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The Suzuki TC120 Cat II

While hunting for a set of exhaust pipes for a Suzuki RG 250 we came across another trail cat. This time it's a runner. The intention is to get this bike mechanically sound with some cosmetic flair

TC120 first batch for sandblasting

Tear-downs are usually a quick job but despite the simplicity of a TC120, this little bike turned out to be a real fiddle. Many of the bolts, shafts and nuts were rusted, seized or had bolts that had lost their heads.

Parts Worked On: 

  • Frame assembly, Front Wheel, Swing Arm

Off with the TC 120 Spokes

This evening was spent removing the spokes with a spoke/nipple wrench. With two sets of wheels we’re hoping to restore at least one good set with some spare. The rust has really worked it’s way around these wheels so we’ll need to go through them with a fine tooth comb.

Parts Worked On: 

  • Front Wheel, Rear Wheel

TC120 Tear down has begun

Only the chain was supposed to come off this morning but the short time spent in workshop ended with more progress then expected.

Parts Worked On: 

  • Frame assembly, Engine

Suzuki TC120 Seat Refurbished

This has been a quick turn around. The fibre glassed seat base was painted in 2pack satin black and conveniently reproduction seat covers available online. As soon as the seat base was painted, new sponge was glued on and the new cover riveted onto the base. It’s looking like the Christmas Holidays will see the little TC120 getting a complete tear-down.

Parts Worked On: 

  • Bodywork

TC 120 Seat Refurb started

This bike is a bit of a side project but it’s starting to get really exciting. The poor thing had clearly spent a great deal of its life outdoors. The seat has been taken off and stripped right back. The sponge started to turn into powder and the metal seat base was rusting away. 

Parts Worked On: 

  • Bodywork