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Blood Sweat Tears and Grease => Projects => Enduro / Dirt / Scramblers => Topic started by: advCo on Jun 15, 2017, 11:28:49

Title: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jun 15, 2017, 11:28:49
Without further ado, I present to you the Van Van!

(https://uploads.tapatalk-cdn.com/20170615/c2455c9426b9d053fd42e22a2fb60f72.jpg)

Canyoncarver picked this old girl up a while back, and a while later I was searching for a CT70/90 I remembered he had it stored. With slightly larger tires and a 125cc 2 stroke motor, the RV125 is a cool alternative and should be a blast. We chatted about it and I made a plan to go out and grab it from him.

Here I am sitting on it in the canyoncarver shop. It's bigger than I originally thought, the beefy tires create a weird illusion that it's a smaller bike than it is, in photos anyways.

(https://uploads.tapatalk-cdn.com/20170615/d8879352f14145c0a6c00cedfeed2137.jpg)

Since we flew out, rented a car and planned to stuff the bike in the back, disassembly commenced.

(https://uploads.tapatalk-cdn.com/20170615/8c89e0d9ac0ccf46c8f243234b3381c0.jpg)

Fit like a glove. Good thing our rental ended up being an SUV. Everything is in there with the exception of the front wheel (woops!) but more on that later.

(https://uploads.tapatalk-cdn.com/20170615/af0f168c6837739b3835dc07bc38fc66.jpg)

Back at the shop

(https://uploads.tapatalk-cdn.com/20170615/88dc65e25ce894079e8ae0265e4690bc.jpg)

I was going to put it back together, fix the motor and ride it but since it was already more than halfway disassembled, I figured why not just go all the way and do it right. So disassembly commenced.

(https://uploads.tapatalk-cdn.com/20170615/ba1362f8dc7ac024a432bbdbbf573164.jpg)
Title: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jun 15, 2017, 11:39:35
So the motor...yeah. Some PO had busted the cases on a rock or something, and "fixed" it with a shitload of RTV and probably a piece of metal. Well that didn't last and here we are. It's on the flywheel side and that is undamaged. I picked up a set of TS125 cases for dirt cheap (TS125 and RV125 motor are basically identical during the years that the RV125 was made) and  a good condition stator cover from eBay first thing.

Other than that, the motor turned freely and feels like there's good compression there.

(https://uploads.tapatalk-cdn.com/20170615/16613e5a303d65104e11ccffebc43d58.jpg)

(https://uploads.tapatalk-cdn.com/20170615/a5c1cadd368595a8cb5d55b43d44cd44.jpg)

No head gasket?

(https://uploads.tapatalk-cdn.com/20170615/f44615572b18e42011e66949e5263c28.jpg)

More damage to the stator cover. Upon further inspection this thing was dropped pretty hard on the left side.

(https://uploads.tapatalk-cdn.com/20170615/7b15a5ccf4360f34dc7693fb32b72f9c.jpg)

That's supposed to be straight...

(https://uploads.tapatalk-cdn.com/20170615/9f4158607f893a34f1b5be3c6e2c90da.jpg)

PO (not canyoncarver  ;D ) did some nice work

(https://uploads.tapatalk-cdn.com/20170615/41cd4b780b2cd7c46bbf669ae72e20eb.jpg)

Torn down just about all the way. I made a DIY crank puller tool out of some 1/4" steel plate, some 6mm threaded rod and nuts, 10mm threaded rod and a threaded bung that Mr. E whipped up (for a different part of this project).

(https://uploads.tapatalk-cdn.com/20170615/181ee46c8485a3c7d87c2a0111d5194a.jpg)

After trying it once or twice and realizing I forgot a crankcase joining screw (doh) the cases split smooth as butter.

(https://uploads.tapatalk-cdn.com/20170615/23ced36f05ae013d26517d70f7ae9f26.jpg)

And that brings us just about up to date with where I'm at. The new cases have been cleaned up and I'm beginning to swap transmission and other internals over.

(https://uploads.tapatalk-cdn.com/20170615/849faa8db82a8688caceba914b579413.jpg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jun 15, 2017, 11:45:46
While the motor is in progress, I have been sourcing parts and prepping for refinishing. Built a little spray booth out of recycled materials back behind the shop so I don't coat everything with overspray. It will get sheathing and probably get expanded later, but I needed this up quick to get moving so it's nothing special.

(https://uploads.tapatalk-cdn.com/20170615/9d7d2ddfd321d3b2d0a0166c0cd8310b.jpg)

Prepped the frame and swinger to test out the booth. Works killer.

(https://uploads.tapatalk-cdn.com/20170615/12af984df48b4324e57213de582c0623.jpg)

And we're up to date.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: mrsadvco on Jun 15, 2017, 11:49:16
 Wooo!


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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Hurco550 on Jun 15, 2017, 12:40:17
you know im in! That thing really is way bigger than I had pictured!
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Kamn on Jun 15, 2017, 13:16:27
Nice work Nick, thats gonna be a fun little ripper when youre done
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Maritime on Jun 15, 2017, 13:31:58
Wow. nice. there was one of these for sale local and I thought it was ct70 size, that's a full size ride. now I wished I had bought it with the $$ I don't have.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: irk miller on Jun 15, 2017, 13:39:10
you know im in! That thing really is way bigger than I had pictured!
+1
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: canyoncarver on Jun 15, 2017, 16:59:13
Hell yeah buddy!  I knew you'd be the guy to take this project and run with it.  And thanks for not implicating me in the po's mess....lol....

Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jun 16, 2017, 13:42:58
More progress on the motor. This gear slip fit into the bearing. I gently tapped it out of the old case, stuck it in the freezer for a couple hours, then heated the bearing and it slid right in.

(https://uploads.tapatalk-cdn.com/20170616/6388a7f97318ff25cfb0a1e7dbcef863.jpg)

New crank seal for this half, transmission and gearshift assemblies back in place and lubed up.

(https://uploads.tapatalk-cdn.com/20170616/44770e328cbe3324f22389691005f33d.jpg)

Now I cleaned up the other half of the eBay case. The gasket surface is pretty nicked up from whoever was in here before. This motor uses a fiber gasket between the case halves... but would it be a good idea to use a super thin coating of yamabond to make sure they seal up nice and tight?

(https://uploads.tapatalk-cdn.com/20170616/4b6173810c3bdda746143c25d0e60da8.jpg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Maritime on Jun 16, 2017, 14:13:01
I would, a very thin well applied layer with save you headaches for sure.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: irk miller on Jun 16, 2017, 14:20:08
Either yamabond or shellac.  I've been using Indian head shellac gasket maker on drag motors for years.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jun 16, 2017, 14:22:26
I will be sure to stay clear of  the upper oil channel with the stuff, either way.

