Pipes Welded

I picked up the pipes from the welders on Friday
and test fitted them, Fit perfect!
Next on the list is a big cleanup in the garage
and get the gear change linkage fitted then fit
the electrics and loom.

Pipe ready for Welding

After sourcing a suitable length of pipe with
the correct bore I cut a section with angled ends
to extend the end can of the left pipe to clear the
swingarm. The end can will be extended by about
70mm. The original internal stinger has been cut
to be welded in place where it would normally be
with the other end with the silencer being able to
fit back into the end can. The stabilizer strap will
have to be remade to span across the 3 sections
of pipe.

The images below show the pipes taped up to give
an impression of the layout/run of the pipe. [its a bit saggy!]

New seals

Finally sorted the dust seals for the front forks out.
Cardiff Motorcycles via E-bay sent a different set
even though I had bought the originals about 2 months
ago. So first fork finished today with the other draining
overnight.

Exhaust run

I made a start today about stripping the frame totally while
the front end was off. I flipped the frame and installed the
engine cases with the barrels and heads in order to finalise
a solution for the left side exhaust pipe. I think I have
sourced a suitable bit of mild steel pipe to extend the
silencer past the swingarm.

Front Caliper Strip

The aprilia front brake caliper needed a refurb so
I stripped the paint and is now ready for a new coat.
The pistons and seals are still good so they will be
going back in.

Rear Brake Caliper

Finally finished the rear brake caliper bracket.
I an using a Honda Varadero 125 Rear wheel
so the bracket and caliper are matching.
There is an extra wedge shape welded to the
bottom to match up with the Yamaha YZF-R125
swingarm.

Party Pooper

I decided to attack the forks yesterday and started
with the right side disassembly, I drained the oil and left
the tube standing up side down overnight.

I went to fit the seals tonight and the dust seal is not
the right size, what a pain.

Fork Refurb Kit

Fork seals and Oil ready to go along with some
Super Glue to apply to a small rust spot chrome
of the left leg.

I have both 10w and 15w fork oil so I think I will
run with the 15w for stiffer damping.

Clocks Refurb

The original RD250 clocks I have needed a bit of fresh
coating. The buckets have been sprayed black and along
with the main bracket have been clear coated.
All nuts and bolts have been replaced with Stainless Steel
and some copper grease to help with future removal.

Because the weather has been terrible lately we have been using our
central heating, perfect for the freshly painted fork bottoms.