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  #1  
Unread 11-01-2017, 03:59 PM
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twinturba twinturba is offline
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Default Bats Aprilia RS "Marco"

Stumbled across this sad, badly neglected Aprilia RS50 and couldn't resist trying to save it from the junkyard to ride once more!


Our role as preservationists, in this small American 50cc world, will be put to the test as we try and get this endangered species back in its natural habitat.

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Current: NCXD, Carlos, Newd, Aprilia RS10k, Max, Bangkok, Derbi ADV

Past: Yuki, Marco, Fumi, '16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, 7x '03 Derbi SM's, 6x 99-04 Aprilia RS50's, 2x Derbi GPR, '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!)
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  #2  
Unread 11-01-2017, 03:59 PM
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Finally got Bats L.A. up here this past weekend to help get Marco on the operating table!

Here it is arriving at the Bat cave in its saddest state










After a little degreasing and disassembly it was ready for the operating table







Once on the table we removed the motor in preparation for a full Bats signature rebuild!





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Current: NCXD, Carlos, Newd, Aprilia RS10k, Max, Bangkok, Derbi ADV

Past: Yuki, Marco, Fumi, '16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, 7x '03 Derbi SM's, 6x 99-04 Aprilia RS50's, 2x Derbi GPR, '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!)
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  #3  
Unread 11-01-2017, 04:00 PM
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Spent some time on Marco today preserving parts for reuse on the restoration.
First I pulled the upper fairing off to disassemble and assess what parts can be salvaged.
The fairing itself is in good condition, but faded so that might be replaced with one from the bat cave or I might refurbish it.



As you can see the windscreen will definitely need replacing.


The one bright spot of the entire bike was the mirrors which cleaned up nicely and appear to have been painted gloss black. These were cleaned up and will be reused in the final reassembly!
Here is a side by side comparison of before and after cleaning.



The headlight was pretty disgusting upon removal, but after a deep cleaning its in good condition and will be reused.
Here are some before and after shots


__________________
www.JeniusBiker.com
Current: NCXD, Carlos, Newd, Aprilia RS10k, Max, Bangkok, Derbi ADV

Past: Yuki, Marco, Fumi, '16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, 7x '03 Derbi SM's, 6x 99-04 Aprilia RS50's, 2x Derbi GPR, '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!)
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  #4  
Unread 11-01-2017, 04:01 PM
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Finished up the tail.
Before:



After:
Brand new stainless clips!


Put the pieces together!


And finally place on the bike for reference!
__________________
www.JeniusBiker.com
Current: NCXD, Carlos, Newd, Aprilia RS10k, Max, Bangkok, Derbi ADV

Past: Yuki, Marco, Fumi, '16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, 7x '03 Derbi SM's, 6x 99-04 Aprilia RS50's, 2x Derbi GPR, '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!)
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  #5  
Unread 11-01-2017, 04:02 PM
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Lots to do up front on poor old Marco:



The biggest task here is going to be the forks thanks to these nasty rust spots on the fork tubes:


Having been in the Aprilia RS50 scene for over 16 years, I happen to have another set of RS50 forks from RCR's old track bike. The only problem was they were modified to fit a larger axel for accommodating an RS125 wheel so I need to swap the tubes over to the old lowers. Here is a side by side of both sets of forks:


On top of having a firmer spring and thicker oil, there was this custom length spacer. This looks a lot like the AF-1 kit and it's going on Marco so I will have to come up with a rear shock to match.


What a mess!


My "custom" Nylon tube protector!


Completed and installed on the bike!


Also put on a new top triple clamp I had laying around!
__________________
www.JeniusBiker.com
Current: NCXD, Carlos, Newd, Aprilia RS10k, Max, Bangkok, Derbi ADV

Past: Yuki, Marco, Fumi, '16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, 7x '03 Derbi SM's, 6x 99-04 Aprilia RS50's, 2x Derbi GPR, '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!)
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  #6  
Unread 11-01-2017, 04:02 PM
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Finished up the other fork today and managed to make an oily mess of it!
[ATTACH=CONFIG]311958[/ATTACH]
[ATTACH=CONFIG]311959[/ATTACH]

And they are in place!
[ATTACH=CONFIG]311960[/ATTACH]

In my attempt to finish up the front end of the bike during this long weekend I also started refurbishing the dash.
Here is the dash in all it's faded, disgusting glory!
[ATTACH=CONFIG]311961[/ATTACH]

