Restoration guides
- Thirteen jobs, from strip-down to registration.
- Start with strip-down if the bike is still whole.
- Torque the manual prints is on the specs pages.
Thirteen parts
Take it apart in an order you can reverse.
Each guide has the tools, the parts to have ready, the steps, the mistakes that are already common, and a specification table. Where the research brief has a figure, the table says sourced. Where it does not, the cell says To verify. That is the whole policy.
- 01Strip-down and assessmentAll generations — Photograph, label and bag the bike, write a condition report, and check the crash points before any parts are ordered.
- 02Frame, swingarm and bodyworkAll generations — How the frame was finished, where to look for cracks, and why fairing brackets do not swap between generations.
- 03Engine ID and top endTwo-stroke — Tell a Rotax 122 from a Rotax 123, then measure the barrel, piston, rings and reeds without using a clearance this site does not have.
- 04Bottom endTwo-stroke — Crank, main bearings, seals, balance-shaft timing, gearbox and the clutch fastening that differs between the 123 and the 122.
- 05RAVE powervalveTwo-stroke — Blade orientation, cleaning, a 12 volt solenoid test, cable adjustment, and the difference between a blade and a restrictor blanking plate.
- 06Carb and jettingTwo-stroke — VHSB 34 and PHBH 28: how to strip them without losing the stack, and which jetting figures are not yet sourced.
- 07Electrics, CDI and ECUAll generations — SEM on the 123, Nippondenso on the 122, and the checks you can do without an invented wiring diagram.
- 08Cooling and oilTwo-stroke — Water pump, thermostat, oil pump and feed lines, and the 60°C warm-up the brief records from MCN.
- 09BrakesAll generations — Axial calipers to 2005, radial calipers and braided lines from 2006, seized pistons, and the fluid and wear limits from the workshop manual.
- 10SuspensionAll generations — USD fork seals, the shock, headstock bearings and wheel bearings. Fork oil weight and quantity are in Haynes 4298. The RS125 oil level and the sag figures are not.
- 11Paint, polish and decalsAll generations — Paint codes are not recorded. Replica kits are decals, not a different engine. The frame polish and the livery list are.
- 12Derestriction and powerTwo-stroke — The law first, then the hardware the brief actually describes: powervalve, CDI, catalyst, jetting and plug. No pinouts.
- 13MOT, registration and importAll generations — MOT prep without invented test limits, then NOVA, the 10-year type-approval exemption, and the V55/5 for an Italian import.
Printable workbooks and torque cards are part of the plan and are not in this edition. Videos for each stage are listed as coming soon.