YZ125 strip and rebuild project

[Red Devil]

So I decided to get myself a mx bike to keep my eye in over winter before the next race season, keep my bike fitness up and keep me entertained between rounds which lead to me buying this little beauty:

https://i1061.photobucket.com/albums/t468/RedDevil92/20130825_140602_zps1f5eae61.jpg

Spotted it on gumtree advertised for £700 so went to have a look at it to discover it had a few issues. There was a knocking from the engine (I guessed small or big end bearing), fork seals were pissing out oil, the shock was bouncier than a trampoline, it needed new pads in the front and a general clean up. After a bit of negotiation I loaded the bike into my van £400 lighter, a quality deal in my eyes.

A few hours in my garage and it suddenly looked like this:

https://i1061.photobucket.com/albums/t468/RedDevil92/20130831_110341_zpse20f7d57.jpg

I was initially just going to take the forks off and drop the engine but decided to completely strip it, check everything, replace anything that needs replacing and try make it reliable as I can for the abuse it is going to receive over winter.

Engine out and on my desk:

https://i1061.photobucket.com/albums/t468/RedDevil92/20130825_175546_zps7b233069.jpg

This is how the flywheel case looked which had actually ripped the gasket. I know this is a dry part of the engine but I'm planning on riding in all weathers and don't fancy water going in there so that will be replaced.

https://i1061.photobucket.com/albums/t468/RedDevil92/20130826_180415_zps46893656.jpg
https://i1061.photobucket.com/albums/t468/RedDevil92/20130826_180429_zps836feb7d.jpg

Piston and cylinder head:

https://i1061.photobucket.com/albums/t468/RedDevil92/20130826_182208_zps1bbb49f1.jpg

Looks like some loose metal has got in there and damaged them both at some point, the bottom end of the engine will be stripped later today to check for debris and the piston will be replaced.

These are the brake pads the chap who sold it to me reckon had 'about another day in them':

https://i1061.photobucket.com/albums/t468/RedDevil92/20130829_220003_zps264604de.jpg
https://i1061.photobucket.com/albums/t468/RedDevil92/20130829_220023_zpsaf65870a.jpg

This is what remains from the bearing out of the bottom chain roller:

https://i1061.photobucket.com/albums/t468/RedDevil92/20130829_220158_zpsdc4c5b91.jpg

Swinging arm bearings...aren't these suppose to move???

https://i1061.photobucket.com/albums/t468/RedDevil92/20130830_204506_zpsd73a640c.jpg

With the seals out...wow.

https://i1061.photobucket.com/albums/t468/RedDevil92/20130830_204901_zps8ec69eb9.jpg

More pictures of progress to be added as I go along!
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[.Bishbash.]

Nice stand!
____________________
Current bike - GSX-R1000 k8

[Aff]

Looks interesting, posting for updates.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Irn-Bru]

Looks well maintained.


____________________
KTM 990 SMT & Suzuki DR-Z 400 SM

[Red Devil]

Yeah it is in a bit of a state, I'll get it sorted though. Not looking to tart it up just get it mechanically sound so it goes well all winter.

Engine down at Newbury Motorcycles today to find the cause of the knocking.

https://i1061.photobucket.com/albums/t468/RedDevil92/20130831_131926_zps5ca537fc.jpg

The clutch basket looks like it could be the cause, hopefully it is so it's not a hard job to sort.

https://i1061.photobucket.com/albums/t468/RedDevil92/20130831_132353_zpsace2f2fa.jpg
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[P.]

That basket looks nice in comparison to the one on my Varadero which isn't knocking at all.

[Red Devil]

Is that your version of fine though? It will be filed down to make it smoother.

Few more pictures from today...

Reed has got a crack in it so those are going to be added to the replace list:

https://i1061.photobucket.com/albums/t468/RedDevil92/20130831_161724_zps3b41cea2.jpg

This is a big problem, this is the kick start assembly and that is the 'stop plate' which has the massive crack in it. Lucky I spotted it and have a chance to replace it before it snapped off and caused shit loads of damage to the engine internals!

https://i1061.photobucket.com/albums/t468/RedDevil92/20130831_170007_zps7e18ea4c.jpg

Engine split in half. One of the main bearings has a slight bit of play, might just replace the lot while it's cracked open.

https://i1061.photobucket.com/albums/t468/RedDevil92/20130831_175920_zps145e83a7.jpg
https://i1061.photobucket.com/albums/t468/RedDevil92/20130831_175926_zpsa70d69e3.jpg

More rusty bearings!!! This is what the rear shock linkage looked like, the bearing sleeves are going to be fun to get out...

https://i1061.photobucket.com/albums/t468/RedDevil92/20130831_171701_zpse9b1c572.jpg
https://i1061.photobucket.com/albums/t468/RedDevil92/20130831_171815_zps45c6614b.jpg

This is turning into a complete overhaul but I should have a quality bike at the end of it.
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[.Bishbash.]

