1977 TS125 Introduction

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1977 TS125 Introduction

New postby d14vd_h on Fri Jun 16, 2017 10:34 am

Hello from Scotland guys;

I have recently purchased a 1977 TS125.
While its a 1977 bike it wasn't registered until 1984 as it was apparently used as a farm bike in those years.

The taco reads just under 8k miles, though can't tell if thats genuine.

Plan to do a light restore, its my first ever bike despite being 34 and despite being an amateur bicycle racer my mechanical knowledge isn't great.

On purchase I dropped it with a local mechanic as the original tyres had perished to a point I thought it would be unsafe to ride - i increased the width of the rear tyre to a 4.0
While the front and rear light operated (from dynamo?) no electrics worked and neither did the rev cable so it was rewired and new battery fitted, i took the opportunity to have the original rear light and bracket restored.

After my first ride this week the left shocker seal seems to have blown so first job will be to rebuild those, then some cosmetics such as cutting the tank and reapplying tank decals.

I also need to replace the bulbs in the tacho.

Regards the fork boots, i'd like to replace the jubilee clips at the bottom and the zip ties at the top - i wondered what the original clips looked like and if anyone had a source?

Ive got the original owners manual, the John Thorpe book and the Haynes manual but still fully expect to have to ask a bunch of questions.
Attachments
IMG_2468.JPG
IMG_2469.JPG
IMG_2466.JPG
Last edited by d14vd_h on Fri Jun 16, 2017 10:34 am, edited 1 time in total.
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Re: 1977 TS125 Introduction

New postby Butcher on Fri Jun 16, 2017 11:15 am

Nice, thanks for introduction. Happy you ride and enjoy the bike.


Um, she might need some money thrown at her and some investment of time and restoring...

That is a sick key-ring! No, wait... 45, 82, 32 and BINGO!


Great bikes of prestege... Ride the bugger and give back.

IMG_2466.JPG



These 125's I know pretty well :)
Last edited by Butcher on Fri Jun 16, 2017 11:15 am, edited 2 times in total.
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Re: 1977 TS125 Introduction

New postby d14vd_h on Thu Jul 13, 2017 3:42 pm

Right, after a sojourn with a classic bike mechanic the TS is back and better than ever before. Idle's and rides beautifully and the mechanic took care of things i didn't know were at fault or had put down to the 'character' of an old bike.

Longest ride to date - 43 miles home - was wonderful...

That said I seem to have rattled the rev counter cable or something as the rev counter stopped functioning mid ride....

Any clues?
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Re: 1977 TS125 Introduction

New postby Butcher on Thu Jul 13, 2017 11:00 pm

Have you checked the rev counter cable is screwed in tightly?
‘Fix it and try again’ - Burt Munro.

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Re: 1977 TS125 Introduction

New postby d14vd_h on Fri Jul 14, 2017 10:08 am

so nervous to touch anything now that the bloody thing works, i'll take a look at the gauge side asap.

it was a new cable (supposedly) after my first trip to the mechanics, so it shouldn't be snapped broken.

I'll try tightening from the outside then take the taco gauge apart and see if all is ok

D
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Re: 1977 TS125 Introduction

New postby d14vd_h on Fri Jul 14, 2017 11:05 am

ok so yep the ridged silver had tightening parts of both sides of the cable are nice n tight

Whats next on troubleshooting list :roll:
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Re: 1977 TS125 Introduction

New postby Butcher on Fri Jul 14, 2017 10:07 pm

That was as clear as mud. Well, does the inner part of the cable turn with engine running mate?
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Re: 1977 TS125 Introduction

New postby d14vd_h on Sun Jul 16, 2017 4:43 pm

Apologies for the terrible previously rushed phone post.

What I meant was the 'barrel adjusters' at each end were tight

I took them both off tonight and had a look inside, but to be honest I don't know what Im looking for.
Attached are some pictures. I'm not entirely sure how the mechanism works.
Attachments
IMG_2755.JPG
IMG_2754.JPG
IMG_2753.JPG
IMG_2752.JPG
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Re: 1977 TS125 Introduction

New postby Butcher on Mon Jul 17, 2017 12:13 am

It works by turning the inner part of the cable. Pretty straight forward.

And to quote myself "Well, does the inner part of the cable turn with engine running mate?"
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Re: 1977 TS125 Introduction

New postby Butcher on Mon Jul 17, 2017 5:48 am

This is not meant to be angled like this. Almost looks like a brass ammo casing ;)

Strange a.jpg
Strange a.jpg (26.58 KB) Viewed 187 times



Caused inner cable to break right here...

Strange b.jpg
Strange b.jpg (26.18 KB) Viewed 186 times





The cable is meant to be straight, perpendicular to central axis. This violent movement has snapped your new cable. I hope your mechanic will address the actual cause and repair. I will keep my mouth shut opinion :) I am sure that your beloved 125 is a blast to ride! :mrgreen:

Sorry about my dry snide remark. I have no idea of your ability / inability. Good luck.
Last edited by Butcher on Mon Jul 17, 2017 5:48 am, edited 2 times in total.
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Re: 1977 TS125 Introduction

New postby Butcher on Mon Jul 17, 2017 5:59 am

"my mechanical knowledge isn't great."

