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Aprilia AF1 125 Replica - Full Rebuild - Updated 6-11-18

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Phil_B
Borekit Bruiser



Joined: 26 Nov 2013
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PostPosted: 18:11 - 14 Mar 2014    Post subject: Aprilia AF1 125 Replica - Full Rebuild - Updated 6-11-18 Reply with quote

I’ve not posted a lot, but have enjoyed looking through the Show & Tell projects here. So here’s my project I’ve been working on when time and money have allowed….

Aprilia AF1 Replica 1991 Restoration.

For those interested I'll give a little background information. A few scanned photos from when I bought the bike.

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Motorbikes/img053_zpsee49702b.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Motorbikes/img051_zps4e38d0c0.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Motorbikes/img054_zps5202c2e9.jpg

I bought this bike brand new back in 1991 aged 17. It was well looked after and regularly serviced until the Aprilia dealer shut, from there it went downhill. I struggled to get other dealers to work on it or get parts and a while later the top end went for the first time. I finally got someone to sort it….or so I thought! Sometime later the top end went again and when I stripped it, I found bits of ring in the top of the piston and in the cylinder head. It looked like the first time it went, they only replaced the rings, and didn’t even bother to look for broken bits of ring. This time, the rings on the piston were intact, but a piece of the old ring had gone down the side of the piston. The bike got covered and left.

In 1997/98 for some reason I'd decided to see if I could get the Aprilia back on the road, the restore was as cheap as possible as I didn't know if I could get it running again, or if I'd enjoy it. A few months later and the top end went again resulting in a nice score down the cylinder and it was left to rust in the back yard.

Fast forward to last year, and I found some old photos of the AF1 and took them in to show the lads at work. They tried to persuade me into attempting to rebuild it, but I told them I probably wouldn't be able to get the parts. A search on the internet brought some interesting finds.

There will be lots of photos in this thread, showing both the appalling state of the bike and the restoration of the salvaged and bought parts. Hopefully some of you will find it worth following the project. There will be some times of inactivity, mainly due to having limited time and waiting for work to be done by others. The aim is to get it running by summer, although the paintwork may have to wait until this winter. I was under no illusion that this would be expensive, and it would probably have been better to buy another but where is the fun in that. Plus this was mine from new, so holds some good memories.

And the restoration began....

Over 2 weeks I stripped the bike in my kitchen (nowhere else to do it!) to assess the damage -

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/StripStage1_zpsfb04b9a8.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/StripStage2_zps3bad2d3e.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/StripStage3_zps4b234df8.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/StripStage4_zps3568e89d.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/StripStage5_zps26419172.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/StripStage6_zpse3c8705a.jpg

From the list of wrecked parts, I knew that the rebuild would be expensive. The finished product will in no way be worth the money spent, but it’s not about that. It’s about bringing the Aprilia back to life and reliving my youth.


Last edited by Phil_B on 21:36 - 06 Nov 2018; edited 1 time in total
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Phil_B
Borekit Bruiser



Joined: 26 Nov 2013
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PostPosted: 18:20 - 14 Mar 2014    Post subject: Reply with quote

Now we move on to a more detailed look as the dismal state that the bike had become. I certainly wish I had stored it better, but I never actually thought I’d get to round to rebuilding it.

WARNING – Some people may find the following photos disturbing!

Genuine mileage from new

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/1s-Clock_zps5ca45abe.jpg

Rear wheel

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/2s-BackWheel_zpsc4d9581c.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/3s-BackWheel_zpsd7106545.jpg

Front wheel

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/4s-FrontWheel_zps9742850c.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/5s-FrontWheel_zpscd8e6dba.jpg

Some corrosion found on the frame

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/6s-Frame_zps0397c35d.jpg

Foot rests & hangers – not pretty

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/7s-RightRearset_zps737ad7a8.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/8s-LeftRearset_zps090b600b.jpg

Seat sub-frame – lots of corrosion & holes found

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/9s-SeatFrame_zps5316079c.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/10s-SeatFrame_zps5c66d19a.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/11s-SeatFrame_zps365ccabb.jpg

Engine cradle – worse than the seat sub-frame

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/12s-EngineCradle_zps8a78a918.jpg

Instrument sub-frame – more rust

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/13s-InstrumentFrame_zps080ad143.jpg

Swing-arm – survived quite well but was full of water!

