Home Forum Members Pictures Contact Events
  #1  
Unread 08-05-2017, 07:15 PM
twinturba's Avatar
twinturba twinturba is offline
the J stands for bat
 
Join Date: Oct 2005
Location: San Francisco
Posts: 1,187
Default The Bats RS "Fumi"

Picked up another sweet ride for the BATS stable! This one we named Fumi and will get some TLC before serving more time on the road. It has 12k miles on it so the previous owner, who I've ridden with before, has gotten some good use out of her over the years!



She has some really nice upgrades on her already!





With 12k miles and no crank done yet its definately time for a full BATS quality overhaul of the motor....Oh wait, I do have the freshly rebuilt Marco motor laying around...HMMMMMM.....
__________________
Current:
RS Fumi,Derbi Newd,Aprilia RS10k, SR50 Scoot, Bangkok Mito, Track Attack Derbi,
Marco Resto

Past:'16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, seven '03 Derbi SM's, 1/2 Dozen 99-04 Aprilia RS50's, two 04+ Derbi GPR's, '00 Aprilia RS250, '99 Aprilia RS250, '95 Cagiva Mito 125, '04 & '95 NSR50R, '90 Honda NS50, '94 Honda RS125, '90 Honda RS80, '88 YSR63 (1st 2stroke!), '89FZ600, '89KLR250(1st Bike!)
Reply With Quote
  #2  
Unread 08-06-2017, 07:01 AM
jkv357's Avatar
jkv357 jkv357 is offline
Almost A BAT
 
Join Date: Sep 2015
Location: Middleton, WI, USA
Posts: 141
Default

Congrats!

Looks really good for 12K.

A lot less to do on it than Marco!
Reply With Quote
  #3  
Unread 08-06-2017, 09:03 PM
twinturba's Avatar
twinturba twinturba is offline
the J stands for bat
 
Join Date: Oct 2005
Location: San Francisco
Posts: 1,187
Default

Actual motor build info for new Fumi engine.

Since the bike has "high miles" for an RS50 the entire motor will get a rebuild as part of the restoration. Here is the tried and true pink Top kit, Polini bearings/seals, and Motoforce race crank.



After removing the top end there was a really strong gas odor and the crankcase had a nice surprise inside!


With that soup lingering in the motor for years there is no way we could put this back on the road without splitting the cases so the full Bats signature build it is!

A few pumps from the Mity Vac and the crankcase was empty so we proceeded with the tear down, more on this soon!



Haven't done this for a few years, but I have a lot of experience, the right tools, the shop manual, and the two stroke master Jedi Carlos (if needed) to make it as easy as possible.

First up, a look at some of the "special" tools from the Bats collection!


First one in action is the CN Racing custom made clutch holder tool that he made from old clutch plates and box steel. That sweet tool and a 19v impact wrench makes removing the clutch bolt a snap!



The next tool comes in handy for removing the nuts on the main and balancer gears its just a little V with the perfect size "nubs" to fit inside the holes in the gear. We used to wedge a dime in between the gears for years before finding this tool!



Next up is just a regular old puller to get the balancer gear off. It might be a little overkill, but it makes the removal easy, safe, and won't damage the gear.



With the clutch out of the way its time for my own custom wood blocks to come out for supporting the motor while separating the cases. The metal plate with a bolt in the top looking thingy is actually the Aprilia factory case separating tool.



That tool, plus a wrench, and love taps from my trusty rubber mallet make splitting the cases so much easier than all the other methods we used to employ when first splitting cases 10+ years ago!



Cases split, hopefully I can start rebuilding soon!



First I had to get the old seals out which was made so much easier with the right tool, the $10 Lisle seal puller. This thing pops them right out with very little effort. Although it is available on Amazon I went to a local tool spot appropriately called Tool Mart which is family owned and gave it to me for a nice crispy $10 bill.




I will have to take a quick trip to another local spot, Bearing Agency, to pick up these other seals for the motor before putting everything together.



I have a brand new set of factory seals for the bike which can be seen here, however I will be using the sweet blue seals that came with the Polini Bearings. I will use that new O-Ring from the factory set.




Here is the case sans bearing and seal, ready for the new bits.



Here is the magic weapon I use to coax the bearings out and make way for the new ice cold ones....It's the Storm!