Thin coat to the one side, or both sides to err on the side of caution?
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Maritime on Jun 16, 2017, 14:35:43
If the one side is good just oil the gasket on that side. The side with the nicks put just enough yamamabond to fill the nicks but not much else almost like bondo filling pin holes, you can apply it then use a razor blade on its edge to smooth away all but enough to fill your imperfections and then let it dry and oil the gasket and put it together.  apply it first with a paint brush so there is almost no excess to ooze over the sides into the cases to not have to clean them.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jun 19, 2017, 08:19:03
Freshening up the Mikuni VM22 that a tube of RTV exploded on at some point..

(https://uploads.tapatalk-cdn.com/20170619/465448a247392365c2a98e1e2d4d1c4d.jpg)

(https://uploads.tapatalk-cdn.com/20170619/abfe11fb19999ee168ac9473c60f85f2.jpg)

After a trip into the new ultrasonic cleaner.

(https://uploads.tapatalk-cdn.com/20170619/b332e56b992249bd7e6f50cbb3d8e83f.jpg)

This carb is set up funky. The floats are two separate pieces that move independently on brass posts, and the drain plug is a banjo bolt into the end of which threads the main jet. Weird. Grabbed a crush washer from the hardware drawer to replace the old junk gasket that was there.

Good as new:

(https://uploads.tapatalk-cdn.com/20170619/31c9737e9baadd40117abb01a7d0b686.jpg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: trek97 on Jun 19, 2017, 08:42:21
(http://www.dotheton.com/gallery/11494-200816163635.png)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: canyoncarver on Jun 19, 2017, 12:03:20
Nice job on that nasty little carb.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jun 28, 2017, 11:46:56
Mostly prep and paint work at the moment, got the cases sealed and painted.

(https://uploads.tapatalk-cdn.com/20170628/ef0618707c82ae4fa729886b12045182.jpg)

Maxed out the spray booth last night.

(https://uploads.tapatalk-cdn.com/20170628/dab7ce9359d9386f3f257249b339260e.jpg)

Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: SONIC. on Jun 28, 2017, 12:28:07
Looking damn good.
That picture of you on the bike threw me for a loop! I thought maybe you were really really tiny for a second.
Definitely expected that bike to be smaller.

Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: irk miller on Jun 28, 2017, 12:35:42
The new Van Van's are pretty cool.  Suzuki's answer to the TW200. 

(https://img.thaibuffer.com/u/2016/thachapol/zzzz88888884/van4.jpg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: JustinLonghorn on Jun 28, 2017, 12:49:38
I am on board, sir.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jul 05, 2017, 16:42:25
Since I don't want to replace all the fasteners on this thing, I decided to try zinc plating.

(https://uploads.tapatalk-cdn.com/20170705/e00444eedaabec697ad66c731a73a185.jpg)

Produced some pretty good results for the first run. I am going to experiment with different time intervals and coats.

(https://uploads.tapatalk-cdn.com/20170705/2c4ff38d44fddf3d471258cbabd2fbd4.jpg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: jimmer on Jul 05, 2017, 17:10:04
Very cool bike and nice work! I need to find one of these!!👍👍
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Bick54 on Jul 08, 2017, 02:05:05
Since I don't want to replace all the fasteners on this thing, I decided to try zinc plating.

(https://uploads.tapatalk-cdn.com/20170705/e00444eedaabec697ad66c731a73a185.jpg)

Produced some pretty good results for the first run. I am going to experiment with different time intervals and coats.

(https://uploads.tapatalk-cdn.com/20170705/2c4ff38d44fddf3d471258cbabd2fbd4.jpg)

I'm intrigued by the idea of zinc plating, do you have a link that describes the process and setup you're using?


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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Jul 15, 2017, 20:25:40
I've been lazy with the powder coater, I should try zinc plating also

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: jpmobius on Jul 15, 2017, 21:26:35
Before you fire it up, check the brass arm where the floats push on it.  Those things sometimes wear a little groove where the steel pin on the floats touch it when the bowl is full.  This can cause the float(s) to hang slightly as the groove moves in an arc and the float moves in a straight line and cause the needle/seat assembly to leak, so if there is any doubt, sand the arms smooth with some #600.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jul 28, 2017, 02:07:17
I will double check the floats before I fill it up with gas. Still a ways to go before we're there, but making progress. Here's a sneak peek.

(https://uploads.tapatalk-cdn.com/20170728/00f261a90aa644ca1e8ba9900a7a4450.jpg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: dakine_surf on Jul 28, 2017, 08:21:23
Motor turned out awesome, love the way those old air cooled 2 smokers had tons of fins... this thing will be a blast to ride!


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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Maritime on Jul 28, 2017, 08:38:53
That looks great Nick, nice job.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: canyoncarver on Jul 28, 2017, 12:01:22
So.... you done yet?
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jul 28, 2017, 13:15:49
Thanks guys. Kelly, I'm getting there..be patient young padawan.

Trying to decide whether or not to go 1st over on the bore or bump it up 2mm over, either way I am going to be grabbing a new piston and ring set since the rings are visibly worn. I slapped it back together so I can get it set up and hopefully started while I am waiting for the piston set to come in.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: canyoncarver on Jul 28, 2017, 13:32:59
..be patient young padawan.

Baahhaha
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jul 28, 2017, 13:35:21
Baahhaha

I'm still trying to get this thing to Barber so you'll get a ride, don't worry  ;)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Aug 05, 2017, 23:26:39
I finally took down the awful wallpaper on the wall behind the bench, so I can get some pics. Here's update on the progress. Got the tanks cleaned and installed. Engine is 75% back together. Rings were really worn so I have a 0.50 over piston and ring set coming in. Need to purge the oil lines and get them bolted back up, as well as reinstall the magneto and flywheel.

Getting ready to start on the fenders/plastics and wheels. Hope to have this thing rolling by the end of the month.

(https://uploads.tapatalk-cdn.com/20170806/2b996d61d4940375e0e4c07eb51c5be5.jpg)

Also, this is too cool not to post. An old pic of Zeppelin on motorcycles, John Bonham center rocking a Van Van.

(https://uploads.tapatalk-cdn.com/20170806/364cc56365a546624bb641fb470914fb.jpg)


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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Maritime on Aug 06, 2017, 07:22:49
Neat
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Aug 10, 2017, 15:53:07
VT plate and 0.50 over piston and rings came in today. Time to ship out the cylinder for boring.

(https://uploads.tapatalk-cdn.com/20170810/bb8994af2c1b16a20a817abf880c8b77.jpg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Hurco550 on Aug 10, 2017, 16:46:55
VT plate and 0.50 over piston and rings came in today. Time to ship out the cylinder for boring.

(https://uploads.tapatalk-cdn.com/20170810/bb8994af2c1b16a20a817abf880c8b77.jpg)
Going with mototech?

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Aug 10, 2017, 16:55:43
Going with mototech?

