Aprilia RS250 Project
Discussion
Things have been slow recently waiting on parts to make progress. The new crank and rods that were due mid Feb has now been delayed until Mid April and not sure I believe that so my new plan is to get the engine back together with the original crank. It appears ok, the bearings are not notchy and do not have any free play. This will allow me to get the bike done, MOT'd, registered and hopefully ran in and I can then spend a weekend replacing the crank with just the cost of a few gaskets.
Fairings are still away at paint, plastic primer has tidied them up and the paint has landed this week so they will be done soon.
Finally got some parts back from Cerakote as well, I cannot believe the difference it makes - especially when you consider these parts are 23 years old.
Calipers before. I tried cleaning them, the baked on brake dust would not come off. Using traffic film remover just damaged the paint.
After Cerakote:
Radiator before, although was good considering its age:
After:
A before and after example on the chambers:
If all goes to plan hope to get the engine back together tomorrow and maybe in the bike Sunday depending on how things plan out.
Cleaned the power valves up last weekend. Not sure if I had mentioned before but found one of the bushes missing from the shaft. I have now seen that this allowed the valve to drop and hit the pistons, I think this is what then damaged the bore so at least I have answer. The damaged power valves mean I need replacements so have ordered up the billet items from the Tuning works which should be with me next week.
Fairings are still away at paint, plastic primer has tidied them up and the paint has landed this week so they will be done soon.
Finally got some parts back from Cerakote as well, I cannot believe the difference it makes - especially when you consider these parts are 23 years old.
Calipers before. I tried cleaning them, the baked on brake dust would not come off. Using traffic film remover just damaged the paint.
After Cerakote:
Radiator before, although was good considering its age:
After:
A before and after example on the chambers:
If all goes to plan hope to get the engine back together tomorrow and maybe in the bike Sunday depending on how things plan out.
Cleaned the power valves up last weekend. Not sure if I had mentioned before but found one of the bushes missing from the shaft. I have now seen that this allowed the valve to drop and hit the pistons, I think this is what then damaged the bore so at least I have answer. The damaged power valves mean I need replacements so have ordered up the billet items from the Tuning works which should be with me next week.
Great stuff. A lot of people fit those powervalves as a preventative measure, their design means they cannot fail in the same way as the stock, must admit, I’m tempted to fit them myself at some point!
Cerakote looks great. Look forward to you having this on the road in the better weather!
Cerakote looks great. Look forward to you having this on the road in the better weather!
Great stuff. A lot of people fit those powervalves as a preventative measure, their design means they cannot fail in the same way as the stock, must admit, I’m tempted to fit them myself at some point!
Cerakote looks great. Look forward to you having this on the road in the better weather!
Cerakote looks great. Look forward to you having this on the road in the better weather!
Thanks all, I am enjoying the project and looking forward to having a go!
Managed a good afternoon on the engine after work:
Still some work to do on this, Power valves hopefully showing up early next week then oil valves and lines etc.
Hoping to the calipers together and brakes bleed tomorrow.
Managed a good afternoon on the engine after work:
Still some work to do on this, Power valves hopefully showing up early next week then oil valves and lines etc.
Hoping to the calipers together and brakes bleed tomorrow.
Had some issues when fitting the new TTW power valves so had to take one of the barrels back off and machine that to make them fit, some of the plating from the replate had just lipped into the bottom of the power valve port - lesson learnt there I would know in future to check this before assembling.
Managed a few hours on the bike yesterday and got the engine back in and some of the big bits bolted on.
Got held up at this point as forgot to order some new Jubilee clips for the water pipes and also waiting on some water fittings and power valve pullies to come back from the blasters as well.
Should get that all sorted this week so next weekend I can get the power valves connected, alll the water pipes on and carbs fitted. Maybe even try and get it fired up but will see how it goes!
Managed a few hours on the bike yesterday and got the engine back in and some of the big bits bolted on.
Got held up at this point as forgot to order some new Jubilee clips for the water pipes and also waiting on some water fittings and power valve pullies to come back from the blasters as well.
Should get that all sorted this week so next weekend I can get the power valves connected, alll the water pipes on and carbs fitted. Maybe even try and get it fired up but will see how it goes!
As is always the way progress has been slower than I would like but getting there.
Not taken photos for a while but carbs and all top end pipes etc have gone on.
Bodywork is now getting there for first paint:
Got a few other bikes going through MOT Wednesday and I can then go back to concentrating on this, hopefully up and running over Easter and then on the road soon after.
Not taken photos for a while but carbs and all top end pipes etc have gone on.
Bodywork is now getting there for first paint:
Got a few other bikes going through MOT Wednesday and I can then go back to concentrating on this, hopefully up and running over Easter and then on the road soon after.
Got it up and running today!
Ignore the amount of smoke, this got better once up to temp. Can only be from the exhaust being blasted and the oil I used to assemble the engine.
Hopefully get things tidied up and almost finished this weekend.
Picked the bodywork up from paint so need to get that fitted and I can then get it stickered and lacquered over.
