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Restoration Project: CBZ 1999

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  • #1

    Restoration Project: CBZ 1999

    Hello brothers,

    Need your help and advice to restore my 11 year old CBZ.

    History:
    - June 1999 Model.
    - 2,00,000 + kms.
    - Stock bike.
    - Currently bike is in Gurgaon.

    Problems:
    - Not in use since 2 years.
    - Got serviced locally.
    - Clutch plates burned.
    - Doesn't inspires confidence as before while on turns and bends. Problem with overall balance.
    - Paint condition is very poor.
    - Rust on many parts including nuts of engine block.
    - Entirely rusted rims.
    - Weak headlight.

    Desirable Work to be done:

    - Restoration to original condition, internally and externally.
    - Some basic mods like better headlight, K&N, Alloys? Please suggest which one for all.
    - Open to further performance mods.

    Help required:
    - A competent and reliable mechanic or workshop in Gurgaon/Delhi who can carry out the job. (Most important)
    - Suggestions or considerations I have to keep in mind as I don't want to part away from the bike.

    Will post pictures of work in progress once it starts.
    Tags: None
  • #2
    Thread approved
    Happiness is finding you have another Gear left....

    Join xBhp On

    Comment

    • #3
      Hey Rockstar
      It seems like you need full makeover.
      For less expense visit karol bagh market.
      You can get any thing there if u search.
      Bikes don't leak oil,
      They mark their territory.

      Comment

      • #4
        @rockstar

        Restoration of a 1999 cbz is a big and tuff job apart from painting.The classic cbz commands japanese parts,which are difficult to source.You will get the indian ones anywhere and at a cheaper price.

        1.For balance and better handling :

        Change steering cone set and swing arm bushes and also change the 6piece bushes called as "kaychi" in hindi.Any mechanic would know that.Also check ur "T".

        2.Clutch plates :

        After changing ur clutch plates do get a diesel flush done since it's run more than 2lac kms.Diesel would remove all the sludge and dirt from the crankcase.And start using fully synthetic oil if u have the moolah for it

        There are much more jobs to do than this.Xbhp guru's could highlight better.Best of luck and keep us updated!!
        Cheers.
        In A War Only Men DIE!!

        Hero Honda CBZ (43500kms) Running on Motul 3100 20w50 Semi Synthetic.
        Fiat Linea Emotion Pack Petrol (17350kms) Running on Castrol Edge Titanium 5w40 Fully Synthetic.

        Comment

        • #5
          thanks pioneeraron for the suggestions. Will surely keep in mind. Now I need help in sourcing a trustworthy mechanic in Delhi-NCR.

          Comment

          • #6
            Originally posted by rockstar1630 View Post
            Hello brothers,

            Need your help and advice to restore my 11 year old CBZ.

            History:
            - June 1999 Model.
            - 2,00,000 + kms.
            - Stock bike.
            - Currently bike is in Gurgaon.
            All the best for the work. Post pics and keep on updating!


            - Not in use since 2 years.
            Guess the battery needs a replacement.

            - Clutch plates burned.
            Clutch plate replacement needed.

            - Doesn't inspires confidence as before while on turns and bends. Problem with overall balance.
            You mean there is bend on the chassis? or anything others?

            - Paint condition is very poor.
            - Rust on many parts including nuts of engine block.
            - Entirely rusted rims.
            Need Repainting.


            - Weak headlight.
            You mean reflector damaged or weak bulb?

            Desirable Work to be done:

            - Restoration to original condition, internally and externally.
            IMO,If there is serious balancing problem,then get the chassis replaced.Dont know the price exactly,for glamour its nearly 4000rs and for karizma its nearly 6700rs.

            - Some basic mods like better headlight, K&N, Alloys? Please suggest which one for all.
            - Open to further performance mods.
            I dont know much about headlights,so my opinion is get the stock headlights and bulb. Dont waste money for L&N Filter,its just waste of money,even after proper jetting ,you may get an increase of 0.3hp,which is mostly unnoticeable.You could have done any other thing for that money.like considering replacing the chassis.

