TS125C Project

Zunspec4 · Post by **Zunspec4** » Thu May 07, 2009 3:35 pm

I had this posted on the old Forum so I thought an update was due.

As bought from your favourite web auction house

The real truth

The start of the re-build

Engine in

Rolling chassis

Sorting the wiring at the moment, which begs a questioin. The parts list at Alpha Sports (TS125C 1978/79) lists a a voltage regulator but I can see no reference to one on the circuit diagram (from genuine Suzuki workshop manual). Any help welcomed, never had A.C. lights before.

Cheers Zunspec

[/img]

H2RICK · Post by **H2RICK** » Sun May 10, 2009 5:26 pm

What Suzuki may call a "voltage regulator" we would know as a zener diode.
IIRC, those tiddlers just use a little black box with a diode in it up near the steering head somewhere. It's about 1" square, IIRC, with one or two wires coming into it and it's got a through bolt grounded to the frame.

Zunspec4 · Post by **Zunspec4** » Mon May 11, 2009 10:37 am

Hi Rick,

I think I worked it out. The US market version of the TS125C circuit diagram shows a "Voltage Regulator" but the UK/European one doesn't. I think you are right though the V/Reg. its a simple Zener Diode type. I wonder why us old world types don't get a V/Reg. someone on a back hander from the bulb companies

If it is useful to anyone I "colourised" the TS125C circuit diagram (also one for the TS125ER, which I did by mistake cos I scanned the wrong page

)

TS125C

http://farm4.static.flickr.com/3620/352 ... e702_o.jpg

TS125ER

http://farm4.static.flickr.com/3568/352 ... e845_b.jpg

Cheers Zunspec

Zunspec4 · Post by **Zunspec4** » Thu Aug 27, 2009 4:40 pm

Hi all,

An update on my TS125 project. Got it running today and had a little play up and down the road. A perky little power band, I can see my gear changing technique getting quicker for this one.

Lots of fettling still needed but basically now a runner

Cheers Zunspec

rngdng · Post by **rngdng** » Fri Aug 28, 2009 5:27 am

It looks great!!! Nice work.

Lane

H2RICK · Post by **H2RICK** » Fri Aug 28, 2009 8:19 am

She's a beaut !!!
It is strange to me why the UK got the low fender version.....on a dirt bike.
Maybe they decided that it was a street bike with offroad pretensions ??
In North America all the TS's from ~1970 onwards got the high plastic fendered version. There's nothing worse than to have the front wheel stop turning because of mud-cloggage when you're going down a long hill......Ouch !! Arse over tit into the poison ivy !!! Or the bog.....

rbond · Post by **rbond** » Fri Aug 28, 2009 11:27 am

Not one to nit pick, but I hope you are going to re-route the clutch cable. I don't think it will last too long laying against the exhaust...... That is however a great restore on the bike. Looks better than new!

Zunspec4 · Post by **Zunspec4** » Fri Aug 28, 2009 12:57 pm

Thanks for nice comments guys. I must admit I am well pleased with how it has come along.

As pointed out a close fitting chrome f/mudguard isn't exactly what you want on an off-roader but it probably was aimed at the UK on-road learner market (Enduro themed). Actually there were not a lot of places you could go off-road in the UK even in the 1970s, and thats reduced by 80% since then as the Bl%dy Ramblers Association have lobbied to get what is there re-classified for pedestrian use only. Still, I shall enjoy buzzing it down the smaller of the Highways & Byways of jolly Olde England, still lots of (semi) tarmac country lanes available

.

I shall keep an eye on the clutch cable although according to the Suzuki manual it's in the right place (does not actually touch the exhaust)

Cheers Zunspec

PS: The next project is going to be a GT500 based Flat Tracker, I'm fed up of chasing genuine/NOS parts either from Suzuki or the Mr Millers of this world. The freedom to Mix an Match cheaper parts from other bikes is appealing.

Zunspec4 · Post by **Zunspec4** » Sun Aug 30, 2009 2:34 am

rbond wrote:Not one to nit pick, but I hope you are going to re-route the clutch cable. I don't think it will last too long laying against the exhaust...... That is however a great restore on the bike. Looks better than new!

Thanks to rbond - I was prompted to look a little closer at the clutch routing. What I then noticed is that there is a wire clip/guide secured by the front heat shield screw. The clutch cable runs through the ring of the clip ensuring it does not touch the exhaust.

The next question is, does anybody have a Part No. or detailed photo of this wire clip/guide.

Thanks for any help

Cheers Zunspec

two-stroke-brit · Post by **two-stroke-brit** » Sun Sep 20, 2009 2:23 pm

what a great restore of a little dualsport.

H2RICK · Post by **H2RICK** » Thu Dec 17, 2009 12:40 pm

Zunspec, lots of 70's dirt bikes used such a little clip/ring gizmo with the wire bent into a circle at either end. My '77 PE250 had one with the smaller circle attached to the top of the cylinder head with a 6mm screw. The larger circle was where the clutch cable went through. Take a look at a wrecker's yard in the dirt bike section. You'll see lotsa them on various bikes. The ones with the
larger diameter wire cross section are more durable.

Zunspec4 · Post by **Zunspec4** » Fri Dec 18, 2009 12:42 am

Hi Rick,

I found a suitable clip amongst the miscellaneous bit's an bobs I had laying around. Not the correct part but it looks as if it will do the job

Cheers Zunspec

PS: It's not really a brown exhaust in fact it has had a "ceramic" coating in pure black. Must be an affect of the camera setting and flash.

How it should look:

H2RICK · Post by **H2RICK** » Mon Dec 21, 2009 8:12 pm

Clip looks "factory" to me, Zunspec.

Keep an eye on it, though. They ARE prone to vibration cracking/self destruction.