Yeah, local guys want $70 for a bore and chamfer.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: JustinLonghorn on Aug 10, 2017, 18:02:11
Van van!
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Aug 11, 2017, 10:31:56
Putting shiny things back where they belong

(https://uploads.tapatalk-cdn.com/20170811/d1fd5bc676bba4c3f4dabd6173a7e5ca.jpg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: canyoncarver on Aug 11, 2017, 20:45:40
VT plate and 0.50 over piston and rings came in today. Time to ship out the cylinder for boring.

(https://uploads.tapatalk-cdn.com/20170810/bb8994af2c1b16a20a817abf880c8b77.jpg)

Awesome!
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: clem on Aug 11, 2017, 21:22:16
Looking good Nick. This is a very cool little bike.

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: mrsadvco on Aug 14, 2017, 13:29:50
Looks like new! Niiiiice


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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Sep 08, 2017, 18:37:41
How's this project going? I might be getting one this weekend that'll need alot of work, might have to bug you for some info hahaha

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Sep 13, 2017, 17:11:58
How's this project going? I might be getting one this weekend that'll need alot of work, might have to bug you for some info hahaha

It got held up for a few weeks with the hurricane and I sent all the hardware out for plating...I have a few more things to paint and then put it all together hopefully before Barber.

Do it!
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Sep 16, 2017, 15:01:07
I'm actually working on 2 rv125s. Both have a high and low gear reducer with missing parts. One has a tc125 motor. (Same thing I guess) looks like both need at least rings, I'm guessing a bore also. Do you know a good ace for parts besides eBay? Thanks

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Sep 16, 2017, 16:50:22
I'm actually working on 2 rv125s. Both have a high and low gear reducer with missing parts. One has a tc125 motor. (Same thing I guess) looks like both need at least rings, I'm guessing a bore also. Do you know a good ace for parts besides eBay? Thanks

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Do you happen to have a spare air pump??

I got most of my parts from eBay. Piston and ring sets are about $35 from Thailand and my cylinder is getting send up to Ohio for a bore.

Mine is the first year with the 5 speed transmission, but my CT104 has the dual range, pretty cool.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Sep 16, 2017, 18:06:59
Both are missing the pumps...i was bummed out. Kickstarters seized on the one working on now.(https://uploads.tapatalk-cdn.com/20170916/d32b5009b51adf4fe10b12ea6327a174.jpg)looks good though lol

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Sep 16, 2017, 18:11:52
So much for an easy runner, time to go work on the ct70
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Sep 16, 2017, 22:16:45
Both are missing the pumps...i was bummed out. Kickstarters seized on the one working on now.

Yep looks good though, mine should look like that after a bit of paint and some assembly.

Would you be able to get me some measurements on that battery cover? They are another unobtainium part so I figure I will probably 3D print one.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Sep 16, 2017, 22:23:16
Sure thing.....i have a.horrible memory (been hit in the head alot) so if I don't get back to you in a day please remind me.

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Sep 16, 2017, 22:23:42
Cover only or box also?

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Sep 17, 2017, 21:47:33
Cover only or box also?

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Got the measurements, just what I needed. Thanks a bunch. I thought it was plastic before but I see now it's just bent sheet metal. Should be able to make one up pretty easy.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Sep 17, 2017, 23:06:00
Cool beans man, hope they are clear enough lol. Both the rvs I'm working on are shot. Fun time. A buddy of mine just picked up a rv90 in really great shape for cheap, started right up.(https://uploads.tapatalk-cdn.com/20170918/ce172a1f37e152d490139e7cec5158ef.jpg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Sep 20, 2017, 20:32:28
How's that cover coming?

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Sep 22, 2017, 13:14:41
Time to get this project back on track. Hardware came in yesterday. Very happy with the results. I sent it out to Parker Metal Finishing in Greensboro, NC. SHINY.

(https://uploads.tapatalk-cdn.com/20170922/3385c0a8100e695a2dbf7b36b4cc47f3.jpg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Oct 04, 2017, 12:54:11
Been busy. Got the wheels and hubs painted. Mounting the tires was a massive headache, between keeping the tube inside the tire and not pinching between the halves, keeping the gasket centered, and bolting them together.

(https://uploads.tapatalk-cdn.com/20171004/a967f02ab0b2338e6c74a1e3220efcc3.jpg)

(https://uploads.tapatalk-cdn.com/20171004/a8c44aef472c049d27658cdc6a704f40.jpg)

(https://uploads.tapatalk-cdn.com/20171004/e7837f6da5b8699d7a9ecd3381c9213a.jpg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Hurco550 on Oct 04, 2017, 12:55:14
Gonna be at barber?

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Oct 04, 2017, 12:56:13
Diggin the tires!

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Title: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Oct 04, 2017, 12:59:59
These updates are gonna be slightly out of order. Last week I painted the seat pan. Last night I tackled the foam and recover.

I took some foam from a crusty old XL seat I had lying around, cut out the most damaged areas to square off the existing foam, then glued blocks in place and carved them down with a woodworking hasp.

Hereís what I started with:
(https://uploads.tapatalk-cdn.com/20171004/36c2b0b0e645bbc50c719f7eb6e336d9.jpg)

Donor foam glued in place and carved down.
(https://uploads.tapatalk-cdn.com/20171004/efa9c3b95b811b2431ac3a0cca840fbc.jpg)

Covered with 1/2Ē upholstery foam. Looks a little lumpy here but it doesnít matter - when you stretch the cover it compresses the foam enough to smooth all the irregularities.
(https://uploads.tapatalk-cdn.com/20171004/fb1e21ecabc871e0f5c658ea42d2dd24.jpg)

Cover installed. I got this cover from eBay and it is fantastic fit and quality. Super happy with the product.
(https://uploads.tapatalk-cdn.com/20171004/ad67a1c473ca352a319be47d27e51ab6.jpg)
(https://uploads.tapatalk-cdn.com/20171004/6db3d8a3b20e1b9d809e4b7633cd8c31.jpg)

Just have to install the strap, Iíll get that done later today.


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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Oct 04, 2017, 13:01:02
Gonna be at barber?

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The race is on my man. Iíll be wiring it up at Kileyís


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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Hurco550 on Oct 04, 2017, 13:13:00
The race is on my man. Iíll be wiring it up at Kileyís


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have Kayla drive and you can work on it on the trailer lol

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Oct 04, 2017, 14:14:55
Oops didn't finish my sentence...what brand of tires are those?

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Oct 04, 2017, 14:19:55
Oops didn't finish my sentence...what brand of tires are those?

SunF. Some Chinese company that makes weird size ATV tires, apparently. They came from Amazon or eBay, cant remember which. I did a swap on the front wheel, so I am running 2 rear rims & same size tires front and back. I'll do a post on the swap later.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Oct 04, 2017, 14:21:46
Cool man, I'm interested in the swap info

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: mrsadvco on Oct 04, 2017, 15:44:00
have Kayla drive and you can work on it on the trailer lol

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Nononono donít throw out suggestions like that. Lol


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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Oct 05, 2017, 01:07:23
I can see it now, wiring it up in the back of the truck going 70 on I-20 West.