Pull things apart and discover how they work. I used to pull apart toasters (shocking!) to work out how they work. Old watches, you name it. I used to disassemble anything I could get my hands on. I could never get them back together though!

Eventually I got hold of a bike, pretty much like yours. I had to rebuild motor (water in it was not very good, if you know what I mean!). eventually did my trade as electronics tech. Fixed videos, MW ovens, TVs, cam corders, basically everything / anything that was put on my desk. Some rooster brought in a cam corder in a chilly bin (eskie to the aussies). Thing was, chilly bin was full of water with camera in it! Dude dropped in salt water and bloke in pub said to flush with fresh water (no insurance).


Hey, awesome introduction. My rev counter cable does not have that brass (golden colour) part. May be wrong cable? No idea. I hope I helped you out there...
‘Fix it and try again’ - Burt Munro.

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Re: 1977 TS125 Introduction

New postby d14vd_h on Fri Jul 28, 2017 8:42 pm

So.... new tacho cable fitted and working like a dream and wow it fits the threads etc a thousand times better than whichever aftermarket number the 'mechanic' who first looked at my bike had put on.

Now everything mechanical and electrical is working perfectly on the bike and it's given me some real confidence to put some miles on and thoroughly enjoying the experiences.

I'm now starting to work on tidying it up aesthetically including finally getting some tank decals on and filling out that oval cutout with a yellow motocross oval to match the fork boots.

I do plan on changing the grips as they are badly perished and punched through at the ends, is it possible to do this without disturbing the throttle mechanism?

A few observations;

There's a touch of run-on from the bike after a long run/ even with the key removed - at idle revs.
I also noticed there was a tiny tiny mount of oil loss from the transmission, just noticed the smallest of drips on the floor and not every day.

Im convinced there should be a rubber 'boot' covering the wires coming from the rear lamp unit so trying to source one of those, and also looking to replace the hi/lo beam switch as the plastic grip has came off leaving just a rusty stub!

D
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Re: 1977 TS125 Introduction

New postby Butcher on Fri Jul 28, 2017 10:41 pm

Well done! Glad you obtained correct cable.


"I do plan on changing the grips as they are badly perished and punched through at the ends, is it possible to do this without disturbing the throttle mechanism?"

Yes. I forget what size grips these bikes use. They do come in different sizes. It is worth spending some money on good rubber grips as this is what you hold onto! Lessens vibrations / jarring etc. (I need new grips as well on my 125).


"There's a touch of run-on from the bike after a long run/ even with the key removed - at idle revs."

How long is "a touch" ? I could speculate and say that there might be some carbon buildup on piston crown / head. And most likely in the exhaust port. I could be wrong. Head can be removed. remove the exhaust, then the head. The 125 has only 4 nuts. Scrape piston crown with piston "up". Avoid getting any crap into bore! Exhaust port can be scrapped out too. Don't damage the rings! The end of a hacksaw blade works well... Finish up with say, 800 grit sandpaper and blow the carbon out... ;)


"I also noticed there was a tiny tiny mount of oil loss from the transmission, just noticed the smallest of drips on the floor and not every day."

Um, where from? I'd hazard a guess and say from the gearbox oil drain bung ?? Might be loose or in need of its gasket ring replacing? clean it up real good and let sit for a while (few days or whatever) and then check for leaks. This will involve getting onto the ground on your back ;) Other possible places to leak from is k/s lever, gear lever, o/p shaft (front sprocket) or from oil pump cavity. ...My 125 leaks from the crankcase just in front of the drain bung! I cleaned up with solvent and added some red silicone. Problem solved! Looks a bit messy though.


"leaving just a rusty stub!"

Ouch! You might like to wrap some insulation tape around it or glue on a knob of some description.

No idea about wiring etc as all of my bikes were butchered before I got them so don't ask me! Check the parts microfiche in the 125 "manuals" section. Um, actually in the wiki :) Take a look... It is in there somewhere.

http://suzukits.informe.com/wiki/
Last edited by Butcher on Fri Jul 28, 2017 10:41 pm, edited 1 time in total.
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Re: 1977 TS125 Introduction

New postby Butcher on Fri Jul 28, 2017 10:52 pm

Re. run-on. After removing carbon, tighten head nuts evenly. Instructions are in the manual. If you don't, you could distort (warp) the head. Also clean the head. If you get flash, you can polish the head shiny, and the piston crown. This prevents buildup somewhat.

...Also align the oil pump. DON'T premix oil, as others say! No need to.


Check out this thread... There is no photos of head, but it is same principle...

http://suzukits.informe.com/forum/ts400-apache-f24/piston-damage-t3454.html


Carbon heats up red hot and ignites fuel even with key off (ignition disabled) ! This is bad as pre-ignition can occur. also excess carbon increases c/r (compression ratio) as there is obviously less volume in the head!
Last edited by Butcher on Fri Jul 28, 2017 10:52 pm, edited 1 time in total.
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Re: 1977 TS125 Introduction

New postby kbzx6r on Sun Jul 30, 2017 2:20 pm

Low octane gas, too hot or the wrong type of spark plug can also cause an engine to run on. So can a plugged up exhaust, especially parts 8 and 9 on the following diagram...
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