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.