TL125S

[Laverda Dave]

Another project arrived in the man cave yesterday.

An old mate from work got in touch to ask if I could re-commission his Honda TL125S. He was given the bike by a mate of his a few years ago as a partially restored bike. Apparently it has a 150cc kit fitted. The photo of the bike makes it look pretty good but it is a bit rough around the edges.
The fuel tank is thick with rust internally, I will try some DEOX-C but I’m not very hopeful in this instance and I might have to resort to the loose nut method of shaking it prior to the DEOX treatment. Externally the tank is scabby in places and the decals are lifting. The frame paint isn’t great either; I think it has been hand painted as some point.

The rear chain cover (cast alloy) has a very nasty crack that will require welding. The internal web is also missing making me think it has suffered a final drive chain break at some point.

The rear tail light is also aftermarket, not sure what it is from, it looks ok but I think the genuine Honda item would look better.

The rear indicators and brackets are also missing, the front indicators are pointed and not the usual flat Stanley type so I will need to find a pair of these.
The worst part is the wiring loom, it is disconnected and very brittle with the usual bodgery showing so I’ll see if I can find one in better condition as they appear to be unobtainable new or pattern.

There are plenty of small minor things also missing; the spring for the l/h footrest is missing as is the rear brake switch spring. There is also cracking to the sidewalls of both tires and there was less than ½ litre of engine oil when I drained it. The seat cover has a rip on the edge of the seat pan and the seat mounting bracket fixing bolt has snapped off meaning the seat cover will need removing to fit a new bolt from inside. There are plenty of rounded nuts and bolts whilst the engine is held together using hex head socket bolts.

Good points, the wheels look original as are the handlebars and it has a genuine Honda exhaust although it does have a huge, thick alloy exhaust flange and I’m not sure if this was an aftermarket item.

The upshot is the owner has asked me to fully restore the bike so the strip down has commenced.  More to follow as the restoration progresses.

If anyone has any advice on these bikes (was a 150cc conversion a period thing?) or spare parts please let me know.

[Rozabikes Tim]

Excellent project Dave. Doesn't seem challenging enough for you compared to ratty!

Even though you say the photos don't show rough bits it looks loads better than most of these you see.

Road gear like speedo and lights not commonly present.

The alloy sprocket cover is like rocking horse dodo. A guy is selling repro items on ebay at about £150. They don't look very good.

150cc conversion very popular then and now. Any bigger and liner walls paper thin. They do take them out to 180 ish but new liner and crankcase opening needs widening.

The fact the pipe is in good nick is a bonus. Very rare although reproduction system available they are a New Zealand import and about £800!

If both sidepanels are like the one shown that looks good that is a result too. They are available as reproduction but only for the earlier K model, not the S as yours.

Chainguard looks tidy but not standard.

If you are looking at parts many common ones on the CT125 we never had here.

Looks like a fun project and something  different to follow.

[Bryanj]

I think the rear light should be same as 500 and 750(not the big F one) as to the rest always work looking up parts on cms and checking Silvers, he does get some odd stock

[Laverda Dave]

Thanks for the heads up Tim and Bryan.

I’ve been looking at the DSS site; he has a few items although mostly service type parts with a few obscure gears etc. CMSNL have a few parts.....at a price!

The side panel lug on one side is broken, the owner has the broken part and I will see if I can repair it using a dowel or something, I know once broken off these have a habit of being very difficult to repair properly due to the strain when pulling the cover off.

I will take the chain guard to the alloy welder I know and see what he can do, I can always dress it once welded. I will need to make up a replacement piece at the back where it was broken off by a chain trying to escape the sprocket.

I feel I will have to repair the wiring where it’s been bodged (I’ll give it a wash in the dishwasher first).

Can you tell me if the seat cover is supposed to be ribbed or is it plain? I have seen replacement covers but they have ribs, the cover on there now (not genuine) is plain. Should the cover also have a HONDA stencil on the back?

Should the left hand footrest be sprung, the one on the right is?

Gear lever, should this be chrome plated or painted, this one is rusty.

As for the fuel tank, oh dear, it’s going to be a challenge for sure, I have never seen a tank so rusty inside as this one is, the rust flakes are loose!

Whilst it is nice to work on something a bit different this has already escalated from a basic re-commission to a restoration. Whilst the owner doesn’t want to spend more than it is worth he wants to hand it down to his son. Whilst I’m restoring this for free and as something to keep me busy over the winter it’s still going to be very difficult to keep costs down when you get into painting frames, new tank and panel paint and decals, vapour blasting and painting engine cases, full gasket and seal set, countless special sized O-Rings etc. The parts and services I can see running into £000’s.

[Deano400]

Dave,
There is a Facebook Group for the TL125, might help you.

https://www.facebook.com/groups/tl125/?locale=en_GB

[Deano400]

And a website.

https://www.hondatl125.com/

[Laverda Dave]

Thanks Deanno. I don't do Faceache but the TL125 website is a goldmine of info. Thanks for the tip👍.

[Rozabikes Tim]

Dave for what its worth and faded memories of mine, gear lever definitely chrome. Seat I had in mind as  ribbed lengthwise. Images accompanying from Facebook site and one sketch from CMS site seem to confirm that. Also Honda lettering...

Maybe look at CMS re footpeg spring.

[Laverda Dave]

Thanks Tim. I'll have to see if I can get a repro cover👍.

[Laverda Dave]

Does anyone happen to know the thread size required to pull the alternator rotor off the crank please?
My puller for the 400/4 is way too big. I'm sure I've read a thread on the forum somewhere about using a certain pitch bolt but I cannot find it using the search facility.

[Bryanj]

Not off hand mate but im sure its one ofvthevfour legs on a honda pullrt

[Laverda Dave]

I have a couple of three leg pullers Bryan. They are not Honda items but I'll try one of the threads and hopefully it will fit......

[Bryanj]

Try looking at cmsnl parts list sometimes they have the special tools listed at the front and the part number should give you size

[K2-K6]

I have a couple of three leg pullers Bryan. They are not Honda items but I'll try one of the threads and hopefully it will fit......

Car wheel bolts are often available in this size area and pitch.  Just don't get caught borrowing one out of a neighbour's car to try it  do that at night 

Also, coppaslip or similar on threads (rotor or puller) exerts significantly more load onto the item to be pulled than dry threads do when you tighten them.

[Bryanj]

Looking at the parts list it looks to me like the coils are in the outer cover and the rotor is a permag hollow one, if so any "legged" puller will probably damage it.
It may be an 18mm  or 16 mm thread but use a HT bolt as it will need to be done up really tight.
The 4 legged Honda puller is a cross with a different thread on each leg, i have one but you are a bit far away.