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Old 03-13-2018, 08:06 AM   #1
BuckNut
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XR-125cc Mini Endurance Bike Project

Ok ok ok, Honda didn’t make a 125cc XR .

Huge shout out to Gabriel and Everett Fox for their generous donation! My 16yo nephew will be very happy moving on from the little 70’s. My smaller kids are a bit dissapinted they can’t race it in TMGP but at least they can start learning a clutch.



What we have here was a unfinished project that had been shelved for a couple years. After a brief inspection, it appears the forks and swing arms will bolt onto our XR-70 carcass frame. If this works it will be a huge win simply because we have almost everything to make a complete bike.



Items in need:
1. Hydraulic perch and brake lever for front disk brake.
2. Complete clutch perch/lever/cable and assembly for case connection.
3. 100/90-12 Dunlop tire (used ok for the moment)
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Old 03-13-2018, 08:37 PM   #2
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My nephew made some great progress today.

The swing arm and forks were a direct swap to the XR-70 frame.



The engine was also a direct bolt on to the XR-70 frame. The upgraded 12” (from 10”) rear wheel with drum brake slid in with some spacer modification.

Everyone has a job!



Progress!

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Old 03-13-2018, 11:13 PM   #3
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nice. is that a 12in front wheel too?
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Old 03-14-2018, 06:13 AM   #4
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Quote:
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nice. is that a 12in front wheel too?
Yes, the original rolling frame had 12” front with 10” rear.
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Old 03-14-2018, 09:42 AM   #5
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Pretty cool the kids are learning this stuff at a young age. Good luck with the project.
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Old 03-15-2018, 07:45 AM   #6
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Garrett keeps plugging away.

Carb has been cleaned.
Throttle tube and cable installed.
Exhaust installed.
Oil drained and replenished..
CDI box and wiring harness in place (requires connections).
Chain installed.
Kill switch installed.

Awaiting following parts.
Clutch perch/cable/bracket
Rear brake rear connection assembly
Hydraulic perch assembly
Fuel shutoff valve

Hopefully parts start rolling in on Monday while Carrie is at work.




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Old 03-15-2018, 08:20 AM   #7
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Those kids are learning so many valuable skills through this process, I'd have to imagine those skills will serve them for the rest of their lives. Basic mechanics, trial and error, patience, the value of hard work and the reward that comes with it...good job man, good job.
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Old 03-15-2018, 07:33 PM   #8
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Some happy kids in the Miller house!

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Old 03-15-2018, 10:39 PM   #9
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This is one of the only moto threads I feel like I have seen on here in years.
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Old 03-15-2018, 11:24 PM   #10
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Bike is looking good!!!
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Old 03-16-2018, 11:59 AM   #11
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yellow wire is probably for lights. Is the stator wrapped on all poles or just one?
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Old 03-16-2018, 12:30 PM   #12
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Quote:
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yellow wire is probably for lights. Is the stator wrapped on all poles or just one?
Oh yea, good call!

Yes, all the poles were wrapped.

So on to another pressing issue. Nephew is having a tough time fitting the chain. The tire is tall and is hitting the front side of the swing arm. When he adjusts the tire back it runs out of adjustment. So he is inbetween chain links for proper adjustments.

Haven’t exactly seen his issue yet other than photo’s he is sending. His idea is to increase the size of the sprocket.


Anyone have a 15 tooth of this type? The spare XR-70 front sprockets have differnt spline pattern.



Or/And a 37 tooth XR-70 rear sprocket? The 37 tooth on the original 10” wheel won’t bolt up to the 12” wheel.

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Old 03-16-2018, 01:42 PM   #13
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I might have a sprocket or two for the front. have to check later when I get home.
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Old 03-16-2018, 03:49 PM   #14
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Well, not exactly how the kids wanted to spend spring break, but they have definitely made the best of things.

Everyone was piled in the driveway waiting for me to get home. After multiple messages throughout the day, everyone was certain the bike was going to roll under it’s own power.

Making me proud! Great way to come home!

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Old 03-16-2018, 07:00 PM   #15
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Brakes and a front tire and this beast is ready for a test n tune at the track!





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Old 03-21-2018, 05:36 PM   #16
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MX6er,

Any ideas why this bike will only start in Neutral? I’m use to pulling in clutch and going while still in gear. Or thisvis just the way these engines are?
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Old 03-23-2018, 09:19 AM   #17
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It is the design of the clutch/kickstart mechanism and how they are placed. My 125 luckily starts in any gear with the clutch pulled in.
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Old 03-23-2018, 07:27 PM   #18
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Tires, brakes and clutch done!



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Old 03-28-2018, 04:44 PM   #19
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I'm just now finding your thread. Thanks for all the progress pictures from along the way! When is the first track day?
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Old 04-01-2018, 08:49 AM   #20
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Shake down test yesterday.


Still have some work to do. First issue was on throttle response with a huge delay. Garret moved the carb needle up one position which solved apex exit response.

2nd issue is the front tire out of true. The bouncing basketball effect inspired zero confidence in pushing ANY types of limits.

3rd issue, this bike back fires like a after off throttle from high speeds. Anyone have suggestions?

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