My budget Rallye build, the RallyeAlp

Discussion in 'Land of the Rising Sun: ADV Bikes from Japan' started by Jeff@TheQuadShop, Nov 19, 2009.

  1. Jeff@TheQuadShop

    Jeff@TheQuadShop TAT survivor

    Joined:
    Nov 28, 2004
    Oddometer:
    5,685
    Location:
    Crestwood, Kentucky
    I may have to sell this bike as I've been out of work for several months now. :cry
    If anyone is interested, send me a PM.
  2. PackMule

    PackMule love what you do Super Moderator

    Joined:
    Aug 8, 2005
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    19,485
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    New Hampshah
    Wouldn't it be better to get a job than sell the bike? (kidding)


    Sorry to hear that, Jeff.
  3. rrittner

    rrittner Expand your sphere of awarness

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    Jun 11, 2008
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    New Castle, CO
    wish you closer
  4. Jeff@TheQuadShop

    Jeff@TheQuadShop TAT survivor

    Joined:
    Nov 28, 2004
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    Location:
    Crestwood, Kentucky
    Actually I'm going to be managing a new Batteries Plus store but that doesn't start untill mid December.
  5. Jeff@TheQuadShop

    Jeff@TheQuadShop TAT survivor

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    Nov 28, 2004
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    Crestwood, Kentucky
    I can deliver!

    My AfricaAlp went to CO. :cry

    [​IMG]
  6. Mercury264

    Mercury264 Once you go Triple...

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    Masshole
    Damn Jeff that sucks :cry
  7. ArthDuro

    ArthDuro quarantined

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    Westsideistan
    damn Jeff sorry to hear that
    hopefully you can hang on to it till december
  8. Jeff@TheQuadShop

    Jeff@TheQuadShop TAT survivor

    Joined:
    Nov 28, 2004
    Oddometer:
    5,685
    Location:
    Crestwood, Kentucky
    Well, I can always build another. I enjoy building them just as much as riding them. :D
  9. PackMule

    PackMule love what you do Super Moderator

    Joined:
    Aug 8, 2005
    Oddometer:
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    Location:
    New Hampshah

    :thumb
  10. Jeff@TheQuadShop

    Jeff@TheQuadShop TAT survivor

    Joined:
    Nov 28, 2004
    Oddometer:
    5,685
    Location:
    Crestwood, Kentucky
    Anybody want to make me an offer before I place a full blown ad? :ear
  11. ArthDuro

    ArthDuro quarantined

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    Apr 12, 2008
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    Location:
    Westsideistan
    too may mouths to feed, but you know I would do it

    not making stickers for a bike you are gonna sell heheh

    if you keep it, it will come with a free set of stickers :D


    good luck
  12. BigDogAdventures

    BigDogAdventures Fart Letter

    Joined:
    Sep 13, 2003
    Oddometer:
    5,746
    Location:
    Mt. Vernon, Illinois
    For 2 years I've been getting e-mails from people asking what happened to the Rallyealp I bought for about $5,000 cash and trade. I've never responded to any of it---but I suppose the tale needs told.

    I brought the Rallyealp home after the purchase on November 20th, 2010 on my trailer on a very cold rainy night.
    The test ride only lasted about 2 blocks--and I loaded it up--it seemed to run fine.

    The bike went from "Ready For The TAT" to a worthless bike with more problems than could be fixed----- in the 3 hour drive home with the bike on the trailer.
    How could that happen ?????-----well here's the story.


    As purchased---Beautiful isn't it ???

    This story ends with a blown motor after riding it only about 100 miles---but there's lot's, lot's more.

    [​IMG]

    When I got home I rolled it off the trailer and noticed a loud clunk noise ????
    I put it on a bike lift with the wheels off the ground and immediately without riding it noticed the head bearings were extremely loose-------not a little ----a lot-----the front forks could be pushed easily front and back making a clunking noise--they were not only loose they were shot.

    I also noticed while turning the handlebars that the fender was hitting the crashbars so bad they had wore almost a hole in the back of the front fender.

    I hadn't started the bike since I did the 2 block test ride---but first wanted to check the oil while level on the stand.
    It wasn't touching the dipstick and I almost put enough oil in it as it it were out of oil to get it full.

    I tried to start it and sparks flew behind the fairing and it blew a fuse.
    The culprit was a very badly routed clutch cable that had worn bare and was in a kink from rubbing on a fairing bracket.
    Not only was the cable trashed-----it would hit the bottom of the ignition switch when you turned the bars and short everything out. You can see in the picture that it had been doing this for so long it worn a big notch in the aluminum bracket.

