This MZ TS125 was a barn find. It had had a hard life, reputably once being used by a local Scouts group to learn to ride in a field.
It was a sorry state. The engine was seized, the rear wheel wouldn't turn; there were a number of parts missing and it looked like it had been dropped on the left side, with bent control levers and a snapped clutch.
The engine was removed and put to one side.
The rear wheel was removed and the drum brake released with a combination of heat and force. The old seat was beyond repair and discarded, so too the handlebars, tyres and rubber parts, headlight and most of the cables.
Debris and corrosion in rear brake drum.
Brake shoes were beyond repair.
The spokes were in need of replacement.......
.....but the hubs were OK once they were cleaned up.
After the strip-down, the frame was treated at any rust spots and painted with a tough coat of satin black paint. The wiring loom was put back in the frame and the wheels were rebuild with stainless spokes.
New parts ordered were brake shoes, silencer, handlebars, tyres, tubes, spokes, wheel bearings, headstock bearings, chain, battery and tank badges.
Only the remnants of the battery tray remained.
A 3D printed part was created with a captive nut for the side panel bolt. It was designed to locate on the old tray stubs, to be secured with two rivets.
Battery tray and battery
This photo shows the bike back on its wheels with stainless spokes and fresh tyres, a replacement seat (thanks to Nic) and the rebuilt rear shock absorbers.
The inside of the tank was badly corroded.
A week was spent slooshing the tank out with vinegar and some loose nuts and bolts. Each day the vinegar was filtered and poured back in for agitation.
A substantial amount of dirt/rust/debris/cack was removed.
The de-rusted tank
The tank was treated with POR tank lining chemicals with good results.......
.....the measuring cup was treated at the same time.
Externally the tank was left as is, to maintain the bike's history and character.
This photo shows the electrics and tin-ware installed. The left side panel had been fitted with an ammeter to keep a check on the 6v electrics. There was a yellow driving light also added at the front, with an LED bulb to be used as a daytime running light, without draining the battery.
Work now began on the engine which is detailed here.
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