Rieju RS1 Project

J.M. · World Chat Champion Joined: 27 Mar 2011 Karma :

Jesus Christ. I absolutely admire everything you've done to this bike, but you don't half seem to have some shit luck! Laughing

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2004 R1 & 2018 XSR900

Just_James · Could Be A Chat Bot Joined: 29 Aug 2014 Karma :

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

You'll have this sorted out and run in on the big bore motor soon enough! It's a stunning big bore sports 50, and you will have mucho fun with it when you get time to play.

I'm having time issue's myself atm, had a list of reasons why I could not take the KMX to the dyno for weeks, but I need to get a move on. I need to start my tuning thread, which i don't want to do without dyno graphs and pics.

I need to have a base line run, then a set up and 2nd run with the intake mods done, and then one for the new exhaust and the secret extra mod which should be happening in November?

I'm not letting anything stop me going to the dirtbike show, even if my KMX is in bits, as seeing some spunky new off roaders is my top priority! Laughing

UncleFester · World Chat Champion Joined: 30 Jun 2013 Karma :

Resevoir was clearly old and brittle, smashing a hole in it there saves you doing it on the road somewhere - every cloud and all that Smile

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Module 1 and 2 passed - October 2014. Happy owner of a 2017 Z1000SX, ex owner of a YBR125 / CB500 / VFR800.

Just_James · Could Be A Chat Bot Joined: 29 Aug 2014 Karma :

Just_James · Could Be A Chat Bot Joined: 29 Aug 2014 Karma :

Sorted a new reservoir in the week and today should have been painting the front mudguard... but I've been itching to try and bodge an end can together from my old Mito one so today did do some bodgineering! Very Happy

The old Mito can

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1762_zpsugxll1sy.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1763_zpsqwbzmkjr.jpg

Started by knocking out the old studs from the flange

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1768_zps7llmwe8z.jpg

Then hacked the the end off the pipe

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1769_zps6keo7hus.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1770_zpsvlvyfzqb.jpg

Obviously the mount is completely different to what I need, the Mito has 4 bolts and the RS1 only has 2 which are much closer together. So next marked out where I will need the bolts / studs

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1771_zpsgxxdeikp.jpg

It's gonna be tight! Shocked

Drilled the holes as best I could then had to file them out to bring them right up to the pipe

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1774_zpsitgf8ii3.jpg

Obviously no room for a bolt head to fit in there so hacked down a bolt to make a couple of studs

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1775_zpszfbvo1az.jpg

Hacked 130mm off the perforated pipe

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1773_zpsvfpu8cce.jpg

Then cleaned up ready for welding

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1777_zps1lvwok69.jpg

I still don't own a welder (probably just as well) so nipped round to my mates where we did play at welding Embarassed

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1778_zpsr6jdc4ka.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1779_zpschj2ljdh.jpg

Not pretty, but functional! Laughing

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1780_zpspoje5oq2.jpg

Next thing to address was the end cap, it's a right mess! It's got the road rash wound, the old 4 holes and my complete balls up of drilling out the holes for the new studs! Embarassed

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1784_zpskqrifhpq.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1783_zps4rrnwfil.jpg

Thinking of the a way to sort it I decide I need a steel disc of similar diameter to plate over it with

If I hang on until tomorrow my mate can make me one up... but I'm impatient and want to get this done so get a bit of steel and screw it to my multi-function length of 3x2...

Then just went full redneck medieval style on its ass with the grinder! Twisted Evil

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1781_zpsgbpkvae8.jpg

... and made... a shape Laughing

A little grinding, filing and sanding in the vice and it was nearer something I'd consider a circle. Far from mint but fuck it, you'd have to lie under the bike too see it anyway

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1782_zpso0nahbuw.jpg

Next, I cleaned up and scratched up the end cap

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1785_zpsnsa3thze.jpg

I then drilled the new holes in the disc, sandwiched some chemical metal between that and the end cap and built up the damaged area on the side.

