Stripping Story! RD02

[Pistol_Pete]

Hi there, I have a 1994 RD02. Today I start stripping it for powdercoating and respray. I am going to start a little thread here letting you know any problems and things i pick up along the way, i will add pictures too. It needs to be done my monday to go off for spraying.

If you have any tips, tricks or questions or just general support please go ahead.

The bike is pretty rusty in places and wasnt generally looked after by the last owners so things are too tightly done up, bodged and seem to shear a lot.

Before i start a quick thankyou to Shuriken who has provided me with some great parts and advice in the lead up to this adventure.

As for the respray colours, i am still a little undecided thinking of matt black with light sparkly fleck and gold or going army green and yellow to make it look like a rocket launcher input appreciated!


Thanks

[phil w]

Repsol Honda colours

[tonion]

Hi Pete
good luck with the project
Do you know the Gary at bluehills campsite ? he appears to know his onions about dommies (he and his missus have travelled the world on them) , could be a good contact for you if you get stuck

Mark

[catteeclan]

Best of luck with the project Pete. There's plenty of help here so I wouldn't worry about any probs or mishaps.
Pics most welcome.

David.

[Pistol_Pete]

well the funny thing is gary is my neighbour, but i dont know him, keep meaning to pop up and say hi, and have heard about his travels, funny how there is so many dommies in such a small radius.

OK so yesterday was really succsesful, i got all the parts off no bother which was a surprise, but i rekon dowsin g all the nuts n bolts in 3in1 repeatedly as i was going round helped. The previous owner had an alarm fitted which they had removed but left a mass of cables, which took a lot of routing to figure out what could be removed and in the end turned out to only be attached to the ignition cables. It was nice to get rid of the un derseat clutter.

I am still to remove the engine and forks, swingarm and wheels but the deeper I get the more stright forward it seems which is a bit unsettling, i guess the hard part must be putting it back together!

Time to order some replacment parts, the more i can do when the engine is out the better. I need new exhaust gaskets, cylinder head gasket, 1 exhaust seal that goes in the sleeve between the silencer and the downpipe as it shredded itself on removal. I also would like to replace most of the bolts for new ones, any reccomendations on where to get them and what type to look for for the best non rusting, binding properties??

pics nwill come just had to go to a party last night, feeling rough today but it was worth it!

Having a downloaded copy of the manual is a great help oh and i got the £100 special offer socket set from halfords which is excellent but doesnt contain 6 sided sockets in sizes between 13 17 which is slightly annoying.

[MadWelshBiker]

Hi,
Talking of parts, where can I get a pair of the clamp rings that hold the exhaust headers to the cylinder head? The pipes on mine are sound but the clamp plates are rusted to hell and are threatening to disintegrate.

Keep happy and ride safe
Mike

[catteeclan]

Hi,
Talking of parts, where can I get a pair of the clamp rings that hold the exhaust headers to the cylinder head? The pipes on mine are sound but the clamp plates are rusted to hell and are threatening to disintegrate.

Keep happy and ride safe
Mike

I'd have thought something like that would be available from a breaker on ebay. Enduro spares maybe?

[Pistol_Pete]

OK then,

I have seen exhaust clamps on ebay before, they werent that cheap though.

Ok so no real dramas taking it apart, the engine is a bit fidly to get out on your own, could do with an extra arm but found that the best way was to start straddling the bike and feed it out to the right a little at a time avoiding crushing of the oil hoses, oh and make double sure everything is not connected.

I would also like to point out the value of the 6 sided sockets, i was having real trouble getting some of the 14 mm bolts to turn and felt it slighly slip so walked back down to the workshop and searched for ages for one and a 2ft breaker bar and presto out it came with a slightly worrying creak but didnt break for a change, also masses of 3in 1 used periodically before getting to the tough looking ones.

after the engine was out it seemed a lot simpler probably was no different but with it looking so bare the end (well sort of) was in sight. when removing the front fork assembly i had to remove the handlebars an through trying to keep it as complete as possible i bent the brake hose pipe a bit, i think its ok but somthing to watch out for.

after it was all stripped off i decided that i would send some more little bits off for coating too, this included the footpegs, downpipes, engine mounting brackets as they were starting to corrode and the top fork bracket where the ignition key goes as brake fluid had made it peel.

So its off for powder coating at BlastClean they quoted £120 for it all i am having the frame in a deep gloss red and the rest in satin black.

Off to france tomorrow to viset my parents and get the old yet tidy DT125r back on the road (well off road). and excited abou seing the results of the coating.

oh for pictures go to http://picasaweb.google.com/petespug...mieRestoration

[catteeclan]

Never was a fan of that colour myself so a change is (I think) a good idea.

That box ain't big enought is it?

Been thinking about yellow on mine but just haven't got the time at the mo.
Have fun with the stroker.

[MadWelshBiker]

[quote=catteeclan;293453]That box ain't big enought is it?
quote]

Good for when moonlighting as a pizza delivery boy.

Are you going to open up the engine? Or polish the cases?

Looking forward to the next instalment

Mike