Christ dude, that's going to be mint afterwards.

How much have you spent on parts so far?
____________________
Current bike - GSX-R1000 k8

[Red Devil]

[.Bishbash.]

aaaahhhh man, would love to have had a spin, but will be getting my own one when I'm up there, but probably getting something a little bigger though, maybe a 450 or something.

EDIT: And ouchy on the cost so far, BUT still going to be a steal on the total cost of the bike
____________________
Current bike - GSX-R1000 k8

[waffles]

Nice! Your total spend so far is still less than the asking price that the seller wanted so I recon you are quids in so far
____________________
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

[prawny1]

I use marine grease in the suspension linkages on bikes, it is water proof so doesn't wash out so easily.

Most motor factors should sell it, this one is quite common




https://img.nokaut.pl/p/10/c2/10c24d932264036aa5eb07f942c68385500x500.jpg
____________________
hellkat wrote:

Some people are only alive cos its against the law to kill them.

[Red Devil]

[Dischord]

awesome keep the pics coming, I've got a soft spot for YZ125's!
____________________
2012 KTM EXC 250

Check out my vids - https://www.youtube.com/user/KTMSparky/videos

[Red Devil]

First lot of parts started arriving today:

https://i1061.photobucket.com/albums/t468/RedDevil92/20130902_212558_zps1500a7ad.jpg

Stripped the end can to see if it needed repacking as I spotted oil on the tip which was a bit suspicious to find the internals looking like this...

https://i1061.photobucket.com/albums/t468/RedDevil92/20130902_211940_zps2f30e523.jpg

Haven't done much this evening as I'm knackered after the gym, will crack on tomorrow after work!
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[.Bishbash.]

Looking good dude, those grips look very grippy and those seals would make the oceans very jealous!


____________________
Current bike - GSX-R1000 k8

[Red Devil]

Those were even worse than usual mate.

More jet washing tonight but got a few small bits done. The frame is back inside and a few bits are back on:

https://i1061.photobucket.com/albums/t468/RedDevil92/20130903_215547_zpsb4134146.jpg

The front brake is lovely and clean! This will be getting sorted over the weekend, I completely forgot to crack the bolts before taking it off the bike though so that should be fun.

https://i1061.photobucket.com/albums/t468/RedDevil92/20130903_193748_zps8cdbba35.jpg

More rusty bearings, this top chain roller is about as much use as the bottom one was.

https://i1061.photobucket.com/albums/t468/RedDevil92/20130903_214347_zpse7536a63.jpg

The wiring was in a horrible state and wrapped in electrical tape which was just filled with dirt underneath.

https://i1061.photobucket.com/albums/t468/RedDevil92/20130903_203754_zps85699b4c.jpg

Stripped it all back and gave it all a quick clean and the connections a spray with wd40, got some proper shrink wrap on the way to put on before it goes back on the bike.

https://i1061.photobucket.com/albums/t468/RedDevil92/20130903_214730_zps0d7249d8.jpg

This is another job on the list for the weekend, popped the spring off just before I called it a night. It feels and sounds like there's very little or no oil in there no wonder it was so bouncy!

https://i1061.photobucket.com/albums/t468/RedDevil92/20130903_220443_zps058f65a5.jpg
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[Fladdem]

Looking good so far.
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.

[Red Devil]

Not much to update, the project is going to be put on hold for a couple of weeks as I'm racing at Brands Hatch this coming weekend then have the championship decider of EMRA at Mallory Park next weekend so my efforts are being put into prepping my R6 and ZX6.