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1788_zps5yn5thld.jpg

Sanded the edges in then painted black

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1790_zpsrx4umoag.jpg

Now need to cut the main body down to size, there was damage at both ends so had to make 2 cuts to get the middle section which is in mostly sound condition

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1786_zpsvgcvvsso.jpg

Coming together now

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1795_zpscnslfff5.jpg

Then wrapped some steel wool

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1789_zpsv5s6fubk.jpg

Then built back up and fitted

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1791_zpsqd48wcl1.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1792_zpsacmwxptf.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1793_zpsp3ogtbkq.jpg

Well happy with that Thumbs Up

As for how it sounds... I'll find out in the morning but am expecting as shite as before but louder Laughing

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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125

Fladdem · World Chat Champion Joined: 29 Jun 2011 Karma :

I'm drunk and can't get my docs off, but keep up the good work Mr James

Thank God for autospell!
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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.

Nexus Icon · World Chat Champion Joined: 26 Aug 2010 Karma :

Whatever it sounds like, it looks the mutt's nuts. Nice work.
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Greetings from Shitsville!

Just_James · Could Be A Chat Bot Joined: 29 Aug 2014 Karma :

Fladdem · World Chat Champion Joined: 29 Jun 2011 Karma :

Oh Christ, I don't know why I felt the need to share that with you. It's my favourite thing to do, look at bike projects while intoxicated. Laughing

It sounds really cool actually, I think it looks great with the shorter can on it as well. You just made me realise, again, how slow I am to do my projects. Stop it! Wink

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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.

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

Nothing wrong with looking at bike projects on interweb when your pissed, as long as your not sat next to a middle age bloke in the pub at the time, talking about going down muddy back lanes, with his hand on your leg. Wink

I like the shorty Mito can on the RS1, it's a cool touch indeed!
The sound is just fine too, so another nice update/mod from OP there.

As for the KMX tuning thread, well fuck knows now. Dyno was supposed to be happening last Thursday, but my battery pissed out all it's electrolyte solution and is dead. I flounced and said no fucking way am I having another non sealed for life battery, the fucking shit Yuasa bollocks! Laughing

I sulked and then ordered a Motobatt Gel item which is 4.8Ah instead of 4Ah, so I see it as an upgrade and that cheered me up a bit lol!

I've had another weekend of doing stuff for other people, and I'm starting to think my KMX OEM+ project will never get finished now. I think it needs someone else on here to take it on and finish the development and get everything finished properly and documented in a decent thread too.

I've got too many unfinished projects and a shed to make comfy. I think the shed on its own with no bike will be enough for me now anyway.

Fladdem · World Chat Champion Joined: 29 Jun 2011 Karma :

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

I'm Steve I am coming out and I love my shed! Laughing

I want a workshop as clean and spotless as James has, and also like your MT5 build area must be in your uncluttered clinical garage too! Wink

Just_James · Could Be A Chat Bot Joined: 29 Aug 2014 Karma :

You didn't say tidy workshop Tut Tut

...you said comfy shed Rolling Eyes

Will you be doing a comfy shed thread? Telling us of what scatter cushions and soft furnishings you go for? Laughing

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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

I could probably make the curtains this weekend out of a floral table cloth, and then use some crushed velvet left overs from female clothes if that sounds good? Thumbs Up

I have managed to get a load of foil backed insulation board that was going to waste from a skip this week, so I'll have to settle for that for now though.

Seriously I'm not sure how far to go with making the shed into a proper workshop, it will get a very basic electric supply and a light, but ultimately despite being a useful size, it's not really tall enough to stand up straight in, so would not be that comfy for working in. My foolish mistake when ordering shed really, and now I have to live with it. Anyway I pimped out the garage and I like that more, but with an old nail of a car stuck in there, it's useless to me and seems a waste.