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/14s-Swingarm_zps127f583a.jpg

Sidestand – don’t fancy this holding up my restored bike

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/15s-Stand_zps01e20eaf.jpg

Exhaust – think this may blow a little

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/17s-Exhaust_zps686beffa.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/18s-Silencer_zps3bbe339e.jpg

Clutch lever assembly

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/16s-LeftBar_zps4daf1f27.jpg

Front brake lever assembly

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/19s-FrontMasterCylinder_zps1e30b7f3.jpg

Front brake

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/20s-FrontBrake_zpse1529cb6.jpg

Rear brake – pad pin badly corroded, the clip was just a pile of dust

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/21s-RearBrake_zps688ca40d.jpg

Radiator

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/22s-Radiator_zps02eec964.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/23s-Radiator_zps8c00d226.jpg

Header tank – nice hole in the corner

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/24s-CoolantHeaderTank_zpscbdf01f4.jpg

Switchgear – both will need replacing

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/25s-LeftSwitchgear_zpsc82a3521.jpg
http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/26s-ThrottleSwitchgear_zpsdf3390eb.jpg

Regulator – hopefully will still be functional

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/27s-Rectifier_zps934050a4.jpg

Fuel tank – can’t open the fuel cap, removed the fuel tap and it wasn’t pleasant

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/28s-FuelTank_zps0a598c6d.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/29s-FuelTank_zps55ba747c.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/30s-FuelTap_zps0b22d0ea.jpg

Seat – might need a new one

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/31s-Seat_zps443c0477.jpg

Top fairing under-tray – bite marks from next doors dog when it got into my yard

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/32s-TopCowlPlate_zps1e7f3662.jpg

Rear shock – don’t think that’s much use

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/33s-RearShock_zpsb70ea5f9.jpg

Forks – lots of corrosion

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/34s-Fork_zps6319c699.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/35s-Fork_zps8b4117a6.jpg

Chain & sprockets – had to remove the chain to move the bike

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/36s-ChainampFrontSprocket_zps1ad262bd.jpg
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Phil_B
Borekit Bruiser



Joined: 26 Nov 2013
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PostPosted: 18:21 - 14 Mar 2014    Post subject: Reply with quote

Will post some more soon Smile
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chris-red
Have you considered a TDM?



Joined: 21 Sep 2005
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PostPosted: 18:26 - 14 Mar 2014    Post subject: Reply with quote

You are very brave. Laughing

Good luck it will be rewarding when done.
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Bendy
Mrs Sensible



Joined: 10 Jun 2002
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PostPosted: 18:34 - 14 Mar 2014    Post subject: Reply with quote

Let her go man, you're just extending the pain for both of you The world's smallest violin player, just for you!
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GSTEEL32
Crazy Courier



Joined: 24 Feb 2010
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PostPosted: 22:04 - 14 Mar 2014    Post subject: Reply with quote

Watching this one with interest... Pass the popcorn ...... I've found mine surprisingly resistant to British weather ..... are you planning respraying back to the original design ?
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Phil_B
Borekit Bruiser



Joined: 26 Nov 2013
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PostPosted: 23:47 - 14 Mar 2014    Post subject: Reply with quote

Brave or stupid Chris....it's a fine line! Smile

It's too late to let go Bendy, the project is too far on.

Yes, I'm hoping to restore it to how it was with as little compromise as I have to. I've not gone for the original engine colours as the colour match for the browny colour was going to be hit and miss, most of it is hidden anyway.

I've got lots more photos to post, the state of the engine is.....special Wink

I'm pretty pleased with how it's going, albeit quite slowly at the moment. Will put some more on tomorrow.
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Kickstart
The Oracle



Joined: 04 Feb 2002
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PostPosted: 23:55 - 14 Mar 2014    Post subject: Reply with quote

Hi

Minor point, but is the spacer missing from the front wheel, the one between the bearings?

And the mph overlay sticker is a joke!

All the best

Keith
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Phil_B
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Joined: 26 Nov 2013
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PostPosted: 00:02 - 15 Mar 2014    Post subject: Reply with quote

Yes, I was told that when I had the tyre fitted, there wasn't one in when I took the old bearings out. Going to have to pull a bearing out and get one made up. This is where you hang out now Keith? Not seen you on the sportsbikeforum for ages.
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Kickstart
The Oracle



Joined: 04 Feb 2002
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PostPosted: 00:08 - 15 Mar 2014    Post subject: Reply with quote

Hi

Spacer should be easy. Part number is 8125469 which is the same as for the RS125.

On quite a few forums.

All the best

Keith
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Carl_steveo
World Chat Champion



Joined: 23 Jun 2008
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PostPosted: 00:54 - 15 Mar 2014    Post subject: Reply with quote

What the fuck did you store that in??? A lake???

