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  4. The Helios Project (Aprilia RS 125 Rotax 122 Biaggi Race Replica)

The Helios Project (Aprilia RS 125 Rotax 122 Biaggi Race Replica)

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  • CalumC Offline
    CalumC Offline
    Calum
    wrote on last edited by
    #76

    Everyone I asked about whether I should or should not, said should NOT!

    Are they mental...

    What's in the box!

    alt text

    Bare in mind, I only want a few components out of this box that are no bigger than a hammer lol!

    alt text

    Any ideas?

    If you guessed a kickstart, then you guess correctly!

    alt text

    And I know what you are thinking. Why?

    Well appreciate this, this bike ain't an everyday bike, chances are, when I do eventually come to ride it, the battery is going to be flat and I'll have to bump it. Which, no I ain't doing.

    Plus, it's totally bad ass crosser stylie yo!

    On a serious note though, £600 for the kickstart from Aprilia. I kid you not, it's genuinely cheaper to buy a whole engine (if you can find one) just to salvage the kickstart out of it.

    This would be my third Rotax 122 engine for this single project. That's, uhhmm, expensive.

    I am going to strip this engine, salvage some of the components, sell the rest.

    I want to go all out on a special conversion (for no other reason than because it will be cool) on this bike.

    And I'll give you a clue, having a spare engine is going to be useful.

    I will gut the cases and leave what I want to modify in place. And hopefully have something to document.

    Eventually I will rebuild the cases and store in case of the inevitable happens.

    This engine comes out of an Aprilia MX125, ETX125 or RX125. But all of which are really hard to source and expensive when you do. That said, I've got this now, and it's blown the budget for this month, which is a shame. But such is life.

    Always Originate, Never Pirate!

    Irongamer727I 1 Reply Last reply
    1
    • CalumC Calum

      Everyone I asked about whether I should or should not, said should NOT!

      Are they mental...

      What's in the box!

      alt text

      Bare in mind, I only want a few components out of this box that are no bigger than a hammer lol!

      alt text

      Any ideas?

      If you guessed a kickstart, then you guess correctly!

      alt text

      And I know what you are thinking. Why?

      Well appreciate this, this bike ain't an everyday bike, chances are, when I do eventually come to ride it, the battery is going to be flat and I'll have to bump it. Which, no I ain't doing.

      Plus, it's totally bad ass crosser stylie yo!

      On a serious note though, £600 for the kickstart from Aprilia. I kid you not, it's genuinely cheaper to buy a whole engine (if you can find one) just to salvage the kickstart out of it.

      This would be my third Rotax 122 engine for this single project. That's, uhhmm, expensive.

      I am going to strip this engine, salvage some of the components, sell the rest.

      I want to go all out on a special conversion (for no other reason than because it will be cool) on this bike.

      And I'll give you a clue, having a spare engine is going to be useful.

      I will gut the cases and leave what I want to modify in place. And hopefully have something to document.

      Eventually I will rebuild the cases and store in case of the inevitable happens.

      This engine comes out of an Aprilia MX125, ETX125 or RX125. But all of which are really hard to source and expensive when you do. That said, I've got this now, and it's blown the budget for this month, which is a shame. But such is life.

      Irongamer727I Offline
      Irongamer727I Offline
      Irongamer727
      wrote on last edited by
      #77

      And I'm worrying about spending £70 on a full kickstart conversion for my dt... Guess your pocket is a bit bigger than mine though😉

      CalumC 1 Reply Last reply
      1
      • Irongamer727I Irongamer727

        And I'm worrying about spending £70 on a full kickstart conversion for my dt... Guess your pocket is a bit bigger than mine though😉

        CalumC Offline
        CalumC Offline
        Calum
        wrote on last edited by
        #78

        @irongamer727 I did say it was cheaper to buy a whole engine just for the kickstart than the kickstart itself.

        Whilst this did cost more than £70, it didn't cost £600. But I was prepared to pay that for it.

        I will strip the engine tomorrow and finish off my current build.

        You understand though, you need a kickstart on a two stroke.

        Always Originate, Never Pirate!

        declanD 1 Reply Last reply
        0
        • CalumC Calum

          @irongamer727 I did say it was cheaper to buy a whole engine just for the kickstart than the kickstart itself.