Leaving Friday AM. Letís see how far I can get.

Current state:
(https://uploads.tapatalk-cdn.com/20171005/96b5969753e0a4c2c290b7f3437055b7.jpg)

Had to place an order from the printer on Monday, so I took some measurements and drew these up. Hopefully they fit well enough.

(https://uploads.tapatalk-cdn.com/20171005/f327f4818374d57213dab62908124721.jpg)

And they have a hot date with these guys tomorrow

(https://uploads.tapatalk-cdn.com/20171005/c6d791de31d1e36ac8fd2bfdebd808b9.jpg)


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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: cbrianroll on Oct 05, 2017, 02:16:52
Yes!! That's looking great!

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Oct 06, 2017, 00:04:18
No sleep til Brooklyn

(https://uploads.tapatalk-cdn.com/20171006/4a034c5cd52eddfd1ae7fdd22c54166f.jpg)


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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Rustyhama on Oct 25, 2017, 05:38:52
I finally took down the awful wallpaper on the wall behind the bench, so I can get some pics. Here's update on the progress. Got the tanks cleaned and installed. Engine is 75% back together. Rings were really worn so I have a 0.50 over piston and ring set coming in. Need to purge the oil lines and get them bolted back up, as well as reinstall the magneto and flywheel.

Getting ready to start on the fenders/plastics and wheels. Hope to have this thing rolling by the end of the month.

(https://uploads.tapatalk-cdn.com/20170806/2b996d61d4940375e0e4c07eb51c5be5.jpg)

Also, this is too cool not to post. An old pic of Zeppelin on motorcycles, John Bonham center rocking a Van Van.

(https://uploads.tapatalk-cdn.com/20170806/364cc56365a546624bb641fb470914fb.jpg)


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Oh man that's freakin' awesome. I was about to comment that my Grandpa had one of those when I was a kid, we called it 'the fat tyre Suzuki'. Then that picture of Bonzo on one, what a classic, I've been a huge zeppelin fan since I was a teen. No moto for JP Jones though!

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Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Hurco550 on Jan 11, 2018, 13:21:14
sooooo...










































done yet?
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jan 11, 2018, 13:53:26
We're at about 97%

Went through a bunch of rigamaroll with the wiring harness, got the wrong ignition switch from eBay seller (correct one is on the way) and a subharness from a fellow from Australia. Hopefully in the next month or so I will have this thing all buttoned up.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jan 24, 2018, 13:36:07
I've been slacking on the updates for this thread, but progress is being made. I'm going to add a few things in out of order to catch the thread up to where I'm at currently. So here goes.

The front fender is plastic, and the PO had it mounted without using the correct rubber shock mounts which resulted in a stress crack on the front portion. Their solution had been to sloppily rivet an aluminum plate as a brace to keep from further cracking.
I said "nay!" to this method, and proceeded to drill out the rivets and remove the plate.

After talking to irk for a while, I decided to go with West System's G/Flex epoxy system, which is a thickened 2 part resin + hardener system that is designed to have some flexibility when fully cured, making it perfect for plastic repairs. This stuff works absolutely fantastic.

(http://www.dotheton.com/gallery/102736-240118111845.jpeg)

First step was to channel out around the crack so I could get a decent bit of epoxy in there for the repair. I used a grinding wheel on the dremel tool while holding both sides of the fender secure. I kept it about 1/4"-3/16" wide so the epoxy wouldn't sag too much. The method to achieve best adhesion to plastic is to sand the surface with 80 grit sandpaper, clean, then flame polish with a propane torch. I cleaned with acetone after sanding (obviously, wait until the acetone is evaporated before you put a flame on it  ::) ) and for the flame polish, you just want to barely touch the surface with the flame. It will go from a rough, dull surface to a nice shiny finish.

(http://www.dotheton.com/gallery/102736-240118111940.jpeg)

Before I epoxied the gap up, I cut a few strips of 6oz fiberglass cloth. I didn't take any photos of it, but before I filled the crack in, I wet out the strip on the back side so I would have some backing for the epoxy. I also added a 1.5" wide x 10" cloth strip going from front to back to add some rigidity to the fender. I used some scrap metal to prop the front half of the fender up  ;D

(http://www.dotheton.com/gallery/102736-240118112007.jpeg)

After a 24 hour cure I sanded the excess down. Not bad and quite strong. My helper approves.

(http://www.dotheton.com/gallery/102736-240118112034.jpeg)

After a little bit of filler, a couple rounds of primer and wetsanding I got the fender and repair looking pretty darn good. I shot it with farm implement paint, installed the decals, then went back and cleared over it a couple weeks later. The orange peel on the clear is pretty bad, but I'm going to leave it as is for now - I may go back and cut and buff it later.

(http://www.dotheton.com/gallery/102736-240118112112.jpeg)

Once all that was done, I installed the correct rubber shock mounts and spacers to hopefully prevent any further damage in the future.





Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: irk miller on Jan 24, 2018, 13:49:00
Hell yeah.  That's perfect.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jan 24, 2018, 13:50:36
Next on the list was the rear fender. This bike had been pretty abused and the steel rear fender took some of those hits. It was creased in a couple spots and cracked, the worst is pictured below. This is after some sanding and a bit of work to straighten it with a hammer and dolly.

(http://www.dotheton.com/gallery/102736-240118113946.jpeg)

Once I got the two sides of the crack lined up, I hit it with the MIG and then ground it down to be fairly pretty.

(http://www.dotheton.com/gallery/102736-240118114030.jpeg)

A few rounds of filler and wetsanding later I was happy with the results. I had some fisheye on the first coat of paint as a result of some rushed prep work, so I ended up taking it back to primer again and repainting it. The decals I made up ended up working pretty well. I created the wide band at the bottom as a U-shaped piece, and the smaller stripes on the sides as separate pieces. I ended up getting the decals installed and having to do some precision trimming with an xacto to get the 3 pieces to blend perfectly. There is about 1/32" of overlap that you can see if you look REAL close  ;) . Again the orange peel on the clearcoat sucks, but I'm not going to worry about it for now.

(http://www.dotheton.com/gallery/102736-240118114923.jpeg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jan 24, 2018, 14:08:58
Last on the bodywork list was the two side plastics. They were in good condition except each one had one of the mounting points broken off as you can see in the "before" pics:

(http://www.dotheton.com/gallery/102736-240118115342.jpeg)

(http://www.dotheton.com/gallery/102736-240118115427.jpeg)

I set out to make the repairs using the same method as I did on the front fender. It was a bit tricky as I had nothing to use as a base. I ended up making a "mold" of sorts out of some cardboard coated with packing tape. I used 4-5 layers of 6oz fiberglass cloth, orienting the weave in alternating directions to improve the strength. I wet everything out with a thick coat of epoxy, being sure that each layer of glass was wet before adding the next. The fiberglass wraps up and inside of the plastic so it had some meat to grab onto.

