Aprilia RS 125/ KTM 640 LC4 Supermono

Next up was to be to start it up for a quick run check, but I accidentally pulled the four wires off the spade connections on the starter solenoid. After several days of fiddling and head scratching I eventually worked it out, put everything back together and Bingo, a dashboard light, then the starter kicked in. Put some fuel and in a temp dripe feed thingy, choke on hit the button and hey presto she runs. Quite well too. Here it is at present.   May need to fit a bigger fuel tank at some stage. But its a huge relief to have it running at last.

The Vcoil went in ok followed by new sump plug, oil changed and oil cooler zip tied on. Need to refill the cooler as there is a small leak at the lower union as I didn't have any new copper washers, I have some now. The cooler is best filled while on its side with the banjos uppermost.

Oh dear Another bodge uncovered. Thought I would just drain the oil last night. Main plug came out after a good whack with mallet on bar, way overtightened but intact. Smaller plug on right of pic is under gearbox, started to turn and then continued to turn. Stripped thread, tried pulling and turning but no good. Going to have to drill and tap plug and make a puller to get decent pressure on to unscrew it. Ordered vcoil kit and new plug.

I've been sorting out the oil system this week, however the oil cooler I got from Triumph tiger has 14 mm  banjo connectors and I didn't realize how difficult this made things. I ended up having to machine some adaptors to convert from M10 fine to M14 fine. Both odd size threads. Here's what I ended up with. Have yet to assemble and fit it as I need to change oil and filters as well, maybe this week.

The front end is finished now. New Disc fitted, new wheel bearings new brake hose and bled. It should stop now, all I need to do is make it go!. Cooling system is done, I used the RS125 header tank and blocked off the large outlet and machined a new smaller outlet from a M8 bolt. Next is the oil system. I have an oil cooler from Triumph tiger that is a nice size. Unfortunately it comes with M14 banjo bolts. cant find any adaptors in the M14 coarse thread to M10 fine that I need. so it looks like a bit more lathe time to make some.