Project Roxy

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

11 years ago I bought my RXS for £250, I rode 9000 miles in the first year then passed my 33bhp licence and have been on bigger bikes since.

The RXS was left in the garden under a cover for a few years not doing anything until a friend expressed an interest in riding and I said he could have it on long term loan. The only condition was that he give it back when he was done. He rode it for a couple of years and then left it for a reason I can't remember. He seems to have buggered about with the wiring there are shit crimps and gaffa tape insulation everywhere Laughing

It was last taxed in 2014 it has been sitting since then.

Anyway I got it back off of him with the idea of getting it running and tidying it up a bit, My missus is going to do a CBT I think, he she likes riding she can have it.

Recently some ridiculously moronic individual tried to steal it, at least I assume that what they where trying it's a little hard to tell. The steering lock is smashed and I think they tried to hot wire it however I can't be sure since all they did was pull the 2 wires that plug into the horn off ripped the crimps off and twisted them together. Eh?

I was genuinely confused, I couldn't find where the wires had come from, I had to get the Haynes out and check the wiring diagram. I didn't even consider they would have done anything to the horn wiring. Laughing

Anyway various wiring bits where tidied up and sorted. Only vaguely interesting bits were (badly) repairing the rectifier (I've ordered another one for the princely sum of £4.99) it still not working with a fresh battery long story short the live feed to the ignition had a dodgy connection in the head lamp. It was a simple case of by passing the connector block. Currently all the electrics work apart from the rear left indicator, that was most of today's work.

As soon as I got ignition the bike started 2nd kick! It seemed to run well too. All it took was a fresh splash of fuel and a new battery.

Had a go at repair the steering lock but couldn't budge it. I'm going to try again using mole grips with a fork tube for leverage. I couldn't shift it with a 2ft pry bar I couldn't get any purchase.

Also had a go at some cosmetic stuff too. I tried to sort a dent out (not very well) and replaced the badge from a spare panel I had in the garage. My dad is going to have a go at the dent and do a bit of plastic welding on the side panels.

I need to do the following.

Replace a leaking gasket and fill gearbox oil.
New fork oil, seals and gaiters.
Fix indicator and replace rectifier.
Bend steering lock back.
Grease and adjust steering bearings.
Replace Brake lever bracket.
Road test to find out what else needs doing!

https://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170119_111054_zpsqcvu4ckm.jpg

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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

ride_to_die · Crazy Courier Joined: 13 Nov 2005 Karma :

Looks like a good project, following with interest.
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I'm not here for a long time, I'm here for a good time.

pepperami · Super Spammer Joined: 17 Jan 2010 Karma :

Well it looks like you have the ingredients for a good little project there, will be watching with interest Thumbs Up

Regular updates with plenty of detailed picture, or I`ll come round your house Laughing

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

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Spent some time on there today. Tidied up the wiring some more, fixed the rear indicator, and cleaned up the earths.

Also 'fixed' the steering lock. It's a bit shit but it works. I striped the head stock and rebuilt with fresh grease. I have also stripped cleaned and rebuilt the forks although I can't do up one of the dampers as it just spins I need a tool to hold it. However the forks are so tiny I can't get anything substantial enough down to jam the damper. Until I do this I can't put oil in the forks or rebuild the front end.

As I was losing light I whipped the carb off and took it inside for cleaning. I then blinded myself with carb cleaner as it hard quite some splash back.

I then lobbed some bits in the ultra sonic cleaner and put my feet up. Laughing

https://img.photobucket.com/albums/v295/chris-red/IMG_20170122_121114_zps3vhriuiw.jpg

It was given a splash of Hammerite after this photo to stop it rusting.

https://img.photobucket.com/albums/v295/chris-red/IMG_20170122_121120_zpscooqrbt2.jpg

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https://img.photobucket.com/albums/v295/chris-red/IMG_20170122_183035_zpssepk14xd.jpg
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

One thing to consider is fitting a carb repair kit to it.