          Whilst this did cost more than £70, it didn't cost £600. But I was prepared to pay that for it.

          I will strip the engine tomorrow and finish off my current build.

          You understand though, you need a kickstart on a two stroke.

          declanD Offline
          declanD Offline
          declan
          wrote on last edited by
          #79

          @calum your telling me a kick start is over 600 pound 🤯

          CalumC 1 Reply Last reply
          0
          • declanD declan

            @calum your telling me a kick start is over 600 pound 🤯

            CalumC Offline
            CalumC Offline
            Calum
            wrote on last edited by
            #80

            @declan New from Aprilia yeah. They only did them for the Sports Production series. The series they used in the SuperTeen MotoGP. So they were a highly specialised order!

            Always Originate, Never Pirate!

            CalumC 1 Reply Last reply
            0
            • CalumC Calum

              @declan New from Aprilia yeah. They only did them for the Sports Production series. The series they used in the SuperTeen MotoGP. So they were a highly specialised order!

              CalumC Offline
              CalumC Offline
              Calum
              wrote on last edited by Calum
              #81

              LOL at this engine. It was sold to me as :

              Came from a Sx in good condition just had new piston con rod main bearings been running for about 5 mind what you see is what you get

              It was also listed as a Rotex engine, not what it should be as Rotax.

              So I can't say I am really surprised. Item was well wrapped and delivered within 48 hours and I got what I actually wanted. But check out the rebuild on this engine.

              Firstly the head is absolutely ruined, straight in the bin this went.

              alt text

              Secondly the bore is totalled, but it's an aftermarket Mitaka one so runs a steel liner, meaning it can be rebored so isn't totally scrap. But definitely affects my resale value 😞 Was hoping to claw back a few sheets on this engine to pay for the conversion.

              alt text

              I didn't get a photo, but the crank journals have a nasty score in them which I would want to fix. Shame. The crank looks okay, although given the damage done to the rest of the engine, I would have it rebuilt.

              And the little end, which was probably what caused the fault in the first place.

              alt text

              Prepped the cases to shot blast next weekend.

              alt text

              I'm going to use this engine as a base to fabricate up the part I want. It's gutted other than the bearings, purely has a means to protect the journals. But in time I will rebuild this engine and leave it as a spare.

              Now back to my engine 😄

              alt text

              As you can see, it's now dual wielding both the Starter motor and the kick start mechanism, which is nice.

              Just missing a titanium bolt that secures the kicker in place, I shall get that ordered.

              Engine has been timed up and all new gears installed.

              Just waiting on PJME to get new clutches in and then hopefully sort the top end out next month. Got some tasty ideas for the top end.

              Always Originate, Never Pirate!

              declanD 1 Reply Last reply
              0
              • CalumC Calum

                LOL at this engine. It was sold to me as :

                Came from a Sx in good condition just had new piston con rod main bearings been running for about 5 mind what you see is what you get

                It was also listed as a Rotex engine, not what it should be as Rotax.

                So I can't say I am really surprised. Item was well wrapped and delivered within 48 hours and I got what I actually wanted. But check out the rebuild on this engine.

                Firstly the head is absolutely ruined, straight in the bin this went.

                alt text

                Secondly the bore is totalled, but it's an aftermarket Mitaka one so runs a steel liner, meaning it can be rebored so isn't totally scrap. But definitely affects my resale value 😞 Was hoping to claw back a few sheets on this engine to pay for the conversion.

                alt text

                I didn't get a photo, but the crank journals have a nasty score in them which I would want to fix. Shame. The crank looks okay, although given the damage done to the rest of the engine, I would have it rebuilt.

                And the little end, which was probably what caused the fault in the first place.

                alt text

                Prepped the cases to shot blast next weekend.

                alt text

                I'm going to use this engine as a base to fabricate up the part I want. It's gutted other than the bearings, purely has a means to protect the journals. But in time I will rebuild this engine and leave it as a spare.

                Now back to my engine 😄

                alt text

                As you can see, it's now dual wielding both the Starter motor and the kick start mechanism, which is nice.

