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Thread: Re-build:The Humble 1983 TVS 50 XL

  1. #1
    Rusted karthik_R's Avatar
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    Thumbs up Re-build:The Humble 1983 TVS 50 XL

    Hi guys,

    I was going through the race website of TVS and read a very interesting statement which said

    "It all began way back in 1984 when Sundaram Clayton Limited (A TVS Group company) introduced its 50 CC mopeds in the arena of road racing, notching up unbelievable speeds of 105 kmph. Since then, there has been no looking back for TVS Motor Company.."

    Back when I was a school goer, there used to be this next door mechanic who had numerous trophies and cups along with the greasy tools. I remember asking him, where did you win them ? To which he replyed with a smile "rally". I proceeded to ask him as to which bike he was riding in the rally. Bang came the answer "XL", I was like TVS XL ??!! He patiently said yes and said there is a race at green pitch, if you are interested you can come and watch. This was back in my 6th grade.

    Rewind another 4-5 yrs back, my dad had bought a second hand TVS 50 XL, a 1983 model. 20 yrs after, the moped rusting to bits,not able to find its share of the porch space with the bikes and car, had to refuge beneath the terrace landing. Today, thanks to the power cut, I was scavenging the house and there lay my dad's humble step thru. This bike carried around 4 passengers in its hay day for till 1999 and was retired by the scooty. I felt this one needs some steroids and decided to bring it back to life. Moved the car out, to make some room and accessed damages caused by nature, rodents etc. The rims, spokes, engine head and a few other parts were rusted, wiring cut, frame bent..I was very sorry for the state of the bike and now, I am doing something I've never done before in my entire life..Yes, restore it. I know some guys here restore bikes like the TZ and RDs..

    Will attach pics and list of parts that needs to be changed as and when brought. And I have decided to do all the dirty work except the painting my self.

    First set of essential bought :

    >>Front and back brake cables
    >>Front and rear brake shoes
    >>Throttle cable
    >> Clutch or the starter cable as they call it
    >> Clutch gate or gata (whatever the lingo)

    Today, the entire bike lays disassembled in bits and carefully stored in a card board box. Spent close to 4 hours with my brother on the disassembly. Hopefully will secure all the spares by the next week..
    Last edited by karthik_R; 10-22-2009 at 10:02 PM.
    TVS 50 XL : TVS VICTOR GL : YAMAHA R15 : YAMAHA FZ1n :: Duke 390

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    Rusted Aryan's Avatar
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    Topic Approved.
    ...in search of that perfect world - My Travel Blog :)

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    CommuTOURer satyenpoojary's Avatar
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    Now this is one of the best things I have read in this rebuild section....
    Best of luck dude...
    Cheers!
    Super CommuTOURer - Talk less, Ride more

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    Satyen Poojary

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    Rusted outworldly maniac's Avatar
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    best of luck friend

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    Rusted blisteringintelligence's Avatar
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    Best of luck kartik,, do update us on the developments...

    PERSEVERE... failure is not an option!


    '88 Premier Padmini | '99 Maruti 800 | '99 Yamaha RX135 | '10 Wagon R | '11 Yamaha FZ16






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    Rusted karthik_R's Avatar
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    Some pics before and after the disassembly..

    Hunting for the next set of spares

    >> Carb gasket.
    >> Front forks assmebly, probably will go for the conventional oil filled ones(tvs xl heavy duty type)
    >> Rear suspension is shot (damps horizontally ) original cause for the bend in the swingarm
    >> Fuel tap and line
    >> Consumables like nuts,bolts, washers (all rusted as of now)
    >> Air filter



    P.S : Didnt clean the bike and has been in this condition for more than 10yrs now.
    Last edited by karthik_R; 07-20-2009 at 10:58 AM.
    TVS 50 XL : TVS VICTOR GL : YAMAHA R15 : YAMAHA FZ1n :: Duke 390

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    Rusted dual disc 200's Avatar
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    Congrats dude, this is something that i'm waiting to see it moving!
    Whenever there is a Rainbow in the sky, I know it's u mastering the art of Cornering. U will always be remembered brother, R.I.P Arun.

    The 5 Speed Restoration
    The Z Restoration


    /2001 Yamaha Rx 135 5 Speed/ 1999 Yamaha RXZ 135/ 2012 Honda Dio/ ?

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    Addicted badriyan's Avatar
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    thats a nice looking tiny kawasaki!!! wish you all the best for the restoration.

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    Rusted ripper's Avatar
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    Quiet an unusual restoration project, very interesting though. Wish you all the best!

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    ah finally some greasemonkey stuff.Incidentally my first 2 wheeler was my uncle's tvs 50 xl .Amazing load carrying capacity.Sold in large numbers in tamil nadu.People over there use them as load carriers be it gas cylinders or cement sacks or a family of 4.
    Best of luck
    Socha Toh Locha.

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