Not sure if that video has no sound for you as well, if so link here:
https://youtube.com/shorts/yOqeiuePEJI?feature=sha...
Ignore the amount of smoke, this got better once up to temp. Can only be from the exhaust being blasted and the oil I used to assemble the engine.
Hopefully get things tidied up and almost finished this weekend.
Picked the bodywork up from paint so need to get that fitted and I can then get it stickered and lacquered over.
Not sure if that video has no sound for you as well, if so link here:
https://youtube.com/shorts/yOqeiuePEJI?feature=sha...
Edited by MK3 Dan on Saturday 30th March 19:08
MK3 Dan said:
Got it up and running today!
Ignore the amount of smoke, this got better once up to temp. Can only be from the exhaust being blasted and the oil I used to assemble the engine.
Hopefully get things tidied up and almost finished this weekend.
Picked the bodywork up from paint so need to get that fitted and I can then get it stickered and lacquered over.
Not sure if that video has no sound for you as well, if so link here:
https://youtube.com/shorts/yOqeiuePEJI?feature=sha...
Amazing Dan. Yes the video has sound Ignore the amount of smoke, this got better once up to temp. Can only be from the exhaust being blasted and the oil I used to assemble the engine.
Hopefully get things tidied up and almost finished this weekend.
Picked the bodywork up from paint so need to get that fitted and I can then get it stickered and lacquered over.
Not sure if that video has no sound for you as well, if so link here:
https://youtube.com/shorts/yOqeiuePEJI?feature=sha...
Edited by MK3 Dan on Saturday 30th March 19:08
sounds good. Nice TVR btw
carlo996 said:
Love it. Congratulations
Marquezs Stabilisers said:
Bravo and congratulations! Would love one of these but beyond me now (both financially and my right knee after a football injury)
y2blade said:
Amazing Dan. Yes the video has sound sounds good.
Nice TVR btw
Thanks guys! Glad the sound is there! sounds good. Nice TVR btw
Still making some progress! Bodywork has been loosely fitted ready for stickers this week.
They fitted a couple of smaller ones today and hopefully most of the rest tomorrow. From there I can start tidying and finishing things.
Not completely happy with how it is running so have since changed idle jets, needles, clips and float gaskets. Still smoking way more from one cylinder but not sure if that is just related to the exhaust being aqua blasted. Once I have taken it down the road if I am still not happy will get it booked into the tuning works for a check over.
They fitted a couple of smaller ones today and hopefully most of the rest tomorrow. From there I can start tidying and finishing things.
Not completely happy with how it is running so have since changed idle jets, needles, clips and float gaskets. Still smoking way more from one cylinder but not sure if that is just related to the exhaust being aqua blasted. Once I have taken it down the road if I am still not happy will get it booked into the tuning works for a check over.
MK3 Dan said:
Still making some progress! Bodywork has been loosely fitted ready for stickers this week.
They fitted a couple of smaller ones today and hopefully most of the rest tomorrow. From there I can start tidying and finishing things.
Not completely happy with how it is running so have since changed idle jets, needles, clips and float gaskets. Still smoking way more from one cylinder but not sure if that is just related to the exhaust being aqua blasted. Once I have taken it down the road if I am still not happy will get it booked into the tuning works for a check over.
One cylinder smoking more than the other is a thing... they all do that Sir They fitted a couple of smaller ones today and hopefully most of the rest tomorrow. From there I can start tidying and finishing things.
Not completely happy with how it is running so have since changed idle jets, needles, clips and float gaskets. Still smoking way more from one cylinder but not sure if that is just related to the exhaust being aqua blasted. Once I have taken it down the road if I am still not happy will get it booked into the tuning works for a check over.
One thing worth checking in the oil pump output and the alignment of the two carb slides and the pump indicator. Checking the oil cc output is a PITA but worth the effort on a fully recommissioned bike like yours.
Also check the fuel float levels especially for the tilted carb as this can be tricky to get right and will affect the overall running of the bike.
Finally, look at getting oil drains fitted to the PV housings as they fill up with oil (especially the front cylinder) and can cause smoking ( refer back to the oil pump set up an cc confirmation). The excess oil can drip into the exhaust and smoking more than the vertical cylinder....
As for jetting, from memory the cylinders are pretty similar except the vertical one has a bigger power jet that opens at WOT...
And fwiw, smoking at idle is a bit misleading. Wait to get her running properly and up on the pipe and see what she looks like...
Good luck
Edited by Steve Bass on Wednesday 17th April 22:01
Thanks Steve,
I had been doing some research and heard about one cylinder smoking more than the other, my difference being it is the upper cylinder. Plus it is mainly white smoke. As you say I think it actually needs a good run and see what happens. Still thinking that it is due to water in the exhaust from aqua blasting.
I had been doing some research and heard about one cylinder smoking more than the other, my difference being it is the upper cylinder. Plus it is mainly white smoke. As you say I think it actually needs a good run and see what happens. Still thinking that it is due to water in the exhaust from aqua blasting.
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