I did this to the wifes YB100 and depite having thoroughly cleaned up the original jets, needles etc, it was like a different bike afterwards. It doesn't take a lot of wear on a needle or main jet to reall compromise its efficiency.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

I got up late so decided to Work from home, which means I could carry on with this for a bit. Laughing

I have been putting the ultrasonic cleaner on every time I go out, it makes a nasty noise and can only run for a maximum of 8 minutes.

https://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170125_155448_zpsklxrow2g.jpg

https://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170125_155501_zps1mdsn2a4.jpg

Spotless inside and pretty clean outside too!

I suspected an airleak too so thought I'd remove the carb rubber and reed block and change the gasket there too as I had one.

Bad move the gasket is welded to the head. I've never known one so stuck, a see a large amount of scraping in my future...

I was trying to figure out a way to lock the damper in place my biggest tool was a spline but it was still too small. I then wrapped a load of Self amalgamating tape around the end of the spline and that bulked it up enough.

Still I had to find a way of getting it to the bottom of the fork leg.

Solution...

https://i.imgflip.com/1ibt0k.jpg

https://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170125_154251_zpshmkhbbdk.jpg

Forks all back together but it started raining so I stopped there,
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Did a bit more, the gear Mechanism was very slack and imprecise.

https://img.photobucket.com/albums/v295/chris-red/IMG_20170128_141637_zpstv8eahr3.jpg

As they were square I assume this is just what the standard of an 80's learner bike is. I decided to pack it out with washers. It feels far better now, more positive.

https://img.photobucket.com/albums/v295/chris-red/IMG_20170128_145147_zpsdbpljbas.jpg

I bit the bullet and did get a carb rebuild kit. I was having trouble with the carb overflowing and I couldn't seem to get it right. I rebuilt the carb with all new bits and it seems to have stopped the overflow. I ran it quickly and it did seem much better. Crisper and better than before and it settled to a nice idle.

I also picked up the plastic side panels that dad repaired for me, I forgot to get photos I'll take some later.

I spent some time working on the new brake perch. The one from Yam bits didn't fit the brake light switch (also from Yambits!)

Perfect fit now!
https://img.photobucket.com/albums/v295/chris-red/IMG_20170201_224843_zpsxhpxsjaq.jpg

Also received a LED flasher unit and I'm just waiting on the bulbs to arrive now. Anyone with an RXS will know the lighting is shit. The indicators are dull, and do not flash well unless the bike is revving. If you have the brake light on the just do not work full stop.

99p of China's finest.
https://img.photobucket.com/albums/v295/chris-red/IMG_20170201_224957_zpsrccqjshl.jpg

The current bulbs are 8w each, the LEDs I've ordered claim to have the brightness of a 21w bulb and only pull 1.5w. So in theory they should be brighter, flash correctly and pull less power. I paid the princely sum of £4.95 for the 4 bulbs and the flasher. I'm thinking of making a video describing the mod if it works as it is a big change for little money.

I might also buy an LED tail light to futher help the load. The battery is tiny! So every little helps!
https://img.photobucket.com/albums/v295/chris-red/IMG_20170201_224916_zpsvb1hj8hb.jpg

I also Bought a job lot of spares for cheap. I'm sure something will come in handy.
https://img.photobucket.com/albums/v295/chris-red/IMG_20170201_225316_zpsnwjvjscl.jpg

I'm hoping to finish this weekend. It should be MoT able. After that it will just be tidying up and fiddling.

Couple of bits,

It's been ages since I've ridden this, but is it usual for the revs to fall slower than a 4t? I'm thinking the lack of engine braking means it won't rev up and down as quickly. If it was a 4t I'd think there was a problem but I'm not sure, I'll need to give it a decent run before I decide either way.

Also does anyone have a short stem (rear) indicator for one of these? I've got one in that set of spares I'd like another so I can replace the front ones with the shorter rears I think it'd look better.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

pepperami · Super Spammer Joined: 17 Jan 2010 Karma :

Loving this thread Thumbs Up

, great stuff with the pictures, it means I can genuinely see and understand what you are talking about Thumbs Up

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

RhynoCZ · Super Spammer Joined: 09 Mar 2012 Karma :

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Vaguely Tempted by this...

