atul_astro

Vacation time, and I was itching for another rebuild to come my way. Insaneroller needed help rebuilding his shogun so I decided to bring the bike home..Me and Jokerman went over to his office to collect the bike the first day..The bike refused to start after many kicks..and then she sputtered a bit..and water came gushing out the silencer..lol Mumbai monsoons, what can I say..The bike was unused for 6 months and it looked like the guy insaneroller had given it to wasnt taking good care of her...W decided to come the next day





Day 2: we come over with 2 litres of petrol mixed with Motul 8002t . I opened the carb and cleant it, got the water off the petrol tank and filled the tank up..The spark plug got cleant and the air filter removed [i had a hunch it was choked]...of course with many sarcastic arguments with Jokerman
and the bike fired to life in the first kick itself

rode her home and it did feel like she wasn't keeping too well..the gears didnt shift well, the tyres wobbled a lot..we reached home and stripped the bike for the grand rebuild of her life

Here's a list of what I feel she should have
A bulletproof engine
Good suspension [ The one on the bike is shot..esp the rear
Good braking [ a front disc should suffice..or the whole bounty would be the RTR front and rear disc setup with that swingarm]
a good paintjob
a few tweaks like a bigger carb and a filter kit and maybe a big assed banshee reed valve and ofc..an expansion chamber

We got the engine opened up...The port setup on this thing is insane!..The intake port, transfer entries, huge exhaust port, thin walled transfer passages. It sure has a radical port setup for a stock bike..No wonder it kicks ass, i said to myself

Here' some pics























My observations so far

1.Cheap assed Sam piston kit with huge bits off it, pitting of course
2.Poorly rebored barrel..The hone marks are there at weird places on the barrel and the piston does not even mate with the liner, indicating a ovality in the bore
3. Crank is shot. Huge big end play and hiss from the big end too. Webs damaged [ some idiot tried his hand at it with a hammer]
4. Somehow, the crank and the bearings were not installed right and the crank webs were rubbing against the cases for a long time now..Main bearings shot
5. Clutch needs a rebuild. Sideways play exceeds 6mm. Clutch Plates are fried and baked
7. Damaged gear shaft. 2 or 3 of the gears show excess signs of wear. Needs to be replaced


Goodies to be going in the engine
A fresh bore kit
A fresh crank
New bearings [HIC main bearings]
complete transmission overhaul [ Shifter forks, shifter shaft, cogs and shafts trued]
Maybe a Yamaha RZ/Banshee fiber reed valve upgrade and a few minor tweaks to the intake
A good 28mm carburetor, preferably a TM28

Many thanks to insaneroller for trusting me with his bike and going in for the MTI treatment I have quite a few plans for this baby, mind you.

Another set of thanks to Jokerman, coz he'll be working with me on this project and the cycle bits, handling and painting is his dept..Your help is always appreciated

Watch this space for more

Cheers

Atul [Motorhead Tuning Inc]

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83' RD350 HT
96' RXG
97' RXZ
91'RX100>09'RX165
2010' HH ZMR

Aryan

Topic Approved.

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...in search of that perfect world - My Travel Blog :)

swingarm

Atul,

Congrats on taking up such a grand restoration job. Waiting eagerly for the final outcome! Just two things I would like to mention - the Shogun stock silencer is an expansion chamber in disguise and please go for original ART piston with original SGP rings.

PS: I have heard a lot good about your capabilities from my friend Pradeep (RX 135) from Bangalore.

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'98 Shogun

'91 RX100

psycho 98

Considering the manifold design of the shogun makes me wonder can we fit in a banshee there, i know nothing is impossible to you please post some pics of the intake port after its done. busy boy atul where are you nowadays

jayprashanth

Atul,

Another tuner gathering working hard up the REP ladder. Great going man.

Nikhil Pereira

Atul all the best for the rebuild....n finding the parts as well.....i know we average jocks will have a big time trouble finding shogun shaolin spares9i know i do) but guess it'll be a cake walk for you......all the best and let us know how shes coming along.....

MavericK46

Psycho saar already has some designs on the Shogun i see
Any chance of of a Shogun project from you..?

@Atul : The Pulsar headlight etc look so outta place on the 'gun mate. Here's hoping to see that Shogun setting the streets ablaze soon !

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yamdoot

sahi hai atul! tell me when find spares.. i might need a few too.. aur wo chu..pulsar ka fairing fhek de sabse pehle..

Raccoon

Seeing a gun in such a state nearly gave me a fit!

Anyway, anybody has any idea whats the best option for the headlight assembly? My gun is still on the stock headlight assy and fairing. Some #$^$&* moron cracked my fairing on the left side recently, while it was parked somewhere. Can't get another fairing anywhere. So whats the best options for fairing/headlight? A TVS supervisor told me I can fit a Samurai headlight without any problems, but I just don't like the look of it on the gun... also it would then be without a fairing, which dosen't look good.

One more thing - is it possible to change the oil seals on the crankcase (kick shaft, gear shaft, sprocket) without opening the crankcase (right side) and and draining the oil and all?

swingarm

If you want a black front fairing, I can help you.

To change the kick shaft oil seal you have to open the right and thus have to drain your oil. If your oil is new, you can pour it safely without any issues provided you drain it to a dust free container. Keep a crankcase gasket handy before you open the right side.

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'98 Shogun

'91 RX100