Managed to get these out of the linkage, it was a pain in the arse!

https://i1061.photobucket.com/albums/t468/RedDevil92/20130907_153943_zps6b43d2a1.jpg

Driving the old bearings out of the second part of the linkage in the vice:

https://i1061.photobucket.com/albums/t468/RedDevil92/20130907_155540_zps5ef4d163.jpg

Putting a bit of heat into the bottom of the shock to help the bearings come out:

https://i1061.photobucket.com/albums/t468/RedDevil92/20130907_162323_zpsd3beb1f0.jpg

Nothing too exciting to be honest! Once the next couple of weekends are done that's me done on the track until next season so I'll really crack on and get it sorted.
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[Red Devil]

Job done at the last race round of the season, my first ever season racing and I finished 3rd in the championship, chuffed with that!

Time to get the new bearings installed, this is the kit for the swing arm

https://i1061.photobucket.com/albums/t468/RedDevil92/20130923_153548_zps01a1e10e.jpg

Installed and greased up, this is what they should look like! Compare that to the first picture further up...

https://i1061.photobucket.com/albums/t468/RedDevil92/20130923_163037_zpsde067e60.jpg

Linkage kit ready to be installed

https://i1061.photobucket.com/albums/t468/RedDevil92/20130923_170008_zpsa0fa3827.jpg

All done

https://i1061.photobucket.com/albums/t468/RedDevil92/20130923_174319_zps138d3f94.jpg
https://i1061.photobucket.com/albums/t468/RedDevil92/20130923_180418_zps16dc32ed.jpg

Swing arm installed back on the bike

https://i1061.photobucket.com/albums/t468/RedDevil92/20130923_194833_zpse59ebfea.jpg

Added some DIY protection against stones to the radiator before it goes back on

https://i1061.photobucket.com/albums/t468/RedDevil92/20130923_205855_zps999fb041.jpg

Nice dirty carb...

https://i1061.photobucket.com/albums/t468/RedDevil92/20130926_201002_zps8300344e.jpg

Stripped down and cleaned

https://i1061.photobucket.com/albums/t468/RedDevil92/20130926_210200_zpsccb66b54.jpg

Jets looked pretty good actually, surprising considering the state of the rest of the bike so after a quick soak they were ready to go back in.

Jets and floats installed back in

https://i1061.photobucket.com/albums/t468/RedDevil92/20130926_211015_zpsbb381e31.jpg

Stripped down the throttle housing and gave it a quick clean and grease up as it felt a bit notchy. Popped the new grip on and adjusted the cable properly, feels much better now!

How the bike stands now, hopefully get some time over the weekend to make progress with the suspension and engine.

https://i1061.photobucket.com/albums/t468/RedDevil92/20130926_220006_zpse64da1c9.jpg
https://i1061.photobucket.com/albums/t468/RedDevil92/20130926_220031_zpsc3f5208c.jpg

Starting to make progress, slowly!
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[Red Devil]

Not much to report as I've been so busy lately but there has been a small bit of progress! Edging closer to having this sorted and hoping to have it finished early next month to finally get out on it.

Stripped down the forks and replaced the oil and seals, the oil that came out was a horrible colour!

https://i1061.photobucket.com/albums/t468/RedDevil92/20130928_143755_zpsaab2718b.jpg

And back on the bike

https://i1061.photobucket.com/albums/t468/RedDevil92/20130928_185224_zps338ca3da.jpg

Replaced the main crank bearings and gave the internal casing a good clean, the casing is now back together and I will get the rest of the internals cleaned up and fitted back in place.

https://i1061.photobucket.com/albums/t468/RedDevil92/20131019_175047_zps5e2d5176.jpg

Gear box out, this was fun to line back up and put back in! Thanks to Newbury Motorcycle Engineers who helps me out with my race bikes for helping me with this.

https://i1061.photobucket.com/albums/t468/RedDevil92/20131019_125532_zps54846a38.jpg

More progress pictures to follow!
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[Norlig]

Fun read. Looks nice aswell!

[Tim..]

Watching
____________________
Project builds: My VFR400 nc30 build thread + Honda Britain Rep VFR + What? Another VFR +Project 'cos I want one' + V8 coffee table
www.marshallracing.co.uk
OCD - Helping to bring the standard of my bikes up and make me slowly go mad since 1999

[c_dug]

Also following.

When you come to sell it do you think you will link this thread as a "look what it's had done"?
____________________
I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[bikertomm]

Sweet mate, loving the progress.

Would bloody love a pop on one of these one day, I need to learn mechanical knowledge


____________________
07' Honda Hornet now full powaah! My guide on performing an oil change!