I'll be following this. It makes me feel more confident about my NSR that needs rebuilding. Thumbs Up Karma
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Phil_B
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Joined: 26 Nov 2013
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PostPosted: 08:58 - 15 Mar 2014    Post subject: Reply with quote

Cheers Keith, will look into that Thumbs Up

The bike did used to live in my kitchen when I moved. The idea was to get a shed but when it died it got moved outside. It used to have a cover on, and for a while I did keep looking on ebay to see if it was worth stripping and selling off. There were never any AF1 parts on there. Eventually I completely lost interest in it, the cover ripped and fell apart and it got left to rot. Hindsight is great, never thought I'd be able to do anything with it.

One thing you'll see in the next few posts I make Carl, is anything is possible with the availability of parts, the ability to throw some money at it, the patience and willpower to succeed!

This project has been/still is expensive, and I could have gone and bought something bigger and better for the money I've spent. But for me, this project isn't about that. I'm lucky enough to be in a good place right now so I can afford to do this properly. For me, this is something for me to do, to get my hands dirty and my mind thinking. I'm not even sure I'll enjoy riding it once it's finished, I'll only find that out at the end.
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c_dug
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PostPosted: 09:26 - 15 Mar 2014    Post subject: Reply with quote

Watching with interest Thumbs Up
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mintex
Nova Slayer



Joined: 10 Jul 2012
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PostPosted: 17:51 - 15 Mar 2014    Post subject: Reply with quote

Maybe we can look out for parts for us both bud as i start to do to my Af1 too Thumbs Up lol
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Phil_B
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Joined: 26 Nov 2013
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PostPosted: 19:35 - 15 Mar 2014    Post subject: Reply with quote

I'm not too far from having all I need. I've put a link in your thread to a place in Germany. I've taken photos from my engine strip which I'll put in here. Also got a PDF of the rotax 123 manual, if you want it sending over pm me your e-mail address.
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Tamsin
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PostPosted: 19:41 - 15 Mar 2014    Post subject: Reply with quote

Gosh, I have to admire your courage on this one I suspect that its going to require some fortitude.

Now, please forgive the next question but I know nothing about bike restoration but have done a few cars... The rotton bits such as the engine cradle - are you going to weld up or replace?
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Phil_B
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Joined: 26 Nov 2013
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PostPosted: 20:12 - 15 Mar 2014    Post subject: Reply with quote

I was under no illusion as to how bad it was before I started, so nothing has come as a big surprise - this has made it easier!

I've replaced all the badly rusted parts, I can't imagine there would have been much metal to weld too Laughing

Will post the engine photos tomorrow, something else to laugh at Smile
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mintex
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PostPosted: 20:42 - 15 Mar 2014    Post subject: Reply with quote

Phil_B wrote:
I'm not too far from having all I need. I've put a link in your thread to a place in Germany. I've taken photos from my engine strip which I'll put in here. Also got a PDF of the rotax 123 manual, if you want it sending over pm me your e-mail address.


Cheers mate, pm sent Smile
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Phil_B
Borekit Bruiser



Joined: 26 Nov 2013
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PostPosted: 16:34 - 16 Mar 2014    Post subject: Reply with quote

Here's a better look at the engine - not that you'd want a better look Confused

Engine – lots of corrosion under the paint and had a strong smell of cat piss!

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/37s-Engine_zps7b46955e.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/38s-ClutchCover_zpse19c2c8d.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/39s-SnappedClutchcable_zps1a4b447e.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/40s-OilPump_zps0137f012.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/41s-BrokenAdjusterScrew_zps7c09eb36.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/42s-DriveShaft_zpsd3385ac5.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/43s-Flywheel_zps0a4f771f.jpg

Power valve – needs a good clean, was hard to get out

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/44s-PowerValve_zpsc673f8d4.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/45s-PowerValve_zps5e4ec2dd.jpg

Top end

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/46s-WaterJacketHead_zps43bbec41.jpg

Cylinder head – you can see the marks from the rings

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/47s-CylinderHead_zpseb5826e2.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/48s-CylinderHead_zpsfd748cdf.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/49s-CylinderHead_zps38e3067b.jpg

First look at the piston

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/50s-Piston_zpsdb44ec9a.jpg

Piston – the problem is quite evident

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/51s-Piston_zps37ff7b50.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/52s-Piston_zps154c5e45.jpg

Cylinder – lots of score marks and dents from the rings

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/53s-CylinderDamage_zpsa313ff0e.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/54s-CylinderDamage_zps3389fd46.jpg

Removed the swing-arm needle roller bearings

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/image_zps00248344.jpg

Frame – strip-down complete!