    [​IMG]



    If it hadn't been for the 30 amp fuse blowing I'd a burnt up the whole wiring harness.

    Here you see the worn place after I re-routed the cable.

    [​IMG]




    While on the stand.
    I just keep finding things wrong with this bike.

    I was going to put a new rear tire on and immediately felt a lot of play in the wheel bearings.
    All the bearings and seals were completely shot.
    I thought I was going to have to get a torch out to get the axle out. It was greased alright but
    the bearing spacer had never been checked or cleaned and
    was a ball of rust inside and out---I was lucky to get it out. I had to carefully and patiently beat
    on it with a long driving pin and big hammer.
    If I had been on the trans am trail and had a flat--I wouldn't have been able to get the wheel off.
    I keep my axles so they can be pulled out easily with 2 fingers.


    [​IMG]



    While doing the wheels bearings---I discover the spokes nipples are rusted solid---I'll have to buy new spokes.

    While dismouting the brake caliper I find the brake pads are wore very crooked---I can't figure this one out yet.
    Is the caliper mounted crooked ???? Was the wheel mounted so crooked in the bike it did this ???
    I've never seen this before--and I've had some ratty abused bikes. I've seen one pad wear more than
    the other--but not this ???

    [​IMG]




    This could be the culprit----the pin that bolts up the caliper is extremely loose---the pin is worn out---the bore in the
    caliper bracket is wore out and everything is loosy goosy. Lower Pin same way.
    The rubber booty was there---It's just off in this picture. I may need a new caliper bracket and pins.

    [​IMG]




    The throttle needed some work---the grip was rubbing the handguards so hard it was making throttle movement hard
    and the throttle wouldn't return properly. Also the cables, throttle tube were completely dry----I expect a really
    easy throttle after I work this stuff over.

    [​IMG]




    After riding the bike just a few miles I decided there was something drastically wrong with it and I dug into the carbs.
    My WR250R would outrun it on top end--and the idle and acceleration were really bad.
    On top of the carb slide diaphrams was some kind of bug eggs---I think ????

    My first hint that the carbs were really out of whack is the fact the bike would start cold
    without using the choke (which was inoperable). No carbed bike should start without the choke
    on a cool or cold day. Somethings not right if it does.

    [​IMG]





    A torn diaphram was found.

    [​IMG]




    The Bug eggs ????

    [​IMG]


    A buch of crap at the inlet to the float valve seat.

    [​IMG]



    Inside the float bowls it looked like a swimming pool that hadn't been cleaned in 4 years.
    The float bowl evidently had a little water settled in the bottom of it for a really long time and had rusted
    the tip of the metal drain screws completely off.

    [​IMG]



    Main jets partially plugged---pilot jets plugged---float not set right.
    One idle mixture screw was set 1/2 turn out--the other 3 turns--probably in an effort to correct
    all the other bad running symptoms.

    [​IMG]



    This is the actual needle seat--there is a screen on the inlet that was engulfed in crud---thank goodness it
    couldn't get to the needle valve. I don't know how this bike ran at all.

    One spark plug looked horrible and I wouldn't have thought it would have fired---the other 3 were worse.
    One looked like you stuck it in the bottom of a crankcase of an old Harley--the oil and soot completely closed
    the gap. I'm worried something more than just neglect is going on here. May be just the carbs being all out of wack
    caused this ?????

    [​IMG]





    Also the choke pistons were stuck in the carburator---I think one was stuck wide open--they were seized up in their bores.
    I finally got them out and sanded them down and lubricated them---they should be alright.



    The throttle needed some work---the grip was rubbing the handguards so hard it was making throttle movement hard
    and the throttle wouldn't return properly. Also the cables, throttle tube were completely dry----I expect a really
    easy throttle after I work this stuff over.

    [​IMG]



    The handguards weren't installed correctly to let the clutch and front brake lever come inside the handguards.
    You can see that in one of the first pictures.
    I took them off and re-worked them and solved that.

    I keep smelling anti-freeze. I removed the fairing and gas tank again and found when the sensor
    was installed for the water temp to the Acewell computer the installer didn't tighten the clamps
    good enough to prevent a leak.



    Mechanics rule of thumb---never put a bolt in that is dry---let alone corroded, rusty or dirty to the point
    it squeaks when you tighten it-----then when you try to remove it-----good luck. It was a pain taking the bike apart--lot's
    of near stuck bolts. Clean the bolt on a wire wheel and lube it with something---I prefer anti-seize mostly--or
    lock tite if appropriate for the situation--never dry tho.
    This is most important on a motorcycle ---as things are more exposed to nasty weather.



