NSR125 Repair and Tidy Up

[RichP]

Thought i'd do a little bit of a blog on getting this bike sorted out since as usual its ended up being more than I thought!

I initially bought the bike as a non-runner, it had an electrical fault but when I went to view, it seemed to have no compression... I could bump it over easily in any gear. Anyway after a some bargaining I purchased it and got it 'vanned back home to start work.

Here's where I started from:
https://img24.imageshack.us/img24/5550/bikei.jpg


Got it into the garden and started stripping. (i later moved to the garage when the sun went in and the rain came out!)
https://img441.imageshack.us/img441/6571/ranomage004.jpg https://img441.imageshack.us/img441/ranomage004.jpg/1/w640.png

The electrical fault was found rather easily, it was a break in the green wire to the clocks, I spliced it back together... I found the previous attempt to mend it by instead of looking for the break, cutting into the wire further up and putting in another amusing.
https://img41.imageshack.us/img41/4347/ranomage003.jpg https://img41.imageshack.us/img41/ranomage003.jpg/1/w640.png

I stripped off the head and barrel to find a rather knackered piston (sorry no pics right now), rings completely seized in and the top looked like it had had a rodent chewing at it!
With some difficulty removing the gudgeon pin I fitted a new piston and rings, slapped it all back together and tried to start it.
It fired up but with a pretty loud knocking noise... Big end, bugger!

So i've just sourced a bottom end off baldy, picked it up today and currently have it in bits to work out how it all goes together!
https://img98.imageshack.us/img98/462/ranomage002.jpg https://img98.imageshack.us/img98/ranomage002.jpg/1/w640.png

I'll need to scavenge some bits off my bottom end to complete this one, i'm also tempted to get the workshop manual printed out in full! Its a pain to look through in .doc format!


Apart from that its mainly cosmetic work, cleaning, missing fairing bolts, cracks etc, i also need a new ignition lead if they sell them, mines cracked and the bit inside the plug keeps falling out!
I've bodged a car one to fit temporarily.

Will try and get photos and keep up to date with progress as i go!

[BenR]

Was this on egay last week? Looks nice! Once you've got the engine sorted should be a belter.
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Current bikes: suzuki RG125UN wolf. Yamaha MT-07

[RichP]

Yep, found on ebay... Not to sure if the owner genuinely didn't know what was wrong... Or was trying to con me lol!
Either way, bikes more stripped down now but ala my post about it in the workshop theres a bloody seized engine bolt thats twisted my socketed allan key right around.

Also need to make sure the oil pump is working correctly, i shall be premixing until i'm sure!

Does anyone know if its normal for the wiring loom to be run through the grey holder part for the fake air intakes..?

Cheers!

[Mystery]

[RichP]

Carrying on from before, I had to take the whole kickstand bracket and assembly out to drop the engine because i couldn't unseize the bolt.

Ended up having to get a new one because I couldn't get the bolt out on the bench either!
Here's the new one refitted.
https://img193.imageshack.us/img193/5628/rebuild001.jpg

And then i had to reconnect the shock to it, my crude method with no paddock stand involved laying the bike on a cushion to take the weight off haha.

https://img44.imageshack.us/img44/3916/rebuild002.jpg

Look at those nasty cracks...
https://img12.imageshack.us/img12/91/rebuild003.jpg

Good job i just picked up these!
https://img524.imageshack.us/img524/137/rebuild005.jpg

Now the bike is back on its sidestand again (Woohoo!) I shall give it a good major clean tomorrow while i've got access to everything.
https://img6.imageshack.us/img6/5591/rebuild004.jpg

Next i've started on swapping parts across and building up my new engine.
My improvised work area!
https://img246.imageshack.us/img246/9421/rebuild006.jpg

First order of business is to strip the head and barrel off the old one, then i'll swap across the starter motor, generator cover and oil pump.