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/image_zps638d3c86.jpg

So now it was quite clear what was needed and the amount of damage this was going to do to my wallet…..but I went ahead anyway. A bit of luck on my side, as I managed to get hold of a lot of the parts I needed off ebay.
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Phil_B
Borekit Bruiser



Joined: 26 Nov 2013
Karma :

PostPosted: 16:57 - 16 Mar 2014    Post subject: Reply with quote

Engine strip down – As this is my first strip of an engine and the pdf I’d got wasn’t the best, I decided to take lots of photos with markers to try and work with the pdf. A bit geeky, but I wasn’t sure how long it would be before I managed to get it rebuilt. My memory certainly isn’t as good as it used to be!

Top end

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/1%20-%20Top%20End%20Removal/PB102011_zpsba390bda.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/1%20-%20Top%20End%20Removal/PB102012_zpsf61c8ebb.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/1%20-%20Top%20End%20Removal/PB102016_zps9e12bed9.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/1%20-%20Top%20End%20Removal/PB102017_zpsddb4335a.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/1%20-%20Top%20End%20Removal/PB102021_zpsd14dcbf0.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/1%20-%20Top%20End%20Removal/PB102022_zpsd494f115.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/1%20-%20Top%20End%20Removal/PB102024_zpsf3878d45.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/1%20-%20Top%20End%20Removal/PB102025_zpsb3d2fcc4.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/1%20-%20Top%20End%20Removal/PB102026_zps17acaa55.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/1%20-%20Top%20End%20Removal/PB102027s_zpsa03bb69e.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/1%20-%20Top%20End%20Removal/PB102029s_zps26bd11e3.jpg

Ignition system

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/2%20-%20Ignition%20System%20Removal/PB112031s_zps6563e15e.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/2%20-%20Ignition%20System%20Removal/PB112032s_zpsda0ce946.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/2%20-%20Ignition%20System%20Removal/PB112034s_zps5dbb1a86.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/2%20-%20Ignition%20System%20Removal/PB112036s_zpsf6e58f59.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/2%20-%20Ignition%20System%20Removal/PB112038s_zps7902b84f.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/2%20-%20Ignition%20System%20Removal/PB112039s_zps79673e5d.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/2%20-%20Ignition%20System%20Removal/PB112040s_zpsa426de5b.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/2%20-%20Ignition%20System%20Removal/PB112041s_zpsf907e580.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/2%20-%20Ignition%20System%20Removal/PB112042s_zps1ea1de03.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/2%20-%20Ignition%20System%20Removal/PB112044s_zpsdc979856.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/2%20-%20Ignition%20System%20Removal/PB122045s_zps34d8467b.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/2%20-%20Ignition%20System%20Removal/PB122046s_zpsdaed2143.jpg

Front sprocket removal

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/3%20-%20Sprocket%20Removal/PB112030s_zps865039bd.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/3%20-%20Sprocket%20Removal/PB122047s_zps2d834151.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/3%20-%20Sprocket%20Removal/PB122048s_zps73eba1e9.jpg

Oil pump

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/4%20-%20Oil%20Pump/PB182049_zps9027c8aa.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/4%20-%20Oil%20Pump/PB182050_zpsc03f925b.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/4%20-%20Oil%20Pump/PB182052_zpscd529b97.jpg

Clutch & primary drive

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB182055_zps5e90c492.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB182057_zpsd3a8545d.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB182058_zps033a298a.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB182059_zpsf0f64b98.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB182060_zps83aabc3b.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB182061_zpsd5ea3f32.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB182063_zpsa5bf3f3b.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB272068_zpse544969c.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB272070_zpsffa46ebb.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB272071_zps786fd4a8.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB272072_zps05d12cf8.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB272073_zpsff65510d.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB272074_zps9a397d42.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB272075_zps7e621a16.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB272076_zps55d517e1.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB272077_zps441d57c6.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/5%20-%20Clutch%20And%20Primary%20Drive/PB272078_zps9523819a.jpg

Drive gear

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/6%20-%20Drive%20Gear/PB272082_zpsf119a912.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/6%20-%20Drive%20Gear/PB272084_zps54d5911f.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/6%20-%20Drive%20Gear/PB272087_zpscb6c95c7.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/6%20-%20Drive%20Gear/PB272094_zps4fcb78ac.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/6%20-%20Drive%20Gear/PB272098_zpsa0c0c36a.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/6%20-%20Drive%20Gear/PB272101_zps5d821ebc.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/6%20-%20Drive%20Gear/PB272102_zpsbb0a5e75.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/6%20-%20Drive%20Gear/PB272103_zps804f36bc.jpg