Laughing

https://www.aliexpress.com/item/Motorcycle-Aluminum-Cylinder-Block-BODY-RXZ135-CYLINDER-set-PISTON-STD-Gas-Racing-order-write-size/32483220130.html?ws_ab_test=searchweb0_0,searchweb201602_3_10065_10068_10501_10503_10000032_119_10000025_10000029_430_10000028_10060_10062_10056_10055_10000062_10054_10059_10099_10000022_10000012_10103_10000015_10102_10096_10000018_10000019_10000056_10000059_10052_10053_10107_10050_10106_10051_10000053_10000007_10000050_10084_10118_10083_10000047_10080_10082_10081_10110_10111_10112_10113_10114_10115_10000041_10000044_10078_10079_10000038_429_10073_10000035_10121-10503_10501,searchweb201603_1,afswitch_1,single_sort_3_default&btsid=2508cb94-ea4a-48b9-a7dd-5b7be634ddc9
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

Serendipity · World Chat Champion Joined: 07 Jun 2006 Karma :

When the carb was overflowing was any crap stopping the float closing off the fuel feed? I had that with mine a few years ago, helpfully diagnosed by the BCF gurus.

https://www.bikechatforums.com/viewtopic.php?t=200998

In which case it may be worth checking if the filters are safely attached to the fuel tap inside the tank.
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2016 CBF1000F - Commuter heaven | 1994 CBR600FR - Awaiting defibrillation

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

More or less done now, Still waiting on my Chinky bulbs. Also might to the odd bit of tidying up on it. It needs new tyres too.

https://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170204_142235_zpscowetoeu.jpg

This is a bit of a problem...

https://youtu.be/QEY-_tLE67E

The pivot is ridiculously loose. I don't know whether to drill out and get some sleeves made or weld up the holes and redrill. The pivot is circlipped on so it can't be tightened.

This was the first little ride. The Rear brake is lethal, it's like an on off switch, The looseness of it doesn't help! I know I look totally ridiculous on it BTW. Laughing

https://youtu.be/H2Jpz2Th-_k
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

ride_to_die · Crazy Courier Joined: 13 Nov 2005 Karma :

Awesome progress, thread is full of win...especially the vid Thumbs Up

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I'm not here for a long time, I'm here for a good time.

redeem ouzzer · World Chat Champion Joined: 06 Oct 2015 Karma :

I have an urge to port fuck out of that and bang a YPVS carb on.

I'll stop now...
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Be a REAL MAN!

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

kgm · World Chat Champion Joined: 04 Jun 2015 Karma :

Regarding the lethal rear brake...is it the original shoes? If so have you given the drum and shies a quick rub with wet and dry? If there's a bit of rust in there it can make the brake really sharp. I get this on my cg if it's been out in really wet weather then left standing for a few days. Normally a few applications of the brake is enough to sort it out but occasionally it needs a rub down. Also ensure the shoes have an angled leading edge on them

redeem ouzzer · World Chat Champion Joined: 06 Oct 2015 Karma :

stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

You could probably weld a plate inboard of the holes and redrill. That would take out the horizontal play too.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Over on the Yammy100 forums a guy reckons he 'fixed' this issue using plumbing olives to take up the slack. I'm going to try that, nothing to lose but pennies worth of brass. If it doesn't work I'm going to trying welding. However I've never welded before so it could be interesting. Laughing

Still no chinky bulbs Crying or Very sad

____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

davethekwak · Nitrous Nuisance Joined: 25 Jan 2017 Karma :

Nice rebuild. I had one of those when they first came out. Great little round town bike.
Where were the shades on that first ride? You completely blew the cool dude look. Confused

stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

I suppose another option would be to overdrill the holes round and get someone to turn up a tophat insert
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

pepperami · Super Spammer Joined: 17 Jan 2010 Karma :

Err Hello! it`s been five days since we heard anything about this bike and I am starting to get withdrawal symptoms Sad

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