                Just missing a titanium bolt that secures the kicker in place, I shall get that ordered.

                Engine has been timed up and all new gears installed.

                Just waiting on PJME to get new clutches in and then hopefully sort the top end out next month. Got some tasty ideas for the top end.

                declanD Offline
                declanD Offline
                declan
                wrote on last edited by
                #82

                @calum don’t know what your on about mate looks ready to race to me 😉 what did the piston look like

                CalumC 1 Reply Last reply
                0
                • declanD declan

                  @calum don’t know what your on about mate looks ready to race to me 😉 what did the piston look like

                  CalumC Offline
                  CalumC Offline
                  Calum
                  wrote on last edited by
                  #83

                  @declan Piston wasn't too bad. Could have used that. But I threw it in the bin. Wasn't even forged.

                  Always Originate, Never Pirate!

                  declanD 1 Reply Last reply
                  0
                  • CalumC Calum

                    @declan Piston wasn't too bad. Could have used that. But I threw it in the bin. Wasn't even forged.

                    declanD Offline
                    declanD Offline
                    declan
                    wrote on last edited by
                    #84

                    @calum so maybe a stupid question but was it rebuilt badly or not rebuilt at all

                    CalumC 1 Reply Last reply
                    0
                    • declanD declan

                      @calum so maybe a stupid question but was it rebuilt badly or not rebuilt at all

                      CalumC Offline
                      CalumC Offline
                      Calum
                      wrote on last edited by
                      #85

                      @declan Nah man I don't think it's a stupid question.

                      So it's been stripped before.

                      There was a rusty bolt on the inside of the engine. That suggests that they just used a bolt that would normally be outside the engine on the inside. Since it was an OEM bolt.

                      Also, the crank is really solid.

                      I reckon, someone who didn't know what they were doing, rebuilt it poorly. Started it up. heard a horrendous noise, and then gave up on the idea after sinking too much money on it.

                      The barrel doesn't look to have been rebored. So it was likely a new barrel at the time. The piston wasn't the highest quality, but it was a decent piston.

                      I doubt the mains were changed, and they clearly didn't bother with the gearbox bearings. I reckon the minimal amount was done. But once it still didn't run right, they gave up on the idea.

                      It's funny though.

                      As I say, the cases are handy for my next project I'll be doing on this bike.

                      And all I really wanted was the kickstart. I've managed to sell some of the bits I've stripped from it on eBay. So that's some way of clawing the money back out of it.

                      Always Originate, Never Pirate!

                      declanD 1 Reply Last reply
                      0
                      • CalumC Calum

                        @declan Nah man I don't think it's a stupid question.

                        So it's been stripped before.

                        There was a rusty bolt on the inside of the engine. That suggests that they just used a bolt that would normally be outside the engine on the inside. Since it was an OEM bolt.

                        Also, the crank is really solid.

                        I reckon, someone who didn't know what they were doing, rebuilt it poorly. Started it up. heard a horrendous noise, and then gave up on the idea after sinking too much money on it.

                        The barrel doesn't look to have been rebored. So it was likely a new barrel at the time. The piston wasn't the highest quality, but it was a decent piston.

                        I doubt the mains were changed, and they clearly didn't bother with the gearbox bearings. I reckon the minimal amount was done. But once it still didn't run right, they gave up on the idea.

                        It's funny though.

                        As I say, the cases are handy for my next project I'll be doing on this bike.

                        And all I really wanted was the kickstart. I've managed to sell some of the bits I've stripped from it on eBay. So that's some way of clawing the money back out of it.

                        declanD Offline
                        declanD Offline
                        declan
                        wrote on last edited by declan
                        #86

                        @calum sold bits already? Well it’s a good thing You didn’t want the engine as a whole isn’t it

                        CalumC 1 Reply Last reply
                        0
                        • declanD declan

                          @calum sold bits already? Well it’s a good thing You didn’t want the engine as a whole isn’t it

                          CalumC Offline
                          CalumC Offline
                          Calum
                          wrote on last edited by
                          #87

                          @declan Literally just wanted the idle gear and the kickstart mate. The rest I already have.

