Buckets of Elbow Grease

. . . is whats needed for the next task, removing the corrosion and pitting of the alloy frame, Swingarm, Bottom Yoke, Hangers and various brackets.

I decided to do a quick [2 hours] test on a section of the frame. I started out with some wet and dry sandpaper [dont know the grade] to cut back some of the pitting. I then used a polishing kit consisting of 3 discs and 2 grades of paste. I started with the rough disc on the electric drill and finished with the medium disc and a final polish with some elbow grease and a clean rag.

After 2 hours of hard graft the pitting is still visible but the corrosion has been completely removed and this section of the frame looks a little healthier.

Pieces

I got the frame, forks and swingarm broken down tonight after removing the rear brake system and wiring loom. The tedious task now begins of cleaning these and then polishing them to start the rebuild.

Engine out

Finally got the engine out and this obviously made it easier to inspect the damage and general state of things.
Again as mentioned there is heavy corrosion on the alloy and 1 problem which is a bit serious looking, there seems to have been oil/water leakage somewhere in the engine. What looks like emulsification can be seen at the cylinder head on the pic below.

The engine type is the Rotax 122 model.

There also seems to have been a leak at the powervalve area highlighted in red. I'm wondering is this the source of all the goo ?

Skeleton

Well Its almost there, Just have to get the engine out and then I can start breaking the frame.

Nude

Well I got the Fairings off to reveal a lot more corrosion, erosion and rust.
All the engine mounting frames are well rusted, there is a serious leak from the powervalve/oil pump area, All the engine casings are well corroded and the exhaust needs some TLC.
The intake manifold rubber is well perished so that needs to be replaced.
Next step is to get the engine out to check if it needs a rebuild and also un hindered access to the frame and swingarm for cleaning and polishing.

 

 

Heavy Corrosion

Here is the second batch of images before the clothes are stripped.

There is a lot of corrosion to all the metals and some general observations below.

1.] the chain and sprockets need to be replaced, I was going to clean the chain in Kerosene but its too far gone.
2.] the rear shock is leaking and heavily corroded.
3.] the l/h gearchange and footpeg hanger seems to have been bent.
4.] the brake discs dont seem to be too bad, although the brake surfaces are rusted they are not
heavily worn
5.] the brake hoses seem good but we would be looking at changing them for braided lines.
6.] almost every nut and bolt while originally being galvanized or coated in some way have been attacked by rust to the plan is to replace them all with stainless steel.

The Start

This bike belongs to my brother, well it used to, he only owns half now!

Its a Full Power Aprilia RS125 1999 Valentino Rossi Replica.

It has low mileage, just shy of 5500miles but it looks like it as way more. It has been sitting in a wooden shed for about 4 years with a blanket thrown over it. The shed was not insulated so the bike got the full effects of the damp cold of the winters and the warm humidity of the summers.

The alloys of the frame and engine are well corroded and oxidised as is the sub frames which are showing off their lovely rust.

The plan is to restore this machine to its original [or as close to it] state.

So as it stands now it is in my garage ready for the onslaught.

These images were taken yesterday with an Olympus OM10 film camera on Expired Kodak Gold 100 and developed in my sink :-)