The Speedo and temp cleaned up nicely, but the tach was so faded you couldn't read the aprilia under the needle, but luckily I have quite a few spares in the bat cave so that was swapped out. All I have to do now is find a replacement foam surround and this part is ready to go back on the bike!
[ATTACH=CONFIG]311962[/ATTACH]
__________________
www.JeniusBiker.com
Current: NCXD, Carlos, Newd, Aprilia RS10k, Max, Bangkok, Derbi ADV

Past: Yuki, Marco, Fumi, '16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, 7x '03 Derbi SM's, 6x 99-04 Aprilia RS50's, 2x Derbi GPR, '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!)
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  #7  
Unread 11-01-2017, 04:03 PM
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Worked on the controls today. Lot's of little details to address on this bike so it's definitely taking more time to sort everything out, but I think the end result will be worth it!

First up was the ignition surround. I had already cleaned up the one on Marco, but didn't like the fact that the printed information was missing. Luckily, I happened to have a spare ignition from one of our old race bikes so I popped the plastic surround off and replaced it with the near new looking one from the spare. Small detail, but makes the difference!



Looks right at home in all its glory!


No pics of the other tedious work, but I replaced the handle bars with nice and straight ones, nearly new stock grips, both sets of switches, and the broken brake lever all from spares I had laying around.





Just for reference her is what it looked like before! Notice that I also sanded, primed and painted the gauge/fairing support in nice black enamel. Also note that these were shot with my iPhone 6+ which I lost last week so the above shots are from an old iPhone 5 that I'm using until the 7 comes out


__________________
www.JeniusBiker.com
Current: NCXD, Carlos, Newd, Aprilia RS10k, Max, Bangkok, Derbi ADV

Past: Yuki, Marco, Fumi, '16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, 7x '03 Derbi SM's, 6x 99-04 Aprilia RS50's, 2x Derbi GPR, '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!)
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  #8  
Unread 11-01-2017, 04:05 PM
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Engine cradle, kickstand, and swingarm just needed a little rustoleum and now look a lot better!




Next up was fitting a better rear shock to better match the upgraded front end.
This tired old stock shock was in a sad state:


I happened to have a sweet gOhlins rear shock from the old Bats 8hr race bike sitting in storage to use. It needed some spacers for a proper fit which I fabbed up utilizing the stock shock spacers and a reinforced dremel cutting blade:



Sexxy!
__________________
www.JeniusBiker.com
Current: NCXD, Carlos, Newd, Aprilia RS10k, Max, Bangkok, Derbi ADV

Past: Yuki, Marco, Fumi, '16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, 7x '03 Derbi SM's, 6x 99-04 Aprilia RS50's, 2x Derbi GPR, '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!)
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  #9  
Unread 11-01-2017, 04:07 PM
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twinturba twinturba is offline
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Another step closer to seeing Marco back on the road!
With all the attention focussed on making him go and look good so far, I wanted to take a little time to figure out the stopping portion.

How can I turn this mess into something that will work?!




Ugly!




A little clean up and a little paint



New Pads


Assembly







Some fresh Motul fluid and bleeding with the Mity Vac and this front caliper is waiting on a disc to grab!

__________________
www.JeniusBiker.com
Current: NCXD, Carlos, Newd, Aprilia RS10k, Max, Bangkok, Derbi ADV

Past: Yuki, Marco, Fumi, '16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, 7x '03 Derbi SM's, 6x 99-04 Aprilia RS50's, 2x Derbi GPR, '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!)
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  #10  
Unread 01-13-2018, 11:13 PM
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twinturba twinturba is offline
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Having a case Splitting party at Bats SF this weekend! Motor furthest away is going into Marco and will have the tried and true TP "rose" kit with Metrakit crankshaft. The motor nearest will be built with the new standard in AM6 building, the TP85 crank and cylinder kit, and be installed in the next project named "Ocho Cinco". Still debating the carb to use as we have both 21 and 24mm carbs.



Here's Ari doing his first solo Split!

__________________
www.JeniusBiker.com
Current: NCXD, Carlos, Newd, Aprilia RS10k, Max, Bangkok, Derbi ADV

Past: Yuki, Marco, Fumi, '16 & '15 RC390, '11 Madass,'98 Chester, '00 Mito, '12 PW50, KTM BR 65, Aprilia BR50, '06 Aprilia RS125, '04 DRD, 08 WR250X, 7x '03 Derbi SM's, 6x 99-04 Aprilia RS50's, 2x Derbi GPR, '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!)
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