                          But for this tasty little conversion I am going to do, it would be nice to have a pair of crankcases to hand 😉

                          I ain't saying no more than that, you will see the results when I finish.

                          Always Originate, Never Pirate!

                          1 Reply Last reply
                          0
                          • CalumC Offline
                            CalumC Offline
                            Calum
                            wrote on last edited by
                            #88

                            Updates are coming...

                            But who can guess what custom modifications I will be doing on my RS?

                            alt text

                            I won't take credit for the idea. I always wanted to do it on my DT, but just couldn't justify the price.

                            I then found a thread detailing a certain other bike made by Honda, whom did the exact conversion on these engines.

                            HM CRE 125 if you're wondering. Looks awesomse, same engine as these RS's, except they ran electronic oil inject for 50% less oil consumption. Amongst other mods.

                            But after not being able to find the parts I wanted, I gave up.

                            Then I found this build thread on a certain other website, and mans was like...yes I'm doing that.

                            Always Originate, Never Pirate!

                            F NINJAN 2 Replies Last reply
                            1
                            • CalumC Calum

                              Updates are coming...

                              But who can guess what custom modifications I will be doing on my RS?

                              alt text

                              I won't take credit for the idea. I always wanted to do it on my DT, but just couldn't justify the price.

                              I then found a thread detailing a certain other bike made by Honda, whom did the exact conversion on these engines.

                              HM CRE 125 if you're wondering. Looks awesomse, same engine as these RS's, except they ran electronic oil inject for 50% less oil consumption. Amongst other mods.

                              But after not being able to find the parts I wanted, I gave up.

                              Then I found this build thread on a certain other website, and mans was like...yes I'm doing that.

                              F Offline
                              F Offline
                              finnerz89
                              wrote on last edited by
                              #89

                              @calum hydraulic clutch?

                              Current bikes:
                              DT125X '07
                              Street Triple R '11
                              Aprilia ETV1000 '02

                              Previous:
                              DR650RSE '96
                              FJ1200 '92

                              CalumC 1 Reply Last reply
                              1
                              • F finnerz89

                                @calum hydraulic clutch?

                                CalumC Offline
                                CalumC Offline
                                Calum
                                wrote on last edited by
                                #90

                                @finnerz89 Spot on mate. How did you know?

                                Always Originate, Never Pirate!

                                declanD F 2 Replies Last reply
                                0
                                • CalumC Calum

                                  @finnerz89 Spot on mate. How did you know?

                                  declanD Offline
                                  declanD Offline
                                  declan
                                  wrote on last edited by
                                  #91

                                  @calum damn give me a chance lol

                                  1 Reply Last reply
                                  0
                                  • CalumC Offline
                                    CalumC Offline
                                    Calum
                                    wrote on last edited by
                                    #92

                                    Front Mud Guards Arrived

                                    alt text
                                    alt text

                                    I look forward to fitting that this weekend 😄

                                    Always Originate, Never Pirate!

                                    declanD NINJAN 2 Replies Last reply
                                    0
                                    • CalumC Calum

                                      Front Mud Guards Arrived

                                      alt text
                                      alt text

                                      I look forward to fitting that this weekend 😄

                                      declanD Offline
                                      declanD Offline
                                      declan
                                      wrote on last edited by
                                      #93

                                      @calum that looks slick how’s the engine coming along?

                                      CalumC 1 Reply Last reply
                                      0
                                      • declanD declan

                                        @calum that looks slick how’s the engine coming along?

                                        CalumC Offline
                                        CalumC Offline
                                        Calum
                                        wrote on last edited by
                                        #94

                                        @declan Should have some updates later in the week.

                                        Always Originate, Never Pirate!

                                        1 Reply Last reply
                                        0
                                        • CalumC Calum

                                          @finnerz89 Spot on mate. How did you know?

                                          F Offline
                                          F Offline
                                          finnerz89
                                          wrote on last edited by
                                          #95

                                          @calum I've had 2 bikes with hydraulic clutches, recognised the cylinder lol

                                          Current bikes:
                                          DT125X '07
                                          Street Triple R '11
                                          Aprilia ETV1000 '02

                                          Previous:
                                          DR650RSE '96
                                          FJ1200 '92

                                          1 Reply Last reply
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