.jpg~original

The only problem I've got with it is, the staples I used were too long, for the thickness of the seat foam, on the sides near the front of the seat. If I press on the vinyl I can feel the ends of the staples in the foam. I did buy some shorter staples but they wouldn't fit my stapler, I'll find the correct ones and replace the offending staples before I use the bike!

I did re-cover the seat on my DRZ, but that was just a case of stretching the new material over the old seat foam, no sewing required.
____________________
"Everybody needs money, that's why they call it money!"

[pepperami]

Moar NOW!
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I am the sum total of my own existence, what went before makes me who I am now!

[dannymassive]

Dam I love these threads!
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Previous Ride's - '01 Aprilia SR125 (Sold) '08 HONDA CBF600n (Sold) '96 CB500 (Sold) '01 FZS 1000 (Sold) '06 CB1300SA (Sold) '07 CB600F Hornet (Sold) - '93 Suzuki Savage LS400 (Sold) '98 Honda VTR1000 Firestorm (Sold) '05 CB600F Hornet (Sold) '01 FZS1000 Fazer (Sold) 2016 Harley Davidson Street Bob SE (Sold) '02 Kawasaki ZX9R (Sold) '98 CB600F Hornet (Sold) '04 Suzuki Bandit 1200s (Sold) '13 Yamaha FZ1-N

[Suntan Sid]

Unfortunately life has interrupted this project for a while so here's an update of where I'm at now!

I've been cleaning, refurbing, replacing and repainting a lot of parts.

First up wheels, I got both wheels in the original pile of bits, the front was reasonable but the rear was shot, the rim had rusted through in a couple of places and the spokes were very rusty. I managed to bag another wheel on Fleabay for £45, not as easy as it sounds because the hub is unique to this particular mode, having a 5 stud hub.

The wheel I got wasn't too bad, spokes were reasonable and the rim was solid. I thoroughly degreased and cleaned both wheels, removed the bearings, oil seals etc. I then spent ages with some strips of emery cloth removing all the rust from the spokes, it was only surface rust but still took forever. I then painted the hubs with satin black enamel, and painted the spokes silver, all hand painted with a brush.

Brand new bearings, oilseals and rim tapes were then fitted.
The wheels came out quite well, although the front does have a blemish in the chrome, but it is nearly 30 years old.

I forgot to take the before piccys, but this is how they look now:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/FWHEEL01_zps5d27a642.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/RWHEEL01_zpsa5baaa86.jpg~original


The side panels needed a repair, the holes for the mount points at the front of the panels had pulled through, so there was no surface for the bolts to act against;-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/SPANEL01_zps3dee621f.jpg~original

I found these soft plastic feet in my local hardware shop, £1 a packet:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/SPANEL02_zpsa7ee1b14.jpg~original

Fortunately they fitted exactly and because they're conical shouldn't pull through the holes, I glued them in using some extra strong, soft plastic, adhesive, it seems to have worked:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/SPANEL03_zps69758898.jpg~original

There is still a problem with side panels, the front connector stud things are snapped on both panels, I might be making some kind of velcro fitting in the future, don't fancy trying plastic welding, I don't think it will be strong enough!

As I'm mentioning plastics, in this case the, soft, offroad sort of plastic, the stuff that arrived with mine was scratched and faded. After some googling, one of the remedies, I found to fix this, was to carefully scrape the faded plastic with a stanley blade, removing the top layer, then wet and dry it down, then polish. Fortunately I had a spare mudguard to practice on. Here's the before and after:-

Before

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/MGUARDBEFORE_zps9d9b3caa.jpg~original

After, but not wet and dried or polished, it does get rid of the fading and general shitiness!

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/MGUARDAFTER_zps503a995f.jpg~original


I've done the same thing on the side panels, the pics don't do the process justice though:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/SPANEL04_zps88a4fdcb.jpg~original


The front mudgaurd came up well, but there are some deep scratches that are not going to come out;-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/MGUARD01_zpsc942538a.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/MGUARD02_zps5db53579.jpg~original


The carb has been rebuilt, new gaskets, needle, jets, float height checked, etc.

