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

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dransy
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PostPosted: 22:13 - 17 Mar 2014    Post subject: Reply with quote

Ive got a right hand side fairing for that bike, same colours on my garage wall if you want it Very Happy
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Phil_B
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Joined: 26 Nov 2013
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PostPosted: 22:41 - 17 Mar 2014    Post subject: Reply with quote

MissTamsin wrote:
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..

https://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...


Taken from the rotax manual - see position 5, screwdriver splitting case using the provided splitting tabs Smile

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Mobile%20Uploads/image_zps344729c5.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Mobile%20Uploads/image_zpsa1e12b9a.jpg
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Phil_B
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Joined: 26 Nov 2013
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PostPosted: 14:25 - 18 Mar 2014    Post subject: Reply with quote

Finally some photos with something positive Thumbs Up

Got hold of some replacement fairings and sub-frames, so did a quick rebuild with the parts just to check the fit before I made the first trip to the powder-coaters.

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/image_zps21af6fb0.jpg

Took lots of brackets, the frame & sub-frames and the wheels to the powder-coaters. Beginning to look like they should belong on a bike instead of the rubbish tip!

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9172003_zps7ec080c9.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9172002_zps80297a36.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9172001_zpsd29dca03.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9172000_zpsad985c05.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9171999_zpsa31dcb14.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9171997_zps63c728f1.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9171996_zpse801db56.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9171992_zps6d6bafde.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9171991_zpsd6d63156.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9171990_zpsde2245f4.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9171987_zps639b84b2.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9171986_zps4e67423c.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9171985_zps86d55237.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P9171984_zps123883ea.jpg

Did a partial rebuild to test as much of the electrics as possible, amazingly everything that I could try worked. I'm thinking of replacing as many of the connectors as possible just to refresh it a little.

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Rebuild/PA192006_zps562c9340.jpg

Got the tyres on and the front disc – need to get a spacer for the front wheel though as it’s missing!

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Rebuild/PB042007_zpsed3ad2c0.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Rebuild/PB042008_zps681ae20a.jpg

After the engine strip down, I sent the cases off to be powder-coated, not done in the original colours but it’s come up well considering how it looked before. It needs a few bits sorting before re-build.

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P3122259_zps0f47c97d.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P3122255_zps618f4f30.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P3122254_zps84a095c1.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P3122256_zps073c1b33.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P3122257_zpsb900bd56.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Powdercoated%20Parts/P3122258_zpsaecca134.jpg

That’s where I’m at right now. Hopefully going to get my replacement forks stripped, bottom castings repainted, and new seals in the next couple of weeks. Then I’ll be dropping my cases off for new seals and bearings before I go on holiday, hoping they’ll be ready for when I’m back.
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Tamsin
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PostPosted: 15:04 - 18 Mar 2014    Post subject: Reply with quote

You really are cracking along on this. Really impressive rate of work!
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Phil_B
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Joined: 26 Nov 2013
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PostPosted: 15:11 - 18 Mar 2014    Post subject: Reply with quote

Thanks, although this has been over the last 6 months really, just only got round to putting a thread together on here.

The updates now will be as they get done. The engine will go away for work to be done whilst I'm on holiday, that is the last of the big 'outside' jobs to be done. Hopefully it should go together reasonably quickly after that....just wish I had more spare time!
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BenR
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PostPosted: 13:12 - 23 Mar 2014    Post subject: Reply with quote

Nice work they are a labour of love. Will be following this one.
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Phil_B
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Joined: 26 Nov 2013
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PostPosted: 13:30 - 24 Mar 2014    Post subject: Reply with quote

Cheers, has been a good project so far. I just hope it's as much fun as I remember!
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expat200
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PostPosted: 10:52 - 25 Mar 2014    Post subject: Reply with quote

Phil_B wrote:


Seems to be a Rotax speciality, the old 4 stroke air cooled singles have levering surfaces between the barrel and head!
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Matt B
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PostPosted: 11:31 - 25 Mar 2014    Post subject: Reply with quote

This is coming along really nicely Thumbs Up
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Phil_B
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PostPosted: 16:44 - 25 Mar 2014    Post subject: Reply with quote

Thanks Matt Smile

Just put an order in to a place in Germany for some parts I've been unable to source elsewhere. Still a few bits to get, but I'm not far from having a complete bike again....even if it is all in pieces!
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Yamaha R3
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bandit_engineer
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PostPosted: 20:45 - 25 Mar 2014    Post subject: Reply with quote

Keeping an eye on this!

Brings back memories of the RS back when i was 17.