Water pump & bearing retainers

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/7%20-%20Water%20Pump%20And%20Bearing%20Retainers/PB272105_zpsb56b0911.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/7%20-%20Water%20Pump%20And%20Bearing%20Retainers/PB272106_zpsfe8e062a.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/7%20-%20Water%20Pump%20And%20Bearing%20Retainers/PB272107_zpsce6eb33b.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/7%20-%20Water%20Pump%20And%20Bearing%20Retainers/PB272110_zpsba84d622.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/7%20-%20Water%20Pump%20And%20Bearing%20Retainers/PB272111_zps3b3b86c1.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/7%20-%20Water%20Pump%20And%20Bearing%20Retainers/PB272113_zpsf03eed3c.jpg

Separating the crankcases

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/8%20-%20Separating%20The%20Crankcases/PB282115_zpsada2db73.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/8%20-%20Separating%20The%20Crankcases/PB282116_zps6287da41.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/8%20-%20Separating%20The%20Crankcases/PB282117_zps5e715b54.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/8%20-%20Separating%20The%20Crankcases/PB282118_zpsff0f8b31.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/8%20-%20Separating%20The%20Crankcases/PB282119_zps81ecdef4.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/8%20-%20Separating%20The%20Crankcases/PB282120_zps417cb96f.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/8%20-%20Separating%20The%20Crankcases/PB282121_zpsaf868412.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/8%20-%20Separating%20The%20Crankcases/PB282122_zps0bc3869f.jpg

Removing gearshift & gearbox

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/9%20-%20Removing%20Gearshift%20And%20Gearbox/PB282123_zps7c547660.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/9%20-%20Removing%20Gearshift%20And%20Gearbox/PB282124_zpsaca9c2b5.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/9%20-%20Removing%20Gearshift%20And%20Gearbox/PB282126_zpsa0c1be7e.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/9%20-%20Removing%20Gearshift%20And%20Gearbox/PB282128_zps756a7609.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/9%20-%20Removing%20Gearshift%20And%20Gearbox/PB282129_zpsead38fc0.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/9%20-%20Removing%20Gearshift%20And%20Gearbox/PB282130_zpse227ac47.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/9%20-%20Removing%20Gearshift%20And%20Gearbox/PB282131_zpsd8884252.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/9%20-%20Removing%20Gearshift%20And%20Gearbox/PB282132_zps6fd6d7ac.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/9%20-%20Removing%20Gearshift%20And%20Gearbox/PB282138_zps6bff4039.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/9%20-%20Removing%20Gearshift%20And%20Gearbox/PB282141_zps47fcefe7.jpg

Removing crankshaft – I used the press at work to get this out

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/10%20-%20Removing%20The%20Crankshaft/PB282142_zps9277dee9.jpg

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/10%20-%20Removing%20The%20Crankshaft/PB292144_zpsbddbe195.jpg

Found this bit of ring stuck in between the crank and the case

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/10%20-%20Removing%20The%20Crankshaft/BitOfRing_zpse246ebcc.jpg
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mintex
Nova Slayer



Joined: 10 Jul 2012
Karma :

PostPosted: 19:53 - 16 Mar 2014    Post subject: Reply with quote

You've taken some good pics mate, good idea, i think i shall be doing the same once i start on the engine Thumbs Up
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Phil_B
Borekit Bruiser



Joined: 26 Nov 2013
Karma :

PostPosted: 20:13 - 16 Mar 2014    Post subject: Reply with quote

Cheers, will see if it works when I come to put it all back together Laughing
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fraggie
Two Stroke Sniffer



Joined: 15 Apr 2012
Karma :

PostPosted: 21:05 - 16 Mar 2014    Post subject: Reply with quote

this should cause you jailtime.
Never use a screwdriver to split a case, you don't need much strength to damge the sealing edges..

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/8%20-%20Separating%20The%20Crankcases/PB282119_zps81ecdef4.jpg
____________________
1999 Dragstar 650cc
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Phil_B
Borekit Bruiser



Joined: 26 Nov 2013
Karma :

PostPosted: 21:09 - 16 Mar 2014    Post subject: Reply with quote

The engine has tabs on the edge to aid splitting the cases. This is how the rotax engine manual states to split them. The mating faces never come in contact with the screwdriver Smile
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Tamsin
World Chat Champion



Joined: 07 Mar 2014
Karma :

PostPosted: 22:10 - 17 Mar 2014    Post subject: Reply with quote

fraggie wrote:
this should cause you jailtime.
Never use a screwdriver to split a case, you don't need much strength to damge the sealing edges..

http://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Rotax%20123%20Strip-down/8%20-%20Separating%20The%20Crankcases/PB282119_zps81ecdef4.jpg


I did wince a little when I saw that...
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