Here is the new bearing in place. Sign of the times, old bearings were made in France and these new ones Taiwan.



Before installing the new crank I was planning to match the cases, but The rose top end lines up so darn well there isn't anything to match. See for yourself!




Installing the crank into the left side case is made easier with this Aprilia factory tool. There was a steel washer with this at some point over the years, but as since run away and was substituted with some scrap aluminum I had laying around.




Crank and Seal in place!

Sweet looking Motoforce Race crank!



Ready to assemble the transmission and get this beast back together!


The operating table in all it glory


heart of the beast is back together again! Need some loctite and those seals I mentioned in the previous post before it's completely assembled. Sould be able to get everything buttoned up this weekend!



The engine is complete and ready for installation just need to clean the 24mm carb and it should be ready to run.
A few pics from the Clutch side assembly:
New Barnett Springs to handle the extra power!

Lots of Clutch sets to choose from so measuring for thickness and assessing the condition to find the best set!


Clutch all together and buttoned up!



Next up was the other side and installation of the brand new stator the Ari ordered.

Flywheel and top end done!


Here is the spark plug info from Top Performance, anyone else use different plugs?
__________________
Current:
RS Fumi,Derbi Newd,Aprilia RS10k, SR50 Scoot, Bangkok Mito, Track Attack Derbi,
Marco Resto

Past:'16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, seven '03 Derbi SM's, 1/2 Dozen 99-04 Aprilia RS50's, two 04+ Derbi GPR's, '00 Aprilia RS250, '99 Aprilia RS250, '95 Cagiva Mito 125, '04 & '95 NSR50R, '90 Honda NS50, '94 Honda RS125, '90 Honda RS80, '88 YSR63 (1st 2stroke!), '89FZ600, '89KLR250(1st Bike!)

Last edited by twinturba : 08-06-2017 at 09:19 PM.
Reply With Quote
  #4  
Unread 08-06-2017, 09:30 PM
twinturba's Avatar
twinturba twinturba is offline
the J stands for bat
 
Join Date: Oct 2005
Location: San Francisco
Posts: 1,187
Default

Did the full motor swap this weekend and even completed a couple of heat cycles!
Draining the fluids and disconnecting everything prior to pulling the high mileage motor.

A few wiring reference pics before unplugging.



Old motor out and ready for the Full Bats signature build to go in!



Bats build motor locked and loaded!

[IMG][/IMG]

Break time so A few reminders after install before I fire it up later.
__________________
Current:
RS Fumi,Derbi Newd,Aprilia RS10k, SR50 Scoot, Bangkok Mito, Track Attack Derbi,
Marco Resto

Past:'16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, seven '03 Derbi SM's, 1/2 Dozen 99-04 Aprilia RS50's, two 04+ Derbi GPR's, '00 Aprilia RS250, '99 Aprilia RS250, '95 Cagiva Mito 125, '04 & '95 NSR50R, '90 Honda NS50, '94 Honda RS125, '90 Honda RS80, '88 YSR63 (1st 2stroke!), '89FZ600, '89KLR250(1st Bike!)
Reply With Quote
  #5  
Unread 08-07-2017, 01:24 AM
twinturba's Avatar
twinturba twinturba is offline
the J stands for bat
 
Join Date: Oct 2005
Location: San Francisco
Posts: 1,187
Default

Got it running with the fully rebuilt motor originally slated for Marco.

__________________
Current:
RS Fumi,Derbi Newd,Aprilia RS10k, SR50 Scoot, Bangkok Mito, Track Attack Derbi,
Marco Resto

Past:'16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, seven '03 Derbi SM's, 1/2 Dozen 99-04 Aprilia RS50's, two 04+ Derbi GPR's, '00 Aprilia RS250, '99 Aprilia RS250, '95 Cagiva Mito 125, '04 & '95 NSR50R, '90 Honda NS50, '94 Honda RS125, '90 Honda RS80, '88 YSR63 (1st 2stroke!), '89FZ600, '89KLR250(1st Bike!)

Last edited by twinturba : 08-07-2017 at 02:20 PM.
Reply With Quote
  #6  
Unread 08-07-2017, 07:11 AM
jkv357's Avatar
jkv357 jkv357 is offline
Almost A BAT
 
Join Date: Sep 2015
Location: Middleton, WI, USA
Posts: 141
Default

Nice work TT!

