Found another project ‘74 Suzuki TC125 Prospector

HWYCRZR

Old Man with a Hat
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I went back to the homestead this weekend to help Mom clean out our old shop and brought my high school motorcycle back. It is a 1974 Suzuki TC125 Prospector. The TC model has a two speed gear box which gives it decent power in low range for hill climbing, but also ca get up to about 65 MpH for road travel. Not bad for 13 hp.
It ran when parked 35 years ago (kind of). Except the kick lever was broken off and the rear sprocket would pop off if you gave it too much gas. So far I have already spent $100 in parts, and haven’t bought the new rear hub or wheel I need. Another project that I will spend more than it’s worth. Not what level I will take it too yet. I will clean it up first, then start resealing the engine and transmission. We will see.
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I have a parts manual coming and two service manuals. You have to get the TS125 manual for the engine and chassis and then get the TC125 man for the transmission and two speed related items.
Already bought a new seat cover, kickstand and rear wheel adjusters. Next is a rear hub/wheel, sprocket, chain, kick starter, engine and transmission seals, rear fender, tires…….. I will soon ha more than the $200 I spent on it in ‘84.
 
Story of when I bought it.
My motorcycle riding started when I was probably in 4th or 5th grade. My cousins had a little Yamaha Y-zinger 50, so when we went to visit we would zip around on it. Helmets? No. They were too expensive, plus the grass was soft.
Anyway when I was in 7th grade Mom and dad said we could buy a motorcycle. I found a pristine’68 Honda 125 street bike that I think I paid $150 for. It was a 4-stroke engine that ran beautifully. When I got it, it never saw pavement again. It was my dirt bike. In about 10th grade I traded the original street tire fo a knobby tire to better climb hills. We after another hard year I got a flat tire and discovered the rear axle was bent. And couldn’t get the wheel off. So I was down. My friend Jimmy, said he would sell me his Suzuki 125 (the one in this thread). I test drove it, it ran pretty good (it only cut out once, but started right back up when it cooled down). So I bought it. I took it home and dammed if every time it got warm, it would quit. I struggle a few weeks and then determined that it would quit getting spark. Finally figured out the point gap was too close. When it got warm, they would close and kill the engine. I adjusted the points an never looked back. My friend Jimmy offered me $250 or $300 to buy it back. No sale. Again I rode the crap out of it through our pastures and coulees.
Time for its second life.
 
That's cool as hell! Hopefully you have better luck with parts than I did with my Suzuki. I had an 88 Quadzilla that was an absolute MONSTER at the dunes. I could stomp mild modified Banshees all day long at the drags. Problem was, it stated costing $500-$600 for random OEM-only parts every season. The factory support just wasn't there.
 
I washed it up this afternoon. I got most of the grease, dirt, and cow **** off of it. It looks like some frame repair is in the cards. I couldn’t be so lucky to find a parts bike or frame for cheap. I wish my dad was in better shape, He could weld anything with any kind of welder. It is about time for me to put my mig welder to good use.
Time to strip the frame.
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Pulled it in the garage today and started stripping it down and pulling the engine.
Next pull the wire harness, rear arm and front end. Then I can start with the frame repair.
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I seem to remember doing this to a Polara once upon a time.
I did find a Motorcycle forum to join. There seems to be at least one guy that has helpful tips and suggestions so far.
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You don't waste any time. I will follow along. I had a 80 YZ125 back in school, I sold it when I was in the Air Force. My youngest has a 89 CR125, it is here at my house so I get to rip it around some. He had a Yamaha 200 Blaster quad that he sold a couple years ago and now wants it back....I told him not to sell it.
I have a similar project that fell into my lap, 02 KX 85, the engine is out of the bike and needs to be opened up because it won't shift. I need to find a pipe for it and carb mounting boot. It will probably be a winter project.
 
It could be. :) I don’t know. He goes by “Trials” and his flag shows Antarctica.
 
Did so “locating” on the frame to rebuild my kickstand mount. Also borrowed pictures off the internet.
I made the mistake of adding up the parts I have bought off the internet. Big mistake. This is a hobby I should be anti spend what I want. It is dangerous when comparing a small motorcycle to a car. All the parts seem like a bargain, add up fast. I have already spent double on parts than the $200 I paid for it in ‘84. I am sure I will have double (or more) of the actual value tied up in this thing. But it is keeping me from taking things apart on the Polara trying to perfect things that no one else would recognize. It is a hobby. As one past Coworker (of my Dad’s generation) said, “some people buy boats for their hobby, I just frequent strip clubs for mine, it is actually cheaper”.
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Did so “locating” on the frame to rebuild my kickstand mount. Also borrowed pictures off the internet.
I made the mistake of adding up the parts I have bought off the internet. Big mistake. This is a hobby I should be anti spend what I want. It is dangerous when comparing a small motorcycle to a car. All the parts seem like a bargain, add up fast. I have already spent double on parts than the $200 I paid for it in ‘84. I am sure I will have double (or more) of the actual value tied up in this thing. But it is keeping me from taking things apart on the Polara trying to perfect things that no one else would recognize. It is a hobby. As one past Coworker (of my Dad’s generation) said, “some people buy boats for their hobby, I just frequent strip clubs for mine, it is actually cheaper”.
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I have a set of those glasses. :lol:
 
I have a set of those glasses. :lol:
I keep a couple in my garage freezer and alternate between beers to keep them cold. I like the bowl glasses for Belgium Tripels, some IPA’s, and porters. It was also good for a Hemperial I had last night. An IPA fused with hemp hearts.
 
I keep a couple in my garage freezer and alternate between beers to keep them cold. I like the bowl glasses for Belgium Tripels, some IPA’s, and porters. It was also good for a Hemperial I had last night. An IPA fused with hemp hearts.
I bought the last case of that when I was told we won't be getting it anymore.

Back to your regularly scheduled programming.
 
Been a couple of years since my last update on the Suzuki TC125 build. I have some catching up to do. Since July 2021 I haven’t made a lot of cosmetic changes, but have a good start on the core.

I had to brush up on my welding and fabrication skills to fix my broken/cracked frame. Where the break was around the foot pedals and rear frame, I ended up drilling through at an angle and welding in a splint rod to tie them back together.
My skills are slowly improving. The tube doesn’t have much leeway between good penetration and blow through. I did add a gas bottle to my welder which helped.

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Drilling for splint rod.
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Rod through hole. Able to weld both ends and through the middle.
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Kick stand plate will also bridge the area.
My welds don’t stand out to much more than the original.
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Also had to re build the kickstand mount as it had been torn off. This was a challenge as I had to shape and weld progressively thicker material to the thin tube.

Started with tracing out a pattern using what was left of mine and pictures from the internet.
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Positioning the kickstand saddle. Did a little hot forging. Also found that if I pre heated the thicker material it was easier to weld to the thinner material.
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Checking the fit before cutting out the mount.
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I am not too concerned about the weld penetration as I had to heat it and bend /hammer/forge it to the right angle and position.
First attempt the bike sat up too straight and the kickstand was a little too far from the frame when up.
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Getting a little better, but sticking out to far when up
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Now about right. Nothing a little heat, large Crescent Wrench, Pipe wrench and hammer couldn’t fix.
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Now time for sand blasting and painting.

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Bikes are fun to restore and a bit simpler/quicker projects .
I went to town on my Maico 490 as soon as I got it. About 10 weeks start to finish . It helped that my buddy owns a powder coating business .
The last pic was taken at Washugal MX park in Washington.
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This is a 69 Yamaha Trailmaster I picked up from a guy I know . His father in law bought it new . Only 700 miles . It was my pit bike for vintage races .

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