XL 125 rc Restoration

[killerbanjo]

So a mate of mine bought an engine from me a while ago that he buggered some how and he never paid for it. So the deal I got was the scrap engine back (Not sure what is wrong with it yet, but that is for another post) and this Xl 125. Whats ideal is if I can get this 200cc engine running again, it will fit the XL! Anyhow here is some pics. All that has done is the frame swing-arm the break hubs and rebuilt the engine (it was in bits). I still need to pickup the fairings, seat, fuel tank and some other bits and pieces then ill get the train rolling.

I have wanted a trail bike for so long and my poor cg125 could do with being treated more fairly , so I'm really exited to get this thing on the road!

Rolling Frame:
https://i.imgur.com/Qa5CYTM.jpg

Engine:
https://i.imgur.com/pOFIxWL.jpg

Loom and some other bits:
https://i.imgur.com/n0OdUBr.jpg

De-greased bolts and bits:
https://i.imgur.com/xdHzgTN.jpg


And a quick question. Anyone know the part number or name of this part of the chain adjustment system? Its the part under the snail adjuster!
https://i.imgur.com/W4gYWBr.jpg



Anyone fancies sending me some parts feel free to PM me as there is only about 73 left on the road in the UK according to https://www.howmanyleft.co.uk/vehicle/honda_xl125rc

[Suntan Sid]

Dunno what it's called, but it's a spacer to keep the snail cam aligned!
I can get you the dimensions if you're prepared to wait, my RC is packed away at the moment.

There is no microfiche, on csmnl, for an RC, I think the Xl 200R has some of the part numbers you need!
David Silver has spares for an RC as do Wemoto!
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"Everybody needs money, that's why they call it money!"

[killerbanjo]

Found the problem with the 200 engine and its a dead easy fix! With that deal I pretty much just got a free xl 125 haha. One of the pushrods had fallen down into the crank case, and the valve clearance was so large on the other valve with the pushrod in I can see how! the pushrod has almost no damage to it and the piston and valves are fine, everything moves as it should now, and I just need some gaskets! XL 200 here we come (Ill post some pictures later)

EDIT: STRIKE THAT ALL OUT! Problem is still here. The kickstart is just NOT disengaging. Ill have to split the cases to find the problem, but the monkey who had this engine (who calls himself a mechanic) rounded off the flywheel bolt, even though I used an impact driver and a 6 sided socket, it has now rounded off even more... Ill post the pictures after work and maybe someone can give me some suggestions

[tomh]

Not sure if it's the same but I split a cg 125 bottom end without removing the flywheel as I didn't want to buy the tool. Just undo the centifrugal filter and clutch and that will be enough to pull the cases apart once removing all the bolts.

I even got away with leaving the oil pump on. Hope that is some help.

[killerbanjo]

Thanks man, I have a CG 125 and this is a CG clone engine, however I have never split the cases on my CG as I have never had to! Anyone know where to get a crankcase splitter cheap? I have used my fathers in the past but me and him certainly don't get on now!

Here is some pictures of the engine . The top end is perfect and looks brand new (that's because its had less than 25 miles on it)

https://i.imgur.com/BFEKy5t.jpg
https://i.imgur.com/JuuLk1G.jpg


And the carb he bought for it, said it was well jetted for the engine, but we will wait and see about that...

https://i.imgur.com/qaj3XaF.jpg

(Pics getting stretched in portrate mode so ill just link them.

[Nexus Icon]

That engine is massive!

Keep us posted with the resto. I love old trailies.
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Greetings from Shitsville!

[killerbanjo]

Ok, just ordered some VHT Epoxy paint, its £14 a can but I heard the stuff is bloody marvelous. Also ordered a Laser 4882 Crankcase Splitter, Cheapest I could find it was about £60, I hope its ok! Also a new set of tyre levers (3 this time) as whenever I use just two I seem to bend one of them!

[killerbanjo]

Ok then, today was fork day so I took them apart. Never realized how bad the chrome was on the tubes, anyone know how much it costs to get them re-chromed?

https://i.imgur.com/d9QwJVe.jpg


Just look at the shit around the seals!

https://i.imgur.com/LyrU5fw.jpg

Here is the lovely oil out of it...

https://i.imgur.com/qztH1rH.jpg


Only done one of the lowers down to alloy as it takes so damn long, ill do the other tomorrow I guess.

https://i.imgur.com/LrrnGmL.jpg


And here is that god flipping damn flywheel nut, it has been so rounded that I really don't know what to do, I'm praying to god the case will split without removable. Why would you put a puny 13mm bolt on a flywheel anyway!? (Click me)

[YBR Ric]

A hex socket (not a bi-hex) should shift that flywheel nut after removal of the burrs, without causing any further damage to it.

