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DT125R FORUM

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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 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 ๐Ÿ˜ž 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 ๐Ÿ˜„

    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 donโ€™t know what your on about mate looks ready to race to me ๐Ÿ˜‰ what did the piston look like

    CalumC 1 Reply Last reply
    0
    • declanD declan

      @calum donโ€™t know what your on about mate looks ready to race to me ๐Ÿ˜‰ 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 itโ€™s a good thing You didnโ€™t want the engine as a whole isnโ€™t it

            CalumC 1 Reply Last reply
            0
            • declanD declan

              @calum sold bits already? Well itโ€™s a good thing You didnโ€™t want the engine as a whole isnโ€™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 ๐Ÿ˜‰

              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 ๐Ÿ˜„

                        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 ๐Ÿ˜„

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

                          @calum that looks slick howโ€™s the engine coming along?

                          CalumC 1 Reply Last reply
                          0
                          • declanD declan

                            @calum that looks slick howโ€™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
                              1
                              • CalumC Calum

                                Front Mud Guards Arrived

                                alt text
                                alt text

                                I look forward to fitting that this weekend ๐Ÿ˜„

                                NINJAN Offline
                                NINJAN Offline
                                NINJA
                                wrote on last edited by
                                #96

                                @calum I'm just curious, are the Magura Hydro clutches not compatible???

                                SEDUCED BY THE DARK SIDE!!!

                                CalumC 1 Reply Last reply
                                0
                                • NINJAN NINJA

                                  @calum I'm just curious, are the Magura Hydro clutches not compatible???

                                  CalumC Offline
                                  CalumC Offline
                                  Calum
                                  wrote on last edited by Calum
                                  #97

                                  @ninja They're mega bucks though ain't they.

                                  And probably not.

                                  This is the clutch actuation on these engines

                                  alt text

                                  Always Originate, Never Pirate!

                                  1 Reply Last reply
                                  0
                                  • MiniaM Offline
                                    MiniaM Offline
                                    Minia
                                    wrote on last edited by
                                    #98

                                    This is really looking sweet ๐Ÿ™‚

                                    Yamaha DT125R Blue 2002, XT 125 1982, Yamaha WR250Z 1992, BMW GS650F 1994, Benelli BN302 2015

                                    1 Reply Last reply
                                    0
                                    • 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.

                                      NINJAN Offline
                                      NINJAN Offline
                                      NINJA
                                      wrote on last edited by
                                      #99

                                      @calum The Magura clutches are expensive, but apart from the cheap Chinese ones on ebay, there's not a lot else too choose from. I want one on my MX for-sure, can you post a link to the thread you found detailing the hydro conversion please???

                                      SEDUCED BY THE DARK SIDE!!!

                                      CalumC 1 Reply Last reply
                                      0
                                      • NINJAN NINJA

                                        @calum The Magura clutches are expensive, but apart from the cheap Chinese ones on ebay, there's not a lot else too choose from. I want one on my MX for-sure, can you post a link to the thread you found detailing the hydro conversion please???

                                        CalumC Offline
                                        CalumC Offline
                                        Calum
                                        wrote on last edited by
                                        #100

                                        @ninja You won't like it, lol. It was using PhotoFuckit and all the photos are messed up.

                                        I'll have this one done by the end of the week.

                                        Here is how Honda did it

                                        alt text
                                        alt text

                                        They've used the original clutch actuation for it.

                                        Here is the thread.

                                        http://www.125ccsportsbikes.com/forums/index.php?showtopic=100907

                                        Always Originate, Never Pirate!

                                        NINJAN 1 Reply Last reply
                                        1
                                        • CalumC Calum

                                          @ninja You won't like it, lol. It was using PhotoFuckit and all the photos are messed up.

                                          I'll have this one done by the end of the week.

                                          Here is how Honda did it

                                          alt text
                                          alt text

                                          They've used the original clutch actuation for it.

                                          Here is the thread.

                                          http://www.125ccsportsbikes.com/forums/index.php?showtopic=100907

                                          NINJAN Offline
                                          NINJAN Offline
                                          NINJA
                                          wrote on last edited by
                                          #101

                                          @calum OK Thanks, perhaps if you have the time you could post a tutorial on how to do it and the parts needed etc. please. ๐Ÿ˜‰

                                          SEDUCED BY THE DARK SIDE!!!

                                          CalumC 1 Reply Last reply
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