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XLCARB03_zpsc9b804e3.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XLCARB05_zps31ccbf48.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XLCARB02_zpsd3f83e21.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XLCARB01_zpsafcc0849.jpg~original

I had cleaned the forks a while back, time to refurb with new seals and oil. No major problems really, I have no bench vice at the moment, (note to self, buy one now you tit!), anyway the tops had to come out so I fitted the bottom clamp to the forks put the lot on the floor, on a blanket, stood on the clamp and undid them with a breaker bar, easy peasy!

Fork dismantled:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XLFORK01_zps21851040.jpg~original

Using the old seal to drive in the new one:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XLFORK05_zpsc43ef0e6.jpg~original

Everything went to plan, and I left the forks for a few days, unfortunately I forgot to tighten the damper bolt fully on one fork and some oil leaked out, so the oil level will have to be checked again!

I've replaced or refurbed all the suspension bushes on the shock, the linkages and the swinging arm.
Here's how I got the top bush out of the shock:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/XLSHOCK01_zpseac2e1f4.jpg~original

A long bolt with the correct size washer to push on the bush and a large socket to push on the bush housing. It took a few goes pushing and pulling but it, eventually, came out.

The shock and swinging arm are now back in the frame along with copious amount of grease and new seals:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/FRAME03_zpsa033c43b.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/FRAME02_zpsc267aa33.jpg~original


New, taper roller, headstock bearings have been installed and are now back on the frame:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/FRAME01_zpsc1a58254.jpg~original


Frame as it stands now:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/FRAME05_zps9bc83fee.jpg~original


https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/FRAME06_zpsacc56097.jpg~original


Front and rear brakes have been refurbed and hand painted:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/BBRAKE01_zpsb3c900bb.jpg~original

There are loads of other bits that have been refurbed as well, but that's were I am now.

My next task will be the engine rebuild, then the wiring.
At some point I want a new exhaust, I've got one from an XR125 but it weighs a ton, could I get away some kind of pit bike exhaust, it would reduce weight considerably?
____________________
"Everybody needs money, that's why they call it money!"

[stevo as b4]

That's coming on really nicely now!
Did it have grease nipples fitted for the rear suspension from new, or have you added these yourself?

[Suntan Sid]

[Suntan Sid]

Some photos from the engine strip down.

Pulse generator thingy is first to go:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP01_zps8172e849.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP02_zps986adbf7.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP03_zps2f540784.jpg~original


Cam wheel off

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP04_zps8bc67914.jpg~original

I assume the cam shaft has been replaced, it's in very good nick no marks at all;-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP05_zpsead076ff.jpg~original

Cam cover coming off:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP06_zpsd519dc63.jpg~original

Rockers are also perfect, a mirror finish, not marked at all:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP07_zpsfc5c87fe.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP08_zps2d45e13a.jpg~original

Head has some coking no obvious signs of damage:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP09_zpsd7a9bab8.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP10_zps7d350422.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP11_zps40e07d50.jpg~original

Cylinder looked ok initially, more on that later:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP12_zps35b15a3e.jpg~original

Piston has some scoring:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP13_zps697a89b1.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP14_zpsa190ddec.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP16_zpsc449d1c6.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP17_zps3ef4bc89.jpg~original

Looks like the exhaust vale has been hitting the piston:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP15_zps8dacc65c.jpg~original

Kickstart return spring is behind that housing, I've got to replace it so the crankcases have to be split:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP18_zpsa0e5b934.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP19_zps89f3dcd4.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP20_zpsbe06ba2f.jpg~original

The deed is done:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP21_zpsea0d6c3f.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP22_zpsf74b0355.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/STRIP23_zps1676e004.jpg~original

This all had to be done at some point, the PO had said that the kickstart return spring was toast, the only thing I wasn't sure about, was whether I had to split the crankcases to replace it, turns out I did.