 After some filing, sanding and drilling the mounting holes, here's what it looks like. There's not a great before picture of this panel, but the entire tab was broken off. The new tab is comprised entirely of G/Flex and fiberglass cloth. I'm confident it will be much stronger than the original.

(http://www.dotheton.com/gallery/102736-240118115831.jpeg)

Here are the repaired areas after finishing and installed.

(http://www.dotheton.com/gallery/102736-240118115901.jpeg)

(http://www.dotheton.com/gallery/102736-240118115929.jpeg)

And here they are all painted up with decals added, and mounted with new rubber grommets and stainless allen bolts. I shot some epoxy black on the "125" emblem and used a paint pen for the numbers.

(http://www.dotheton.com/gallery/102736-240118115959.jpeg)

(http://www.dotheton.com/gallery/102736-240118120025.jpeg)

(http://www.dotheton.com/gallery/102736-240118120043.jpeg)

 8)



Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: trek97 on Jan 24, 2018, 14:23:28
Wow sheís really lookin super.  How did you treat the engine?  It looks great too.  Iíve been mulling over thoughts on Rachelís 400 engine finish.  Also, that green is really nice, I will see what she thinks of that for the tank.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Sonreir on Jan 24, 2018, 15:17:45
Looking good!
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: canyoncarver on Jan 24, 2018, 17:05:39
Damn glad this bike ended up in your hands buddy.  Beautiful work.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Maritime on Jan 25, 2018, 09:03:35
great job!
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: SONIC. on Jan 25, 2018, 10:48:52
Looks awesome!
You ride it yet? 8)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: crazypj on Jan 25, 2018, 11:28:27
I don't remember them ever being Van-Van, isn't that a Yamaha 'thing'? ( just can't remember wat they were named in Britain)
Real good idea to make a case puller, case can and will distort if just pried apart. then becomes very difficult to stop air leaks
It's possible to take the early TS 125 motor to nearly identical spec RM but that would probably make bike unrideable with double the HP
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jan 25, 2018, 11:38:22
Thanks guys, its really coming along so far.

@Trek - I used Duplicolor engine enamels on this one, bead blasted most of the engine parts except the cases which I just degreased and cleaned. Primer + Color, no clear as I wanted more of a factory look finish.

@PJ - These original RV125s were only referred to as Van Van in the Japanese market. When the new model was introduced in 2003 (I think), they used the Van Van name for all markets. The TS125 motor is identical to the RV125, as I swapped TS125 cases for the busted cases that came with this motor. The TS185 is also a bolt in upgrade that I'm keeping in mind.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jan 25, 2018, 11:44:15
The plastic cover for the front brake switch was all busted up and is another one of the many unobtainable parts for this bike. I made a quick 3D model and sent it over to the printer. With a little filing and clean up, it went right into place.

(http://www.dotheton.com/gallery/102736-250118093953.jpeg)

(http://www.dotheton.com/gallery/102736-250118094226.jpeg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jan 25, 2018, 11:53:13
The G/Flex is really coming through on this project. Another part on the unobtainium list is the actuator for the dimmer switch on the hand control unit. Every single one is broken just as this one is. I was lucky enough that the thumb switch stayed on long enough for me to get it here through ebay. The first time I tried to test the switch, the thumb piece broke right off.

(http://www.dotheton.com/gallery/102736-250118094530.jpeg)

I used an old kneaded eraser, some tape and a toothpick to make a mold for the G/flex that would get me close enough to the correct shape. Not the best solution as the epoxy stuck to the eraser, but I was able to peel most of it off and then scrape the rest with an xacto.

(http://www.dotheton.com/gallery/102736-250118094607.jpeg)

The hole was in the wrong spot, so I had to do a couple of rounds of epoxying but here is the actuator with the correct position hole and filed down to fit. Should be better than new.

(http://www.dotheton.com/gallery/102736-250118094631.jpeg)

And here is the switch all buttoned up and back on the bars. Fitment is great and should last plenty long.

(http://www.dotheton.com/gallery/102736-250118094702.jpeg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: crazypj on Jan 25, 2018, 11:56:54
That brake switch was always a horrible piece. It should syill be available as Suzuki used it on most bikes until pretty recently (2010 or so)
One GREAT thing they did was to  incorporate the internal parts into a semi sealed unit. (if you ever had to 'chase' the tiny springs and ball bearings you know what I mean) Any parts person who says they cant get one needs to buck up and learn how to use Suzuki part numbering system.
 I like the way you figured out how to repair light switch, there are probably thousands scrapped which only need the tab repaired
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jan 25, 2018, 12:36:47
So back in April of last year when I went out to New Mexico to pick this bike up from good sir canyoncarver, I realized about 200 miles from there that I'd left the front wheel in his shop. I knew I wouldn't be ready for it for a while, so I set out on some research about front wheel swaps. The original front wheel on the RV125 is a 14" tire which is only available from Bridgestone for $200. To hell with that! After a bit of digging, I found a few people who had actually swapped another rear rim onto the front, as it bolts directly on to the front hub and only requires the use of an aluminum spacer to get the wheel centered.

After a few cancelled orders I was able to find a good shape rear wheel and hub for around $60 shipped.  I couldn't believe the price since the thing damn near weighs 30 lbs with the tire on it. Once it got here I set out to work.

I soon found out, that this particular bike was the first production year which has a slide-through front axle rather than one that bolts up from the bottom. The design was changed in '74 after the first year of production. The front hub on this bike has a completely different offset than the later hubs and forks, so the swap would not be as easy as I originally thought.

Bolted everything up and the wheel was offset 10mm to the right (looking forward), so I drew out a plan to get everything centered. Initial bolt up pic:

(http://www.dotheton.com/gallery/102736-250118101242.jpeg)

After some brainstorming, I figured the only way to make this work was to remove 5mm from the fork lower where the brake panel bolts up (the left side pictured here was originally 10mm wider than the opposite side, so I was not concerned with compromising the strength by removing 5mm). That got me closer to centered, but I'd need another 5mm to get there.

(http://www.dotheton.com/gallery/102736-250118101350.jpeg)

After talking with hurco, we decided it would be doable to stick the hub in the lathe and skim 5mm off the mounting surfaces where the hub bolts onto the wheel itself. The master at work:

(http://www.dotheton.com/gallery/102736-250118101409.jpeg)

With removing 5mm from the mounting surface on the hub, I was actually a bit concerned with the structural ability of the hub. I decided to draw up a spacer and have my uncle waterjet it out of some ~5mm aluminum. When everything is bolted together, the spacer will pick up some of the load from the hub.

(http://www.dotheton.com/gallery/102736-250118095507.jpeg)

After all that, the only thing left was to get everything tight back in between the forks. Mr. E was kind enough to whip up an aluminum axle spacer for the right side for the final piece of the puzzle, which you can see here placed outside of the original spacer/dust cover.

(http://www.dotheton.com/gallery/102736-250118095601.jpeg)

Here you can see the brake side bolted up, the fork lower now looks identical to the opposite side.

