Aprilia RS250 Project

[MK3 Dan]

Suzuki! They are having a batch of 100 made that are apparently due early Feb.

Get a huge discount from them through work so not worth looking elsewhere! Also it is my reason for replacing rather than rebuilding, not a lot more to go with new.

[MK3 Dan]

It will go down to my local balancer so will see what state it is in!

[MK3 Dan]

Very little progress at the moment. Still waiting on the crank which is now mid Feb.

Cerakoting of calipers, exhaust and radiator still away with them on holiday for a bit.

Fairings and tank at the bodyshop still!

Did have some nice carbon show up.

[MK3 Dan]

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.

[MK3 Dan]

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.

[MK3 Dan]

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!

[MK3 Dan]

AceOfHearts said:

Looks fantastic! Sorry if i missed it, but where did you get the Cerakote done?

Thanks!

It was done by a place called TS Engineering in Market Harborough - I have no affiliation with them but do highly recommend them, the quality of the work is amazing.

[MK3 Dan]

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.

[MK3 Dan]

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...

Edited by MK3 Dan on Saturday 30th March 19:08

[MK3 Dan]

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!

[MK3 Dan]

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.

[MK3 Dan]

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.

[MK3 Dan]

Had some progress with the stickers today, in my opinion it transforms the looks!

[MK3 Dan]

alvington89 said:

Looks great. Are you going to match the seat units graphics to the original scheme as well?
https://www.sargentsofsussex.co.uk/8995-aprilia-rs...

Thanks, yep that was this afternoons job so stickers are completed and the fairings are all going off for lacquer next week.

[MK3 Dan]

Just realised I haven't updated this for a while!

It is now completely back together and has been MOT'd with no problems other than an advisory for the front headlight, which I knew about and is on the list to clean up at some point.

Got it insured, filled out all the paperwork and sent it to the DVLA last week, just 4-6 nervous weeks to wait and see if it is successful!

Only slight issue I have is the rev's hanging around 3000 rpm at idle but it will go down if put in gear and some slight load put on it. I have had the carbs apart and cleaned them all again for no change, along with replacing o-rings, needles etc and using some gasket sealant on the intake rubbers. Seems to be air leak but even checking around with brake cleaner it doesn't seem to change the running. Have taken it down a private road and it seems to ride ok but revs are capped for a bit whilst it goes through some running in.

[MK3 Dan]

Steve Bass said:

Fantastic result!! One of the nicest ever and a real credit to your work.
As for the idle rpm issue, also check the air solenoids as a sticky or leaking one will have the same effect. Try blocking the air tube from each of the solenoids and see if it changes the idle rpm....

Thanks Steve, really appreciate that.

That is a good call on the solenoids, must admit I haven't even thought about eliminating them. Will give that a go this weekend and see what happens!

[MK3 Dan]

alvington89 said:

Just had a quick look back at what the bike was like when you started on the restoration and wow, there's no comparison to what it looks like now. You really have made a superb job of it as it looks mint now.

cirian75 said:

Very well done, better than new.

Marquezs Stabilisers said:

That is utterly stunning, well done!

Thanks all, really looking forward to getting it out on the road once the registration lands - if there are any problems then it will be a track day to give it a go!

Spent some time today trying to sort out the high idle issue, tried the solenoid's as Steve mentioned and despite thinking it was sorted when warming it up once warm it was the same. Some more looking around and checking throttle cable free play etc I noticed some excess movement in the junction box for the throttle, PV and oil pump cable. It seems to be worn and whilst I think the throttle is completely closed it is not telling the throttle position sensor that the throttle is completely shut (tested this with a multi meter, 1v at closed 1.2v when it is closed but TPS isn't) - I wonder if this effects the ignition timing. The second you gently push the TPS with screwdriver shut the revs drop to normal. I tried shimming the box to remove the free play but this made no difference.



Going to contact Sean at TTW to see if he has any options on a replacement TPS. Sat here thinking about it as I type I also want to check my oil pump cable and setting to make sure that it isnt holding anything slightly open.

I am at least a little releaved that it is not something too major and at least now I know the problem I can set about fixing it!

[MK3 Dan]

And a short run up video for 2 stroke noises!

https://youtube.com/shorts/it0ZC_zjxEM?si=LRM28YqV...

Edit for failing to embed! Hopefully the link works.

[MK3 Dan]

Thanks yet again Steve, did think that would be the case.

Zeeltronic is still high on my list of mods and having a look I think it is about £550 for the ECU, USB lead and ignition tester so needs to be sooner rather than later. In the meantime I will have another look this weekend and see if I can anything temporarily with a spring or something. I was holding off to ensure that I didn't need to be paying out on import duty/tax again.

However, I was rather surprised to receive a letter from the DVLA today, only 2 weeks after the forms were, sent but unfortunately they have rejected my first application!

I didn't know that a dating letter needs to have been issued in the last 12 months. The one I was using came with the bike from another attempt in 2019! There were some notes about it being accurate with a date and how the info was found but think it is all part of the same paragraph that details the date problem. I will send an e-mail tonight to the RD350 owners club that issued this and hopefully get that sorted quickly.

They have attached a sticker to the form which I can only assume is all the different sections it needs to be processed through and they are all ticked including the Nova section, that was my worry, and they have also provided an envelope with the name of the person who started processing it so it goes straight back to them. I am hoping this means once the dating is sorted it will be processed quickly without other issues.

Fingers crossed!

[MK3 Dan]

Finally received the registration on Friday evening!!



Been great to get some mileage in on it. Couple of minor issues to sort, main one being an issue with the front brake master cylinder which I was never happy with after stripping it but the rebuild parts are not available.

Seems like I will end up on first name terms with the cashier at the local petrol station!



Exactly as I expected it be on the road, doesn't like slow speed work and is hard work compared to most things but get it on the right road with low traffic and get it singing and its great. Also feels a bit quicker than I expected!

Little flyby video:

https://youtube.com/shorts/EnXB8FJA4qU?si=Eww2p0Gu...