Looking forward to the end product! Cool Mr. Green
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Phil_B
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PostPosted: 21:37 - 25 Mar 2014    Post subject: Reply with quote

It's good to see some interest in this. I know it's not a big beast of a bike, but it had some pretty neat stuff when it fist appeared. The upside down forks and the single sided swing arm made it stand out. I think it still looks good now Smile
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Tim..
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PostPosted: 21:53 - 25 Mar 2014    Post subject: Reply with quote

Following Thumbs Up
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j.silvs
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PostPosted: 15:35 - 26 Mar 2014    Post subject: Reply with quote

Following

At least you know the history of the bike from when it was new!
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Phil_B
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PostPosted: 22:47 - 26 Mar 2014    Post subject: Reply with quote

Started to strip the forks, found a stripped thread in the drain hole, will have to get that sorted at work!

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262266_zps41216023.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262267_zps1a0a5472.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262268_zpse7c86f7e.jpg
https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262269_zps9c037bc1.jpg


https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262270_zps84d8bd52.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262273_zps1c88f4e2.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262274_zpsb21e4ad2.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262275_zpsedeadf1b.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262278_zps32a54112.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262279_zps0864fce8.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262280_zps3906cc5a.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262281_zps8179b8d0.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262282_zps72a56cc8.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262283_zpscd1581fe.jpg

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P3262284_zps1f1069c5.jpg

Still got the other fork to strip, then I'll be repainting the bottom castings, fitting new seals, scraper, and I've also got some protectors to go over the chrome.
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This restoration is ruining my bank balance! Restoration project - 1991 Aprilia AF1 Replica
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_mjs_
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PostPosted: 04:58 - 27 Mar 2014    Post subject: Reply with quote

Just seen this for the first time, amazed at the difference a bit of powdercoat has made to those bits Shocked
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Phil_B
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PostPosted: 09:22 - 28 Mar 2014    Post subject: Reply with quote

Parts arrived from Germany, great, fast service Smile

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Rebuild/image_zpsb548baf5.jpg
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Kickstart
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PostPosted: 18:28 - 28 Mar 2014    Post subject: Reply with quote

Hi

Who was the supplier in Germany?

All the best

Keith
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mintex
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PostPosted: 19:55 - 28 Mar 2014    Post subject: Reply with quote

Kickstart wrote:
Hi

Who was the supplier in Germany?

All the best

Keith


+1 please tell lol Very Happy
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Phil_B
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PostPosted: 20:02 - 28 Mar 2014    Post subject: Reply with quote

I got the parts from here....

https://www.centroricambi.de/index.html

You'll have to translate the site as its in German, Google Chrome does a good job of most of it. He has spares for the AF1s and RS, not all the parts you may need are available, not sure if its Aprilias old stock or he still gets stuff made. As I don't have much experience with bike parts I don't know how it rates price wise, I was just thankful I could find the last few bits I needed.

You can pretty much work out what you need from the assembly drawings on the pages, worth a look if you're stuck for anything Very Happy
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Kickstart
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PostPosted: 20:28 - 28 Mar 2014    Post subject: Reply with quote

Hi

If you know the part numbers (I have the part lists here) then some are still supplied by Aprilia. Can find some here:-

https://www.apriliagenuineparts.co.uk/

although never ordered from them so don't know how good they are.

All the best

Keith
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BenR
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PostPosted: 12:52 - 05 Apr 2014    Post subject: Reply with quote

Any updates?.......c'mon chop chop you slacker. Laughing
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Phil_B
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PostPosted: 17:06 - 05 Apr 2014    Post subject: Reply with quote

Laughing The only update is I've fixed the stripped thread in my fork leg. Not had much spare time due to studying for my Divemaster exam. I'm dropping the crank, engine cases and barrel off at PJME on Wednesday. All the work should hopefully be done for when I get back from my holiday, then I can get the engine rebuilt.

It's slow going due to lack of time, but I'm not in any rush. I want to get it looking the best I can when it's finished Smile
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Phil_B
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PostPosted: 20:40 - 08 Apr 2014    Post subject: Reply with quote

Stripped the other fork and found an odd part inside, the one on the left is from the first fork, the one on the right from the second. I can only guess that in a previous strip the owner lost the original metal part, and thought it would be ok to replace it with a cut piece of plastic from something….the things people will do! Looks like I will have to strip my original forks to replace the bodged bit.

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Stripdown/P4082286_zps5481eda6.jpg

All the cases, crankshaft and barrel packed ready to drop off at PJME tomorrow.

https://i1344.photobucket.com/albums/p655/Aprilia_AF1_Replica_Rebuild/Aprilia%20AF1%20Replica%20Rebuild/P4082285_zps2edeb32c.jpg
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Shreeve
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PostPosted: 22:09 - 08 Apr 2014    Post subject: Reply with quote

Love picture heavy restorations!

I agree with the comment about a little powder coating making it look amazing Smile
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