(http://www.dotheton.com/gallery/102736-250118095759.jpeg)

Whew. Looking back now that swap was WAY more work than I thought. But with a bit of planning and some helpful friends with lathes, everything lines up right and now I have a few more options as far as tires go.

(http://www.dotheton.com/gallery/102736-250118103042.jpeg)



Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jan 25, 2018, 13:01:08
Now back to the fun unobtainium bits that needed fabrication. Somewhere along the line the PO had gotten rid of the factory airbox cover and replaced it with a now-rusted-out sheet metal version, installed with gobs of liquid gasket.

(http://www.dotheton.com/gallery/102736-250118104227.jpeg)
(http://www.dotheton.com/gallery/102736-250118104246.jpeg)

No bueno. After asking around on some RV125 groups and searching ebay to no avail, I decided to go ahead and make one up.

The threaded portion inside the airbox is recessed back from the outer face of the airbox, probably so it won't dig in to your leg if you decide to dump the thing. I used some scrap 1-3/4" exhaust pipe I had lying around to french in a recess for the wing nut. The face is (I think) some 3/16" scrap. I welded it all up, painted it gloss black to match everything else, and cut a rubber gasket to seal between the cover and the airbox. Used a bit of Yamabond to stick the gasket to the cover, and installed everything with a freshly made and oiled UNI foam material air cleaner. I took a large rubber grommet I had in the parts bin, cut one side off and glued it onto the back of the filter to help it seal to the inner wall of the airbox.

(http://www.dotheton.com/gallery/102736-250118104319.jpeg)
(http://www.dotheton.com/gallery/102736-250118104402.jpeg)

And here we are all installed.

(http://www.dotheton.com/gallery/102736-250118105055.jpeg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jan 25, 2018, 14:02:41
Another missing part that was difficult to source was the metal cover that holds the battery in place. DTT member cbrianroll happened to have one of these on hand, and he was able to send me a bunch of measurements and pics which was much appreciated.

I drew it up in CAD as a flat piece, printed the drawing and transferred it to some sheet metal. I added flanges so I could fold the edges over to make it more rigid, as I only had 22ga sheet metal on hand. Cut out the shape with tin snips and hammered all the edges flat.

(http://www.dotheton.com/gallery/102736-250118115249.jpeg)

I haven't folded metal since high school metal shop so I figured this would be a fun project to dip into that again. I clamped a piece of angle iron to the workbench and started tapping away with a hammer. After 30 min of hammering and a few test fits, here's what I ended up with.

(http://www.dotheton.com/gallery/102736-250118115316.jpeg)
(http://www.dotheton.com/gallery/102736-250118115343.jpeg)

Again, it got painted gloss black to match everything else. I used some sticky back cork sheeting I've had kicking around on the inside for tighter fitment and to avoid any rattles or vibrations.

(http://www.dotheton.com/gallery/102736-250118115407.jpeg)
(http://www.dotheton.com/gallery/102736-250118115428.jpeg)

And with that, folks, we are up to date. All that remains on the punch list is wiring, check the timing, prime the 2t oil pump, add fluids and source a sprocket cover.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jan 25, 2018, 14:28:51
I almost forgot, made this little bracket out of some aluminum angle I had lying around. It bolts up to the stock coil mounts and tucks the new coil up underneath the plastics nicely to leave room for the ever so rare air pump.

(https://uploads.tapatalk-cdn.com/20180125/1bd78ef369eb1130bc48b49b522f798b.jpg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: JustinLonghorn on Jan 25, 2018, 15:46:39
I can definitely dig it, man!
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: crazypj on Jan 25, 2018, 16:49:50
I don't think I've ever seen the 'bicycle pump' even though worked on plenty of Suzuki's over the years. Isn't a specific manufacturer and not 'Suzuki' branded? I do remember reading a road test (yep, that long ago) saying you would grow old trying to actually inflate tyres with it  ;D
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Jimbonaut on Jan 26, 2018, 13:13:40
Man there's some serious genius shit going on in here.  Using kneadable eraser as a mold?  Inspired.  Dude your ride's looking great, the green looks bloody excellent (doesn't it always) and fab work is really inspiring.  Great build man.
Title: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Feb 03, 2018, 00:56:17
Ha, I was going to 3D print a little mold but I just grabbed a nearby eraser off the desk and went with it. Took some filing to get it to fit but much more efficient.

With the help of new DTT member here morto, Iíve been gathering the necessary pieces to put a stock harness back together. I plan to make a new harness from scratch eventually.

When I got the bike, the harness had been lopped off before the headlight bucket, so a lot was missing. Including the very difficult to pinpoint ignition switch and sub-harness in the headlight bucket that I only realized I was missing after trying to wire the thing up and staring at it blankly for a few hours.

The complete original harness and the old chopped harness. Sub-harness to the left, connects to main harness inside the headlight bucket.
(https://uploads.tapatalk-cdn.com/20180203/2845133ee75893d8d3796cd7fad9ca2c.jpg)

Original Suzuki Ignition switch. There are 3-4 part numbers in Suzukiís parts fiche for this piece, but only one of them is actually the correct part. Shrugs.
(https://uploads.tapatalk-cdn.com/20180203/91cb81cc5e6450594b1b87507e718c9d.jpg)

And now the most important bit on the bike...

This old rack came with the bike, and it had kinda been bent to fit and the left side mount was flipped over and booger welded back on. Seeing as I replaced the mount on the frame since it was bent, I needed to refit it to my liking.

Cut the left side mount off, then trimmed both mounts down a bit to clean it up and get rid of the unnecessary holes. I painted the bottom half in black to cover up the rusty bits and get some paint on the welds, but I wanted to leave the top part original chrome for durability. Wasnít sure how it would come out, but I think it looks ok and I wonít have to worry about paint chipping when Iím doing beer runs.

Before:
(https://uploads.tapatalk-cdn.com/20180203/8f3e5804976b1007735085562a013979.jpg)

After re-fit, paint, and some new hardware:
(https://uploads.tapatalk-cdn.com/20180203/c9d4c4738bb6d30046163faf94faae99.jpg)

(https://uploads.tapatalk-cdn.com/20180203/6d956eb10e1e9eb6f4a0775732675e7c.jpg)


aaaand success
(https://uploads.tapatalk-cdn.com/20180203/0f2f00f6e2012903d14862d1cc2e3729.jpg)

Now I just need to go to the flea market and buy a hip vintage milk crate to go on the back
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: trek97 on Feb 03, 2018, 11:22:30
Dude its really looking AWESOME.