What have I found out, this engine has been apart before, after market gaskets, and looks like the camshaft and rockers have been replaced.
The K/S return spring had snapped at the small inner hook, that holds it in place, no sign of it in the crankcases or the mesh filter! The K/S mechanism was missing both thrust washers, which could be the reason the spring snapped.

The cylinder bore has a horizontal groove about 3/4 of the way down. The piston has scrape marks, some blow by and as I said above the exhaust valve has been hitting the piston at some time!

My, highly inaccurate, digital vernier indicates it's not had a rebore. Fortunately I have an old fashioned Motorcycle dealer/workshop a couple of hundred yards from my front door. I took the barrels, from both engines, in this afternoon, they're going to rebore the barrel from the engine in the photos, not sure what they're going to take it out to, according to their big yellow book there seems to be plenty of oversizes to play with.

The only thing I couldn't remove from the engine was the oil pump, it's held in place with two phillips, countersunk, screws, I didn't even try with a screwdriver, went straight to the impact driver, turns out it had no impact at all, nothing moved, so its still on there!

My only other problem getting the thing apart was one of the cam cover allen bolts was a bit worn, as soon as I tried moving it I could feel the key turning slightly, in the cap head. I tried hammering a torx bit in and using an impact driver, that just rounded the cap completely. Moley's wouldn't shift it, not enough space. Tried knocking it round with a drift and hammer, no joy. Finally I went with the next size up torx bit, I was lucky it didn't burst the cap, but I managed to get a turn on it with the impact driver. You can see the offending item in the sixth photo.

So that's were I'm up to, waiting on a rebored barrel, new piston etc. I've got new valves to install, and need to order a few bits and bobs!
____________________
"Everybody needs money, that's why they call it money!"

[garth]

Ah, I can smell the burnt mineral oil from here!
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You ain't a has been if you never was

[Suntan Sid]

As you can see the tacho cable had been cut.
The screw locking it in place was totally knackered, apart from a small hole where the the Phillips head used to be, nothing at all to get a grip on, funnily enough the other engine I have has exactly the same problem.
I attacked it with an impact driver first, hoping I might get some of the screwhead back into shape, no chance whatsoever, I was afraid of hitting the driver too hard and cracking the casing.
I left it overnight, soaking in penetrating oil, then used a dremel to cut a slot across the top of the screw, a bit from the impact driver, a socket a wrench and some, extreme elbow grease, finally got it moving.

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2001_zpszk13nuey.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/TACHODRIVE02_zps16f6f889.jpg~original


Stator out, a bit grubby but intact:-

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

Valves out:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2004_zpstvi2a7vj.jpg~original

There was some very slight pitting on the valve seats so I decided to give them a light polishing.
Turned out to be a bit of a PITA, the exhaust valve is small, consequently the small suction cap didn't stay stuck, had to do it a couple of twizzles at a time. Got it all done in the end.

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2008_zpsfiel7b9b.jpg~original

Valves back in! Collets arghhhhh!

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2008-2_zpslogbbaon.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2008-1_zpskimtmdtv.jpg~original


Painting!

I asked a question about paint in the workshop, at the time I was contemplating spraying them, but it was too cold.
I got some, brush on, satin black, engine paint, it went on well, not a brush mark in sight, unfortunately it dried unevenly resulting in some satin, some matt and some gloss!
Eventually repainted with Halfrauds black gloss high temp paint, that's gone on well no brush marks, would have preferred a satin finish, maybe the gloss won't collect crud as easily!

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2009_zps5nlr5okv.jpg~original

Engine reassembly

The reason I had to split the crankcases was to put in a new kickstart return spring.
A PO has been in here before, unfortunately, they'd forgot to put a thrust washer back on the kickstart shaft, so I had to check everything else for missing bits, there weren't any!