    Air cleaner-----the air cleaner wasn't quite long enough to seal good on the rubber seal at the back of the airbox.
    I could see some dust had by-passed the already dirty air cleaner. I got to do something to the airbox to fix that
    or ruin the piston and rings--I'm afraid some damge to the motor has already been done.



    At this point I had done extensive repairs----put on new tires---new wheel bearings---new head bearings---heated grips--bunch of re-wiring.
    I was trying to get it road worthy.

    [​IMG]


    Got my new diaphrams and pistons----$118 a piece---ouch.

    [​IMG]


    The sprocket bolts are seized and would be impossible to remove for a sprocket replacement
    on the road-----it will take some serious shop tools, impact wrench and probably a lot of heat to get
    them out---I may have to cut them out and get new ones.

    After a month working on it in the garage in the dead of winter I finally got it out for a ride.
    Now that the carbs were rebuilt and perfect it had lot's more horsepower---lot's more.
    So much more that the clutch now slipped badly. No way you could tell this before as it was running sore badly.
    So---it needs a new clutch.

    But I kept riding it that day------now I got about 100 miles on it since I bought it and while shifting into 3rd gear on a nice country road---------it thru a rod.

    So now as Paul Harvey use to say.

    "Now you know the rest of the story"

    I was promised some money as an extremely partial re-reimbursement---it's been over 4 years and I've given up on that.

    I'm 61 years old----and this is definitely the most deceitful thing I've ever had done to me.
    It was a $7,000 lost to me after all was said and done.
  13. meteorpilot

    meteorpilot YEE, ahem. YEEEHAW!

    Joined:
    Dec 17, 2006
    Oddometer:
    72
    Location:
    Indianoplace, Indiana
    Wow, Mark. What a disappointment. Thanks for the heads up! Sorry you had to take one for the team.
  14. Mercury264

    Mercury264 Once you go Triple...

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    Location:
    Masshole
    :huh
  15. Transalp Jas

    Transalp Jas Been here awhile

    Joined:
    Feb 13, 2006
    Oddometer:
    809
    Location:
    Corner Brook,NL
    I remember following the build-up of this bike. It seemed thorough and well-done. The previous owner seemed to really know his way around in the garage. I'm shocked that this bike was in such horrible condition.

    I wonder how many of the problems resulted from excess wear and tear from such extensive modification? Like many TA owners on this board, I've modified my bike based on this (and other) build threads. I haven't done nearly as much modification as the previous owner of your bike. I did mainly suspension mods. No AT tank or fairing, no new front rim or brakes, no rear disc addition. Still, it makes one think.

    Sorry for your troubles. Most of us buy used bikes, and there's usually one or two little surprises waiting for us when we get them home. Nobody should be stuck with the mess you ended up with. I hope you have better luck in the future.
  16. mas335

    mas335 xendurist

    Joined:
    Jun 17, 2006
    Oddometer:
    2,192
    Location:
    Piedmont region NC
    I also remember this bike and in fact we spoke by phone about it. If I remember this correctly it is a bike that I considered buying this from the original seller before Jeff bought it. When I learned the actual history details on the bike it had me running away from it fast, real fast.

    I seem to remember that Jeff was a friend of yours? I had always hoped the right thing would be done and you would get your money back.

    I've been self employeed most all of my life and if there is one thing I learned it's this, you only learn the true character of a person when money is involved.

    On a side note, I thought a friend of mine in GA. was buying this bike from you?
  17. BigDogAdventures

    BigDogAdventures Fart Letter

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    5,746
    Location:
    Mt. Vernon, Illinois
    I honestly don't remember who bought it.


    He was a really nice fellow---hope he did good with it. I think he had a motor--not sure ???
    I did tell him it "Wasn't" ready for the TAT.

    BigDog
  18. BigDogAdventures

    BigDogAdventures Fart Letter

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    Location:
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    All bazillions PM's replied to.
  19. BigDogAdventures

    BigDogAdventures Fart Letter

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    In response to all the PM's about this---yes, buying this bike was probably the most dis-heartening thing to ever happen to me. People can be so disappointing when it comes to money-------------they will turn on you.

    BigDog
  20. BigDogAdventures

    BigDogAdventures Fart Letter

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    Nope------------no money yet---------it's been over 4 years now.