Just needs this...
(http://www.dotheton.com/gallery/11494-030218092115.png)

https://www.ebay.com/itm/Vintage-1920-Beer-tapper-cooler-Dispenser-collectable-art-Bar-tavern-pub/292404676108?hash=item4414ad460c:g:ErMAAOSwImRYln0V
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: trek97 on Feb 28, 2018, 21:28:04
Cant see the pics
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Feb 28, 2018, 21:28:59
Cant see the pics

Yeah. For some reason the DTT app changed and I can't upload pics in order. Really annoying. Need to repost.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: trek97 on Feb 28, 2018, 21:30:12
Yeah. For some reason the DTT app changed and I can't upload pics in order. Really annoying. Need to repost.

Ill let Tim know.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Feb 28, 2018, 21:40:57
I finally bit the bullet and ordered a whole bunch of stuff from Vintage Connections to get this thing wired up. Stuff is absolutely top notch quality, I won't be caught doing any electrical work without it ever again.

(http://www.dotheton.com/gallery/102736-280218193833.jpeg)

A neat little trick I use when putting new connectors on old wire is to use a mild acid bath to clean off any corrosion. White vinegar and as much salt as will dissolve in the vinegar comprise the acid. Then a bit of baking soda and water in a separate glass, this mixture is used to neutralize the acid. I use shot glasses for containers. Hold the exposed copper wire in the acid bath for about 15-20 seconds, swirling it around if possible. I like to splay out the wires so everything gets cleaned. Pull them out and then dip into the baking soda mixture, swirl them around a bit. Dry off with a paper towel.

Before:
(http://www.dotheton.com/gallery/102736-280218193147.jpeg)

After:
(http://www.dotheton.com/gallery/102736-280218193210.jpeg)

This trick works great especially if you need to solder an old wire.

The wires had been cut on the headlight, so I carefully removed what was left of the old wires, soldered on some new ones and then covered with some heat shrink for protection. Finished off with a new block connector.

(http://www.dotheton.com/gallery/102736-280218193228.jpeg)

(http://www.dotheton.com/gallery/102736-280218193254.jpeg)

Hereís the subharness installed and everything wired up. All the lights work, haven't been able to test the headlight yet since I only had it running for about 10 seconds. Need to order a rear brake switch, the one I ordered from China came DOA. Surprising.

(http://www.dotheton.com/gallery/102736-280218193313.jpeg)

Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Feb 28, 2018, 21:58:39
I filled an oil can with some 2/ oil for the line bleeding. The center bleeder screw bleeds the main line from the oil tank and pump itself - its kinda hidden in the first pic but you can just barely see the top of it between the two oil line bolts/behind the chain. That can be pulled and then replaced once all the air is out of the main line.

(http://www.dotheton.com/gallery/102736-280218195304.jpeg)

The small lines are bled by removing the small screw inside the nut that fastens the lines to the pump, in the above pic the left bleeder screw has been removed. You can see a small plastic washer is behind the screw so be careful not to lose it. Medium pressure on the tip of the oil can ensures a good seal, and a few pumps will get oil all the way up through the lines. Kind of awkward to hold the oil can on there and take a pic at the same time, but you can get the jist.

(http://www.dotheton.com/gallery/102736-280218195401.jpeg)

Here you can see a pretty large air bubble in the line before bleeding, and after bleeding the lines are nice and full.

(http://www.dotheton.com/gallery/102736-280218195443.jpeg)

(http://www.dotheton.com/gallery/102736-280218195424.jpeg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Feb 28, 2018, 22:09:18
After getting the oil lines bled and all that fun stuff, I rolled her outside for the first start. Put entirely too much fuel in the tank before checking that the float valve and petcock were working. Last time I'll make that mistake. On the bright side, uncured Duplicolor engine enamel AND Rustoleum Appliance epoxy are both fuel resistant, which was surprising. Ended up with about a pint of fuel pissing out of the petcock all over the motor and walkway. Not sure what the deal is as I rebuilt the petcock. Going to pull it off and test it on the bench before I put any more fuel in the tank.

I actually managed to get her running after a few attempts. Since the petcock and float were both malfunctioning, it flooded out and died pretty quick. But I heard it run for a good 10 seconds, so there's that!

However, during this series of mishaps I discovered that the kickstarter gear is completely botched. The ratcheting mechanism only grabs about 10% of the time. So you can kick it over a couple times then bust your shin open when it doesn't engage. Awesome. I ordered a new assembly and annoyingly pulled the motor out to prepare to split the cases again.

(http://www.dotheton.com/gallery/102736-280218194131.jpeg)

On the plus side, this motor takes about 20 minutes to pull and it only weighs about 25 lbs, so it could be worse.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: crazypj on Mar 01, 2018, 10:36:50
You sure it isn't just the drag spring on kickstart? very unusual for the gears to be trashed unless teeth are broken off
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Mar 01, 2018, 11:08:40
You sure it isn't just the drag spring on kickstart? very unusual for the gears to be trashed unless teeth are broken off

I'm not sure what it is exactly. Its probably the spring or a worn mechanism. The gear looked fine to the untrained eye when I put it back together. Either way, all that stuff happens between the crankcase halves, so they have to be split to assess the problem.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Jimbonaut on Mar 01, 2018, 11:21:59
Getting close man, bet you're jonesing to get this thing mobile...

Just watched a couple of vids of 70's Van Van's doing laps of people's yards, wow these things look like a ton of fun.  Saw the 2018 model at the moto show this weekend which I'm sure is also loads of fun, but yours has it licked.  Hope you're on the road soon mate
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: 1fasgsxr on Mar 01, 2018, 13:30:41
I just did a similar thing...dump a gallon of fuel in it to see if its leaking at the pump...yup its leaking >:(
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: crazypj on Mar 01, 2018, 14:44:12
The gears can 'look' completely worn out but still work , the internal springs always look OK(it's obvious when they are broken) but can be completely worn out.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Mar 02, 2018, 09:40:42
And weíre here again.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Jimbonaut on Mar 02, 2018, 09:58:20
I can't decide if I like the left side of the crankcase more or the right.

It's a split decision.

Thanks, I'll be here all week.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Mar 05, 2018, 20:51:26
This little bugger is whatís giving me an issue. I ordered a spare gear set and itís worn as well. Got a NOS pawl coming end of the week.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: trek97 on Mar 05, 2018, 21:03:08
Got a NOS pawl coming end of the week.
Sometimes NOS the best way to go.  Be done and forgotten.
(http://www.dotheton.com/gallery/11494-200816163635.png)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: canyoncarver on Mar 05, 2018, 22:56:55
See?  Now you are Van Van specialist.  :)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: crazypj on Mar 07, 2018, 17:32:14
I don't think I've ever seen pawls as messed up as those?
 Usually people lose them.
Maybe they were fitted wrong as there are 'left' and 'right' offsets for the pressure springs (&plungers) behind them
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Mar 26, 2018, 15:19:15
Over the weekend I decided to get this thing buttoned back up. Space is at a premium in the shop and I needed this motor off the bench. I installed a new set of points and while doing so, found a short in the wire going from the primary coil winding on the magneto to the condenser. I soldered a new piece of wire with insulation in place and installed everything.

