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TL125S

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AndyD:
Dave,
Is it 1.25 - the Honda tool seems to show maybe 1.5 pitch.
If any help I can see if I've got any fiches for the TL125 in the pile in the garage - haven't used any or the scanner for a while but may still work with a bit of persuasion.
Cheers,
Andy

Laverda Dave:
Thanks Andy.
Thankfully you won't need to fire up the microfiche for this one as the owner has supplied both the parts book and the full manual but thanks for the offer 👍.
I see what you mean about the thread pitch with the Honda manual stating both pitch sizes. The part offered by Honda Classics doesn't state the pitch. I'll have another look at what I need and will probably by a 14 x 1.5 and a 14 x 1.25 pitch bolt as they will always come in handy.
I'm in the middle of fabricating the missing cable and other brackets at the moment, very therapeutic as pulling and pushing at the moment is really painful considering I have apparently torn three tendons in my shoulder (rotator cuff accord to my GP) and I have no idea how I did it!

Murf:
Hi Just seen your post,
I had a TL125 trials bike back in the day which I did use in competitive trials for a short time.  As  trials bike it was ok and reliable but did lack a bit of pick up and instant power for coming out of say a very tight slow turn straight into a steep climb or jumping up a rock ledge.  I did get a Sammy Miller 150cc conversion for mine and had it bored out. The kit also included a more straight through exhaust, which did away with the large triangular box type silencer fitted as standard.  The bike was better as a 150 but still a bit underpowered for me, I am sure a better rider could of course done better on it than me.  For the Sammy Miller kits I seem to remember that a standard piston from another Honda was used.  A lot of the bikes that were used in trials were bored to 150cc or even a bit more. The cylinder liner was a bit thin at 150 though. 

In its 150cc form the  bike was nice on the road and had a nice thumpy 4 stroke single feel and sound when accelerating. 
That exhaust flange is not a standard thing.
Mine was not fitted with any lights or indicators, though I do believe there was a lighting kit for it.

Good luck with the rebuild.

Laverda Dave:
Thanks for your comments Murf. It does appear very few of these bikes have the lighting kit still fitted making it impossible to find any replacements. If you have any photos of your old bike especially of the back it would help me to fabricate some of the brackets that have been cut off the one in my garage :).  If you have any parts for the old girl lurking away in a damp cardboard box in the garage or up in the loft that you'd like to sell off please let me know (I know its a long, long, long shot after all these years but worth asking anyway  :))

Laverda Dave:
A bit of painfully slow progress to report.
 
I had to halt the strip down of the bike following the engine removal because the more I stripped it down the more Items I found were missing, bent or damaged. The frame has been de-lugged all over including the tool box, rear indicators, ignition barrel holder, helmet lock etc. Also missing were all the cable guides on the front forks. The front brake cable has been rubbing on the tire with the outer casing being rubbed down to the metal inner casing.

In view of the above and it being impossible to find replacement cable guides I have made them using the still available (pattern) inner cable guides. I studied the parts book and photos and from these I scaled up the images to work out where they should fit and the sizes. I had to make three in total, 2 x front brake cable and 1 x throttle cable guides. The same applied to the front reflector brackets that were also missing. I made them from cardboard first and once happy I made them from some 1.2mm metal sheet. I am assembling all of the brackets to the bike as a dry build to make sure everything is where it should be and doing what it should without fouling anything.

I still have the ignition barrel bracket and the rear indicator brackets to make. The front headlamp /indicator stay I purchased from eBay in France arrived and of course it isn’t a TL part as advertised but off something else! I need to modify this (it has already been previously modified by a PO) to make it fit properly and to cut off and make a new bridge piece for the horn mounting. Once all the missing brackets are all made I’ll finish stripping the frame down and get it checked for alignment.  I will get the cable brackets chrome plated and everything else can go off for powder coating with the frame.

I still need to find a suitable headlight shell as the Honda part is unavailable. The headlight itself I can get a pattern replacement but the only shell I have seen has the appearance of a boiled egg with its head smashed in! I have found a l/h handlebar switch, it is used, in Germany and costs an eye-watering £214, I’ll look around for a pattern or near to it part as it is not my bike but a mate’s and he’s not going to want to spend that kind of money on a s/h switch (err.... I would though :o).

I checked the rear sprocket whilst I was in stripping down mode; I think a shark would be proud of teeth like these, another part that will be going into the scrap bin!

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