How's the running in the big bore motor going? Are you baiting ped bois yet? Laughing

Just_James · Could Be A Chat Bot Joined: 29 Aug 2014 Karma :

Big bore motor isn't getting run in at all, I haven't ridden it since I broke the mudguard Sad

Just don't have the time at the moment, too busy with other stuff... and it's cold and dark when I come home! Laughing

Can you not just raise your roof... or excavate your floor? Very Happy

Coincidentally, one of the things I'm on with is building a new shed for my Mum. It will be a fairly decent size at 3.4m x 3m (and tall enough to stand up in), I'm going to have shed envy when I'm done with it Mad

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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125

Fladdem · World Chat Champion Joined: 29 Jun 2011 Karma :

A shed for mum, Steve should be interested in mother-sheds. Laughing

Not like us manly men with our proper uncomfortable, dank and dreary man-sheds, eh? Middle Finger

You should bait ped bois, it's fun, I do it with my CRM with 125ers, I sometimes try to blag it's a 125. Laughing

Anyway, I want to dig the MT5 out this winter, I've seen a very nice build going on on here, it's spurring me on.
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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.

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

If it makes you feel better, I've done less than 100miles in 2015 on that bloody KMX. It was MOT'd in May, then the Wilber's shock went on soon after.

After that it sat until last week in the shed, not ridden all through the best of the summer months. My best MTB hasn't even had an outing yet this year which is even worse.

I'm no longer fit to own any two wheeled machinery based on the above behaviour, hence why the comfy pretty shed would be the best option for me. Laughing

Adam, My need to see your MT5 (big cubic inch) immaculate angry beast is greater than your's to see a skinny 125 that wants to be a motard when it grows up! Laughing

I might get all inspired again anyway at the Dirtbike show this weekend! Thumbs Up

Just_James · Could Be A Chat Bot Joined: 29 Aug 2014 Karma :

VFR Vince · Two Stroke Sniffer Joined: 15 May 2015 Karma :

a lot of attention to detail has gone into this and its really paid off. top job! Very Happy

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Bikes dont leak oil, they mark their territory

Robzki · L Plate Warrior Joined: 04 Jan 2016 Karma :

Great read, thank you. Any updates? 😃

Just_James · Could Be A Chat Bot Joined: 29 Aug 2014 Karma :

Nothing of an update at all I'm afraid.

Other than tucking it into the corner of the workshop, I haven't touched the bike since my last post Sad

I should have some time (and space in the workshop) freed up within the next few weeks so I can get back on it.

Plan then will be to get it jetted right and respray the front mudguard then get back out and enjoying it again! At that point I can finally make a start on the Mito rebuild too Embarassed

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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125

Fladdem · World Chat Champion Joined: 29 Jun 2011 Karma :

Damn it!!! I got super excited when I saw it had been updated. Embarassed

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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.

Just_James · Could Be A Chat Bot Joined: 29 Aug 2014 Karma :

A little update on this... I've still not touched it! Embarassed

I have been sans missus (mostly NBR) for a while now and so.. although peace, bonus and win... I've had absolutely no time for the bikes Laughing

I sold the NSR a few months ago as I knew there was no way I was going to get around to it anytime soon and needed the storage space for tools / equipment and am now having to consider selling this one Neutral

It's probably done less than 50 miles since I MOTd it last year and I've still not even got around to jetting it properly since the top end rebuild or respraying the front mudguard.

Storage space is a real issue now and I'm not going to have room for more than one bike for the foreseeable.... so it's either let this one go and do the Mito build or sell the Mito for parts and run this.

I have considered dropping the fluids and keeping it in the house (largely as a 'cause I can' statement Laughing

) but it's just not mint enough to be on display so I think it's gonna have to go.

I will respray the front mudguard and get it jetted best I can before putting it up for sale but it's a very difficult one to value Confused

I'm thinking offers around £1500? That would give me a nice budget for the Mito and give me the room to do it... still a tough call to let it go though Confused

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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125

ride_to_die · Crazy Courier Joined: 13 Nov 2005 Karma :

It's a shame you have to get rid as it was a good project and a keeper I would've thought.

When I saw the thread had been updated after ages I thought you'd bought something else and had been working on that!
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I'm not here for a long time, I'm here for a good time.