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

Main Shaft and lay shaft:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2006_zpsthvgx7zm.jpg~original

Selector and forks:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2005_zps7xwkpna9.jpg~original

More bits back in:-

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

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2011_zpsws7niobj.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2012_zpsyvlazzk6.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2013_zpskdesyr77.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2014_zpsmcssgtkh.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2015_zpskspibdzp.jpg~original

Oil Filter, (Especially for Mentalboy), before and after de-crudding:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2016_zpspc2q4odc.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2017_zpsyxn8ilti.jpg~original

Oil Filter back on:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2018_zpstplcvq41.jpg~original

Cam chain tensioner on:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2019_zpstueuercz.jpg~original

Flywheel:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2020_zpssav9tmhj.jpg~original


The only real problem I had, putting the bottom end back together, was destroying a new drive shaft oil seal when doing the two halves!



Had to get rid of these 'orrible connectors, the PO had cut the connecting block off and used these:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2021_zpsehdkucru.jpg~original

I guess I had lost an inch or two off the wires so I ordered up some bullet connectors, crimps, shrink wrap sleeves and got my soldering iron out!
I snipped off the old connectors and, on the stator end, crimped on the male bullets.

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2022_zpsrswda33w.jpg~original

On the loom ends I needed to add a couple of inches of wire as well as the female bullets.

Bullets on:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2023_zpsjweltqv4.jpg~original

Wires cut and stripped for joining:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2024_zpszjkqamcx.jpg~original

Ready for soldering:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2025_zps0mraejtp.jpg~original

Done:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2026_zpsezgcaxw1.jpg~original

Joints shrink wrapped and sealed:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2027_zpsi46sscoh.jpg~original

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2028_zpsmyw5fxgj.jpg~original

This bit of wirirng was a big deal for me, having had no success ever, trying to solder anything, I spent a couple of hours practicing before I cut a single wire! Turned out ok in the end!

This is how the engine stands at the moment:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/XL125RC/Crankcase%2029_zpsjoass5ev.jpg~original

Bottom end's done, Will start assembling the top end once I've painted the cam cover/case.
____________________
"Everybody needs money, that's why they call it money!"

[killerbanjo]

Looking really nice mate, keep it up!

[Suntan Sid]

This has been on the back burner recently, been on holiday, TT etc so there hasn't been much going on.
I'd been putting off ordering the bits I needed until I knew I'd have time to fit them.

The last thing I did was strip and prime the petrol tank, that was back in April, I've been waiting for just one sunny day since, to finish the job. Last week there was finally a day without, fcukin' rain, so I got that done,

Lost the photos though, LOL!

Took delivery of a few final bits today, battery, tyres, inner tubes, rim tapes, rim locks, tyre levers, chain and sprocket kit and fuel pipe.

First things first, I had to remove a load of stuff off the bike that I'd put on, basically, to get all the correct fasteners in place. I then had to extract the project out of the cellar and into daylight, for the first time in two years, it wasn't as awkward or as heavy as I thought.

First job was to fit the tyres etc., onto my refurbed rims, all went very easily, no problems at all, just took my time used plenty of soap and water for lube and managed not to nip the inner tubes, hurrah, (been there done that)!

Et Voila:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/Wheels%2001_zpsmc1zjmgk.jpg~original

Frame out of the cellar for the first time in ages:-

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

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/FrameOut%2002_zpswko0lvhv.jpg~original

The idea today was to end up with a rolling chassis and torque all the suspension pivots.

Forks in and Paddock stands on:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/FrameOut%2003_zps7evhtmfe.jpg~original

Front wheel and brakes in:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/Frame%2004_zpsg8o0jc12.jpg~original

Back wheel and brakes in, it finally resembles a bike again:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/FrameOut%2005_zpsenatka4n.jpg~original

Had to put the original handlebars in, for maneuverability purposes, I've got some Renthals, that came with the bike, they'll be going on soon. Strangely the original handle bars don't fit in the clamps, I assume they've been changed to accommodate the Renthals.

Must mention Mrs Suntan who helped get the thing out of the cellar and held a tyre lever in place, with her vice like grip!

Not holding out much hope, but if we can get a few days without it pissing down I might get this finished soon!
____________________
"Everybody needs money, that's why they call it money!"

[cormac83]

Nice, some good progress there.
Keep it up.
____________________
Suzuki GSX750 Inazuma