Winter Project - 1999 Aprilia RS125 restoration

[HIGHSIDER]

If it's only rust, and there's little wear, get a wire brush similar to the photo and give a good dressing down with a mini grinder, easy does it, don't get the spiral twist type wire brush head, it's too aggressive and can shape the disc, all you want here is to remove the rust scale and bring it back to life as it were..


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When you've that done, wrap the disc in brown paper and seal it from any moisture that can settle and make the rust appear again, the wire brushing has exposed the disc surface, try and protect this if it's not going back into the caliper straight away, wrap it up and only take it out when you're ready to fit back on the bike..
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[kevin-46]

Originally Posted by HIGHSIDER

If it's only rust, and there's little wear, get a wire brush similar to the photo and give a good dressing down with a mini grinder, easy does it, don't get the spiral twist type wire brush head, it's too aggressive and can shape the disc, all you want here is to remove the rust scale and bring it back to life as it were..


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When you've that done, wrap the disc in brown paper and seal it from any moisture that can settle and make the rust appear again, the wire brushing has exposed the disc surface, try and protect this if it's not going back into the caliper straight away, wrap it up and only take it out when you're ready to fit back on the bike..
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i used one off these as well it turned out well

[2strokelover]

thanks guys, i assume the disc is made of stainless steel and i didnt think it would have rusted that much, anyway i'll give this a try for sure!

I have the engine painted so the rebuild can be started now . . .


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[dobo]

Painted the engine WTF?? Didn't see that one coming
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Great thread - have you got something special in mind for a colour scheme is it?

[2strokelover]

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no its just an anti corrosion measure tbh and i didnt fancy the black!

worth €9.90 imo!


the plans for the bike in general is to keep it as stock as possible, the engine wont be seen
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[Kealan]

haha the red engine looks crazy!!
If you're looking for bearings when your rebuilding it, try CBS (Central Bearing Supplies) theyre beside GRP4, way cheaper than buying bearings labeled as RS125 ones:)

[2strokelover]

thanks kealan!

got them there al ready ! tanx

[2strokelover]

"The engine re-build has officially started. The right hand main bearing is on the crank and in the right hand case along with the shim and seal. First step was to fit the right hand main bearing on the crank which I did by cooling the shaft in the freezer for 1 hour and heating the bearing for about 5 minutes in a tin can with a gas torch. The bearing just slid on with no tipping or tapping. To then fit the crank shaft to the right hand case I again cooled the crank in the freezer for about 90 minutes and heated the crank to 100 degrees C in the kitchen oven - they just fell into place!"

I hope to have the engine complete enough to fit to frame ans swingarm this weekend . . . all going well !


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[Dub Duke]

Love this thread. Keep up the good work and keep posting!

[2strokelover]

thanks DD.

I had a productive evening today, managed to get the gearbox and left hand crankcase assembled. Again to fit the bearings in the crankcase I heated it to 100 degrees and popped the bearings into the freezer for about an hour. In preparation to fit the left hand case complete I cooled the left hand crank with some cooler blocks and compressed air . . . and yep the case just slid down to meet its partner.

I fitted the bolts had tight with a little copper grease on the tips to aid removal at a later stage.

Hoping to put a good few hours in tomorrow to get the engine finished enough to fit to frame and swingarm . . .


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[louis]

Good stuff. great when things go together without having to call in the hammer!

[Touch-me-im-a-dinosaur]

Would love to do this myself but ive always had moneypits to start with lol.
She looks great man!

[2strokelover]

Louis - yea I was a bit worries about fitting the l/h case, luckily it was a doddle.

Touch-me - thanks - the beauty about this build IMO is there is no deadline as its not my primary transport and whatever is needed is small-ish money, a bit here and a bit there sort of thing.

'The hardest part of the engine build is behind me with the crank and crankcase assembly complete. I put in about 4 house in the garage today to get as much done on the engine as possible before it goes back into the frame. The exhaust manifold is soaking in a diesel bath to aid the de-coking, I want to put on the engine before it goes into the frame. I'm going to have to spend a few hours organising the space to make the bike rebuild easier'.


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[My First Suzuki]

That's a class job & a great thread. Keep 'em coming
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[Airmax95]

fair play lad
would love to do something like this but have a clue about bikes mechanically
cant wait to see it finished so hurry the fook up
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[2strokelover]

tanx guys!

Airmax - yall have to wait a while
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its about 9.30 in the evenings when i get to
the garage after a days work and stuff.

have to spend a few hours to clear a proper space
for the rebuild - hope to start that tonight.


all going well

[2strokelover]

'Spent a while this evening cleaning and tidying the working space to start the bike rebuild. I got the engine mounted into the frame, swingarm and rear suspension - all the mounting bolts have yet to be tightened and the originals have been replaced with stainless steel where possible.'


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[kevin-46]

can wait to see it after.... im goin to sort out my zzr i got in bad con ive but about 300 in it so far have to respray it next

[Airmax95]

Originally Posted by 2strokelover

tanx guys!

Airmax - yall have to wait a while
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its about 9.30 in the evenings when i get to
the garage after a days work and stuff.

have to spend a few hours to clear a proper space
for the rebuild - hope to start that tonight.


all going well

just pack in your job and do this full time loike feen
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[2strokelover]

tanx guys -

yea it wouldnt pay the mortgage
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im gonna really enjoy putting this back together now
that the hardest part is over - - - i hope.