Got the motor back in, cleaned up the needle and seat and replaced the petcock gasket to rid the bike of any fuel leaks. Runs like a dream. Still looking have a couple of odds and ends to finish up but now its time to break in the rings and enjoy this little monster.

(http://www.dotheton.com/gallery/102736-260318130719-3542590.jpeg)

(http://www.dotheton.com/gallery/102736-260318130721-3543373.jpeg)

(http://www.dotheton.com/gallery/102736-260318130722-35461138.jpeg)

(http://www.dotheton.com/gallery/102736-260318130721-3544316.jpeg)

(http://www.dotheton.com/gallery/102736-260318130723-35472169.jpeg)

(http://www.dotheton.com/gallery/102736-260318130722-35451495.jpeg)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Mar 26, 2018, 15:23:22
And then shortly thereafter I decided to explore the pits in the new construction area of our neighborhood.

Did some muddin'
(http://www.dotheton.com/gallery/102736-260318130724-35481931.jpeg)

Climbed the hill
(http://www.dotheton.com/gallery/102736-260318130725-3549691.jpeg)

Probably the best terrain to test this thing out
(http://www.dotheton.com/gallery/102736-260318130726-3550779.jpeg)

Before a bath
(http://www.dotheton.com/gallery/102736-260318130728-35512211.jpeg)

This thing is an absolute blast to ride. With about 7 psi in the tires it was conquering 12-16" deep ruts without hesitation.

And the tires are surprisingly smooth on the asphalt.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Maritime on Mar 26, 2018, 15:24:28
Nice, I see a BOTM nod coming your way next month ;D
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Jimbonaut on Mar 26, 2018, 15:33:44
Proof, if any more were needed, that the more green in this world the better.

Congrats man, mud-caked tires never looked so good.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: morto on Mar 26, 2018, 16:48:03
awesome job Nick. just imagine how good it would be if you could let the tires down and pump them back up while out and about  ::)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: canyoncarver on Mar 26, 2018, 16:49:40
Just think, that thing was just a crusty carcass with a hole in the case that just sat in my barn only a year ago.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: JustinLonghorn on Mar 26, 2018, 17:24:42
Yep.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: trek97 on Mar 26, 2018, 21:18:06
Dude that thing is so cool!!!  An what a job you did on her too.   8)
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: crazypj on Mar 26, 2018, 23:59:07
That thing is so cute you want to hug it (until it got dirty)  ;D
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Jimbonaut on Mar 27, 2018, 09:51:42
Pardon the interruption - I read that you bled the oil lines before firing up the bike for the first time.  I'm pretty close to firing up my KLR after an engine rebuild, but know bugger all about bleeding the oil lines - is it something I should know about?
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Maritime on Mar 27, 2018, 10:27:02
Pardon the interruption - I read that you bled the oil lines before firing up the bike for the first time.  I'm pretty close to firing up my KLR after an engine rebuild, but know bugger all about bleeding the oil lines - is it something I should know about?

His is a 2 stroke so he bled the auto oiler lines to get air bubbles out which can starve it for oil and seize it. Your KLR being 4 stroke you just need to crank the engine over without spark plugs to circulate oil to the head prior to first start.  once you see oil in the cam area of the head your good to go.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Mar 27, 2018, 10:29:49
Thanks for all the kind words fellas. Feels good to be at this stage.

Jim - what Maritime said. Those oil lines are for the 2/ oil supply to the main crank bearing and the piston. So any air bubbles can starve either component of lubrication and cause a heap of problems.


Sent from my iPhone using DO THE TON
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Hurco550 on Mar 27, 2018, 10:32:47
I generally like to run some pre mix through the first tank after a rebuild (snowmobiles too). Though in the case of these Suzuki bikes, it doesn't help the direct oiling to the crank bearings.

Sent from my SM-G920V using Tapatalk

Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Mar 27, 2018, 10:35:53
I generally like to run some pre mix through the first tank after a rebuild (snowmobiles too). Though in the case of these Suzuki bikes, it doesn't help the direct oiling to the crank bearings.

Sent from my SM-G920V using Tapatalk

Yep, I had premix in to start but for some reason (maybe the oil?) it leaked past the carb gaskets and contributed to the mess. She smokes like a chimney, pretty confident everything is working as intended there
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Jimbonaut on Mar 27, 2018, 10:38:40
Ah, I see.  Nice explanation, cheers chaps. 

Trying to convince the missus that she needs one of these RV's as a scoot around town.  So then I could find one, fix it up, give it to her and then immediately knick it and thrash it around the woods at my mate's cabin.  Got it all figured out. 
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: crazypj on Mar 27, 2018, 10:38:54
Oil in fuel won't cause a leak but seals may swell up a little and stop leaking after a while?
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: clem on Mar 27, 2018, 20:23:28
Nice job Nick!

Sent from my SAMSUNG-SM-G930A using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)

Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Nov 17, 2018, 13:27:20
Kayla traded her CB200 for a sweet little red RV90 last weekend. Bros.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: trek97 on Nov 17, 2018, 13:41:50
Holy smokes.  Can you plate those things for street?
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: irk miller on Nov 17, 2018, 14:29:21
Kayla is smart.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: JustinLonghorn on Nov 17, 2018, 15:03:35
I can dig it.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: Maritime on Nov 17, 2018, 16:05:25
Nice!
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: clem on Nov 17, 2018, 16:31:07
The luck you have dude.

Sent from my SAMSUNG-SM-G930A using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)

Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Nov 19, 2018, 09:19:42
Holy smokes.  Can you plate those things for street?

Yeah, the red one actually has a title. The green one is VT plated, I need to transfer it over to Texas.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: clem on Nov 19, 2018, 20:09:31
They look like ant eaters. More funky than a CT70 that's for sure. You guys should have a blast getting around on those.

Sent from my SAMSUNG-SM-G930A using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)

Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: trek97 on Nov 20, 2018, 00:27:31
Yeah, the red one actually has a title. The green one is VT plated, I need to transfer it over to Texas.

Now thats awesome man.
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: waktaylor on Nov 25, 2018, 18:27:25
soooo good. great work on restoring
Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: advCo on Jan 25, 2019, 10:56:02
This thread is now a tale of two Van Vans.

I pulled the carb on the 90 last night to give it a once over in the ultrasonic. The bike has been having trouble starting since I got it and leaking a little fuel. The float valve is stuck so if a trip through the ultrasonic doesnít free it up I may have to replace it.

Title: Re: The Van Van - '73 Suzuki RV125 "tracker"
Post by: crazypj on Jan 25, 2019, 20:32:33
This thread is now a tale of two Van Vans.

I pulled the carb on the 90 last night to give it a once over in the ultrasonic. The bike has been having trouble starting since I got it and leaking a little fuel. The float valve is stuck so if a trip through the ultrasonic doesnít free it up I may have to replace it.
Do you have part number for shut off? I have a NOS Suzuki one but can't remember if it's for 125 or smaller carb. (probably should have got part number before posting  ::) )