Well picked up a trials bike off of marketplace a couple weeks ago, it’s a little rough but mostly all there. A list of work performed so far… Replaced throttle cable, clutch cable,rear brakes, sprockets and chain,changed oil, cleaned carb, new plug, new coil, new tires. Things to do: replace front brakes (have them just need to do it) build air box (working on that now) build a silencer (material on order) Always wanted one of these so this should be fun! Here’s a few pics of the air box build. This winter I plan to tear it completely apart rebuild the forks, widen the pegs, build new wheels for it do some frame mods have it powder coated, new fenders and paint the tank.
Not sure yet? The opposite side will have a hinged door so the filer will come in and out through there. Thinking about a panel style that can slide in and the door can secure it
It came with a crusty pod filter I've never liked an open airfilter on a dirtbike I know alot of guys do it, I just dont like it.When you wash the bike you gotta wrap a bag around it, creek water has easy access to your engine and you have to clean them more often. Im thinking about running the crankcase vent into the airbox too, this will help keep water out fo the engine in those deeper creek crossings. Im goin gto pick up one of those pinched style airbox drains, maybe the one off an XR would work?
Your air box is an amazing piece or work. A Honda RSC logo would be more period correct, than the HRC one.
Thanks Norman, The tank decal was already on it (but i agree)and I'm pretty sure the tank was painted with a brush??? Im just going to ride it cosmetic wise this sumer since im sure I'll hit the ground often while trying to learn this trials ridding thing.
Managed to get a little more garage time this morning. Made the air intake for the box and the mount for the intake tube. The last pic showed I managed to keep it tucked in pretty good, just a little peaking out there. I think I’m just going to run it without side covers, I don’t think that do much for keeping my pants off the exhaust so…… Might cut off that huge oversized heavy steel tab that holds the lower section of the right side cover.
For foot pegs, the IMS aftermarket pegs for a KLR650 are literally a bolt on (pin-on?) mod. They are wider and longer than stock and work well for me. For the forks, start with a fluid change. There isn't much to rebuild inside of them - they have no bushings on the fork lowers or the fork tubes. If the seals are leaking, change those. Original seal was a 31x43x12mm, Honda makes a kit with a washer to adapt a newer 31x43x10.5mm seal to fit, and those are dirt cheap from various aftermarket manufacturers. I like 7.5w fork oil (Maxima 125/150), others like a thicker 10w. Personal preference. 它看起来像你失踪的尾气out of the muffler. Easy enough to fabricate up something to replace that. I got a great deal on a used Sammy Miller exhaust so I'm running that now on mine, but I still have the stock exhaust in a box. A little sandblasting and some high-temp grill paint will clean that right up. You probably don't need any additional silencing, since it's a pretty quiet bike as it is. B&J Racing has a throttle cable that will connect to a "standard" Domino trials throttle - it works very well. While you're at it, replace the clutch and front brake cable. And the tires - a new set of Dunlop 803GPs will grip a lot better than what's on there now. I changed out the bars for a set of Renthal 6" aluminum trials bars - no fear of bending them now. Change the engine oil often - 1 quart even fills it, and with only the pickup screen and centrifugal spinner to filter, it gets dirty quick. The crankcase vent hose on mine is run up along the frame spine underneath the gas tank, even higher than the top of the airbox. So it would take more than a little water crossing to do any harm. You can get fiberglass reproduction side covers off of eBay, but you'll have to paint them. I'm running cut-up number plates on mine as makeshift covers. When I get around to painting and fixing the tank, I'll do the side covers at the same time. It's good to have something for your leg to rub other than the metal bits. The airbox looks great, and is probably better than the original Honda part, with its 90-degree snorkel that's made of unobtainium...
Yeah I was looking for an original box for a while, but they seemed way to expensive and were always in poor condition so that what lead me down this road. Im going to for sure rebuild the forks soon and after rebuilding my sons Husky 450 air fork im sure these are a walk in the park. I've replaced all cables except the front brake cable, but it looks like the previouse PO must have replaed it in his short ownership. Im not sure what bars these are but they seem very robust, and they feel good to me so I'll just run them for a while. What it really needs is the wheels rebuilt sooner than later. Ive been keeping an eye out for a complete set for a good price so maybe Ill get lucky! It runs really good, not tons of power but wasnt expecting that. Power is on par with my wifes old ttr125 honestly but the balanceability (is that a word?? should be..) is awesome and its all kinds of fun..
Managed to make the lid, now just need a couple mounting points and the filter (yeah wise guys I’m using a filter) and it’s good to go! Some sanding tomorrow should smooth the embossed section right out.
This bike needs a top end, Im going to remove the top end and see if I can just replace rings and hone the cylinder but I never get that lucky.Where do you guys get motor parts for these bikes? You think the dealers can still get parts for them?I see alot of cylinders, piston, pin, clips and rings as a kit on line but they all come from China, not sure I want to go that route unless the original parts are not availabe.
I don't remember the details anymore, as it's been almost 20 years since I had a TL125. Some folks used to use a ATC 185 cylinder and piston for more power. I would imagine you could use Google and find something. I see B&J racing has a 150cc kit. http://www.bjracing.com/tl125.html A word of warning however, call, don't Email. Also, don't be in a rush to get anything from Bob, he works at his own pace, often much slower than waiting for paint to dry.
My 1972 Honda trials had a Yoshimura magnesium big fin jug with an overbore to 138cc. I replaced the tiny trials carburetor with one from a SL125 Honda, and a big air filter from an XR185. I put longer damper rods from a 70's era Honda MX. Wasn't any better or worse as a trials bike, but on tight woods single tracks it embarrassed bikes with4 times the displacement.