Currently stopped till i get the Generator cover off!
https://img193.imageshack.us/img193/2323/rebuild007.jpg

[Mystery]

you think yours is dirty mines hasn't been washed since it got out the show room i dont think, i've stripped mines down as well to give it a good clean out not dropping the engine though , got a dodgy wiring prob with mine to stop it from running right as well
____________________
Carbon knuckles assure you maximum protect against debris and unfortunate accidents or if someone cuts you off, their side mirror.Mopeds are like chubby chicks.. they are really fun to ride until you're friends catch you on one

[RichP]

https://www.youtube.com/watch?v=HREqf4wIukA

That set of guides is awesome!
I wouldn't go as mad as he did but i'll give it a damn good go!

I wish i'd known how effective WD and a toothbrush was on my last bike!

Well ive swapped the starter motor across from my old bottom end, need some bottom end gaskets now so i can fix my generator cover on... Don't know who will have them locally on a sunday... Liquid Gasket lol!

Trying to decide what to do with the chain and sprockets, it needs new ones but they're still servicable... Probably go the winter with them, plus i'll feel the difference more!

I need to drain the transmission oil from the old one now so i think i'll call it a night and fry up some chicken i've got in the fridge.

[RichP]

No pics for this update, i can't be arsed to upload them right now.

Engine is back together (finally), and its gone back into the bike.
Thought before i finished up i'd have a quick try and start it, turned it over compression good. So i hooked up all the electrics, pushed the carb back on a jubilee clipped it, hooked up the fuel feed (i've premixed the fuel till i determine if the oil pump is working).
Turned it over... Nothing.

After tons of fiddling, by lifting the plug out it seems no fuel is getting in, can't think why.... Also when i turn the air out it feels as if air is being blown out somewhere down the left side, can't put my finger on where...

BASTARD FUCKING THING! WHY CAN'T SOMETHING WORK FIRST TIME!
Sorry, needed to get that off my chest!

[baldy]

That's why i didn't rebuild that engine, because i knew it would be a ball ache.

Did you turn the fuel on?
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One day i will rule the world, just not today.

[Billing]

put something like clutch cleaner or wd40 on the outer edges of where the gaskets are, then try turning it over with some force, any air leaks will be apparent because it will 'puff' the fluid out of the way worked for me and my ts125 head gasket
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'84 TS50X, '91 TZR125, '89 CBR400RR, '91 VFR400R NC30, '98 R1
"Hey copernicus! Why don't you navigate yourself to the back of the line with your feet and stand there with your shit."
BCF Eastern members map here ---> g.co/maps/2tm8b PM me to be added to it!

[Welshd1k]

while you got it in bits check the pipe for the restrictors
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Current >Cb600fx hornet, ns125rk90 21.7bhp@wheel<
Sold >,zxr400 h2 (33bhp kit) rd350 n1 rd350 lc2<

[RichP]

Leaving it restricted till i get the proper jets in etc!

[RichP]

Will do a proper post this evening with pics etc... But at half one in the morning i moved it across the garage under its own power!

[RichP]

Ok the bike is now running and on the road!
At the moment it has a huge flat spot between 5 and 8, this is (i think) a combination of not connecting the powervalve up yet (so stuck open), way to much oil in (premix and the oil pump... better safe then sorry when bleeding oil pumps) and consequently a very oiled up plug... i have a replacement as soon as this tank of fuel is through...

Some pictures of the various bits of it, and i will at some point get a video of the bike in action.

https://img185.imageshack.us/img185/6458/dsc00129l.jpg https://img185.imageshack.us/img185/dsc00129l.jpg/1/w640.png
https://img62.imageshack.us/img62/9277/dsc00130d.jpg https://img62.imageshack.us/img62/dsc00130d.jpg/1/w640.png
https://img260.imageshack.us/img260/8012/dsc00131.jpg https://img260.imageshack.us/img260/dsc00131.jpg/1/w640.png
https://img97.imageshack.us/img97/989/dsc00132cl.jpg https://img97.imageshack.us/img97/dsc00132cl.jpg/1/w640.png
Giving the chain a bit of the old mega clean:
https://img524.imageshack.us/img524/1744/dsc00133w.jpg https://img524.imageshack.us/img524/dsc00133w.jpg/1/w640.png


Currently left to do, connect up power valve... Means removing the radiator... bugger!

Put all the fairings on, and a load of minor jobs i can't remember right now!


BUT ITS RUNNING!