[killerbanjo]

Thanks Rick, I filed it down but a 13 was so lose on it that I hammered on a 12 and got the little shit off! The 3 allen bolts took a god damn beating with the impact driver but finally came off too. Now got to find a bolt the size of the outer hole to pop it off.

https://i.imgur.com/8pxXZ44.jpg


In other news, my tyre levers came and check out the condition of the rims

https://i.imgur.com/9CZzHCO.jpg

Got to go work in a couple hours and still waiting on my crankcase splitter... Ordered on the 17th, paid £6 for 24 hour delivery and 3 days later still ****ing waiting. Doing my head in...

[killerbanjo]

So I managed to get the cases split before work! Because the engine is so new the case split so easily, in fact I completely split it just turning the bolt with my hand haha! Anyway here she is with the kickstart removed, tidy little engine.

https://i.imgur.com/koKE8gA.jpg

And here is the cheeky little shit on the right hand case that thinks its allowed to fail! Ill get the little bugger out tomorrow, order a new one along with some circlips for the kickstart mechanism that I took apart just to make sure it was a-ok.

https://i.imgur.com/MUvXNrP.jpg

More tomorrow!

[killerbanjo]

Well I just can't shift the outer race of the bearing. Ill have to buy some pullers... I have spent over £100 in tools in the past 4-5 days and there more to buy yet lol! I have used a blowtorch, and oven as well as a homemade puller. Both the wheels are scrap so a really frustrating and shitty day to be honest... Anyone even reading these? Could sure do with some tips.

[killerbanjo]

A resonable day. Forks have been primed

https://i.imgur.com/s6r72Gm.jpg


Painted, and rebuilt!

https://i.imgur.com/qGRJmc7.jpg


Cleaned up the seat a little, but going to look for some sort of black polish, I think you can get it for car dashes and such...

https://i.imgur.com/Hutru7Z.jpg


And started on the fuel tank, the paint job on the fuel tank, frame and swing arm are just so god damn shit. It has been brush painted with caliper paint... and the monkey calls himself a mechanic

https://i.imgur.com/MewT53M.jpg

[killerbanjo]

OK! The fuel tank is painted

https://i.imgur.com/8XfXzjt.jpg


So is the swingarm

https://i.imgur.com/E73k8KN.jpg


And I started on the frame but stupid me didn't have enough paint - I swore I had 2 cans left not 1... Btw yolks are on to balance the frame. Ill do the on their own so don't worry!

https://i.imgur.com/wkoIWrV.jpg


And this super sexy stainless Micron exhaust came...

https://i.imgur.com/0DzjzY6.jpg


That's it for today folks!

[killerbanjo]

As it stands right now. Its starting to look like a bike again eh?

https://i.imgur.com/UOjroFL.jpg

( Have not had a shower so look a little skanky )

[gavcarter]

[killerbanjo]

Woah is that an engine?!

https://i.imgur.com/LRIwkpR.jpg


Yes its all back together... Turns out the kickstart pinion gear had seized and I had not noticed... No discolouration or signs to give away that it was not how it should. I bought a cg 125 kickstart and that fitted right in.

Need to buy or make a loom. Never made one before so I'm not sure how it would turn out. Any one got any suggestions?

[Boxing]

Nice project.

It'll probably be a lot easier to buy a loom in a good condition. And get the CDI etc.

Could give your own wiring a whirl if you're just wiring it to the CDI etc and not planning on putting an ignition or lights in.

[killerbanjo]

Heres how its looking. Chain is on, I filled a small hole in the tank that leaked... Waiting on tank rubbers from Davesilvers. Ordered an "atv pitbike etc" loom off of ebay. It included the works for £50 apart from the lighting wiring but included reg and cdi etc. New clutch and throttle cable on the way. Thats the wrong one in there right now just to test it. Going to get a new throttle body and grips and some stubby levers too. Need headlight and ears but that can wait until payday.

https://i.imgur.com/EtAdING.jpg

https://i.imgur.com/VxhOO5B.jpg

[Suntan Sid]

[Howling TerrorOutOfOffice]

Yep.

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[killerbanjo]

[Suntan Sid]

Cool!
I'll keep my eye out, need a better exhaust for mine.
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"Everybody needs money, that's why they call it money!"

[Bunny Lingus]

I want that bike! Nice work & cool pics. As soon as I saw that bearing I thought gonna be a right pain getting that sucker out...
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Bunny Lingus & The Flipside Faggots

[killerbanjo]