You make it look easy!

The video wouldn't run for me.
Reply With Quote
  #7  
Unread 08-07-2017, 03:49 PM
twinturba's Avatar
twinturba twinturba is offline
the J stands for bat
 
Join Date: Oct 2005
Location: San Francisco
Posts: 1,187
Default

Quote:
Originally Posted by jkv357 View Post
Nice work TT!

You make it look easy!

The video wouldn't run for me.

Thanks!

I've done motor swaps and rebuild numerous times over the past 15+ years of working on the RS50's. I did this one old school style out in the driveway, sitting on the ground lol!

Video embed should be fixed...Let me know any input you have on the videos as we would like to incorporate more in the future.
__________________
Current:
RS Fumi,Derbi Newd,Aprilia RS10k, SR50 Scoot, Bangkok Mito, Track Attack Derbi,
Marco Resto

Past:'16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, seven '03 Derbi SM's, 1/2 Dozen 99-04 Aprilia RS50's, two 04+ Derbi GPR's, '00 Aprilia RS250, '99 Aprilia RS250, '95 Cagiva Mito 125, '04 & '95 NSR50R, '90 Honda NS50, '94 Honda RS125, '90 Honda RS80, '88 YSR63 (1st 2stroke!), '89FZ600, '89KLR250(1st Bike!)
Reply With Quote
  #8  
Unread 08-07-2017, 04:11 PM
twinturba's Avatar
twinturba twinturba is offline
the J stands for bat
 
Join Date: Oct 2005
Location: San Francisco
Posts: 1,187
Default

Finished the third and final heat cycle today before I take it out for some break in miles so it was time to get the clothes back on Fumi. We have a bunch of Pro-Bolt kits for the Aprilia's that we bought in bulk from AF-1 when they were on closeout so I figured since I needed to change out some bolts anyway, why not do it right!

These bolts are made of ultra lightweight Ergal so you save a few grams of weight over the stock bolts


I have used these on a few bikes now and I use all the spacers, washers, and the Anti seize that come with the kits.


You may be wondering why I chose to use the red anodized on Fumi. Well they match the after market Clutch lever so perfectly!


Here is an example of where over time bolts have been lost, misplaced, or rusted out and need to be replaced with something more fitting.
Before:

After:


And here she is with clothes back on and the new Jewelry in place!


Just a few more things to address and Fumi will bea ready to roll!
__________________
Current:
RS Fumi,Derbi Newd,Aprilia RS10k, SR50 Scoot, Bangkok Mito, Track Attack Derbi,
Marco Resto

Past:'16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, seven '03 Derbi SM's, 1/2 Dozen 99-04 Aprilia RS50's, two 04+ Derbi GPR's, '00 Aprilia RS250, '99 Aprilia RS250, '95 Cagiva Mito 125, '04 & '95 NSR50R, '90 Honda NS50, '94 Honda RS125, '90 Honda RS80, '88 YSR63 (1st 2stroke!), '89FZ600, '89KLR250(1st Bike!)
Reply With Quote
  #9  
Unread 08-09-2017, 06:41 AM
jkv357's Avatar
jkv357 jkv357 is offline
Almost A BAT
 
Join Date: Sep 2015
Location: Middleton, WI, USA
Posts: 141
Default

Video is working now. I'd like to see more of the BATs cool little 2-stokes in action.

You guys know how to have fun out there! Looks like a good group and a good time for sure.

The Derbi would fit right in.
Reply With Quote
  #10  
Unread 08-10-2017, 04:39 PM
jkv357's Avatar
jkv357 jkv357 is offline
Almost A BAT
 
Join Date: Sep 2015
Location: Middleton, WI, USA
Posts: 141
Default

Hey TT - how do you guys work it when you are going out for a longer ride and have limited range?

There's an upcoming event that I want to ride the Derbi to, but it's at about the max roundtrip range on a good day.

EDIT: Do you convert the engines to premix, or run them with the injector?

Thanks.

Last edited by jkv357 : 08-13-2017 at 06:13 AM.
Reply With Quote
Reply


Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

vB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump


All times are GMT -7. The time now is 05:52 AM.


Powered by vBulletin® Version 3.6.8
Copyright ©2000 - 2017, Jelsoft Enterprises Ltd.

Ad Management by RedTyger