            Is the spares available @ SVC? parts like chassis?etc???


            All are my opinions and thoughts.Any one can correct me if i am wrong.

            Comment

            • #7
              There is a lot of work to be done IMO.

              But depends what do u wanna start with first. Cosmetics or the engine and chassis?

              If Cosmetics, then make a list of all parts ( Cowling, headlight, tail light, indicators, side panels, tank side panels ( The TPFC ones ), Tank, seat, handlebars, grips, levers, mudguard, inner mudguard, rear mud flap, footrests, brake and gear pedals, rubbers, mountings etc. And start collecting one by one.

              Simultaneously, Strip the bike completely, inspect the chassis, and look for rusting. Get it cleaned and repainted.

              For the unbalanced conditions, check the handle T and race and cone set etc as suggested above.

              The classis CBZ used a lot of japanese parts. Get the bushes for the rear swing arm OE japanese if possible.

              There are a lot of things that can be re-used or repaired, you will have to go thru all the parts and figure that out.

              Keep querying and keep posting here...


              My offerings to the gods of speed -

              - KTM Duke 200
              - Yamaha RXZ 5 speed


              Comment

              • #8
                Originally posted by jd666 View Post
                There is a lot of work to be done IMO.

                But depends what do u wanna start with first. Cosmetics or the engine and chassis?

                If Cosmetics, then make a list of all parts ( Cowling, headlight, tail light, indicators, side panels, tank side panels ( The TPFC ones ), Tank, seat, handlebars, grips, levers, mudguard, inner mudguard, rear mud flap, footrests, brake and gear pedals, rubbers, mountings etc. And start collecting one by one.

                Simultaneously, Strip the bike completely, inspect the chassis, and look for rusting. Get it cleaned and repainted.

                For the unbalanced conditions, check the handle T and race and cone set etc as suggested above.

                The classis CBZ used a lot of japanese parts. Get the bushes for the rear swing arm OE japanese if possible.

                There are a lot of things that can be re-used or repaired, you will have to go thru all the parts and figure that out.

                Keep querying and keep posting here...
                Thanks to all contributing. The challenge is now to find a good mech in gurgaon. Can you suggest someone? I ll start with the internals first.

                Comment

                • #9
                  I do have a mechanic, but he will only be able to work on weekends. The good thing that i liked about him was that,

                  a) he has worked in mumbai rather than just on the streets of gurgaon, so he knows his stuff.
                  b) is ready to work the way you want him to ( no hammering, or forceful working on parts, clean work, and clean results ).
                  c) Understands your requirements quickly so you dont have to explain to a mechanic scratching his head why would you like to restore a 12 year old commonly available bike.

                  PM me your number, ill chat you up tomorrow morning and help out.


                  My offerings to the gods of speed -

                  - KTM Duke 200
                  - Yamaha RXZ 5 speed


                  Comment

                  • #10
                    Thanks to JD for all the help yesterday. With his guidance, I've decided to approach the work related to bikes in five stages:

                    Stage 1: Engine overhall. Complete replacement of all faulty components, if need be, crank/cylinder as well. Clutch replacements. Accelerator assembly replacement. Replacing all springs.

                    Stage 2: Suspension replacement: Front and rear. Replacing all faulty, worn out cables. Adding Karizma alloys, if possible the entire Karizma disc assembly. Changing of all bushes.

                    Stage 3: Complete strip down and repainting of engine, chasis, frame, plastic components, silencer. Might go in for a custom paint.

                    Stage 4: Replacing Tyres, Meter, Rubber Kit, Levers, Headlight (Clear one), Battery.

                    Stage 5: After completing the running in, will add K&N and upjet.

                    Some questions: Should I go for synthetic oil after engine rebuild? If yes, which one?


                    Will post pics before the work begins. :-) Please suggest wherever necessary.

                    Comment

                    • #11
                      Originally posted by rockstar1630 View Post
                      Stage 1: Engine overhall. Complete replacement of all faulty components, if need be, crank/cylinder as well. Clutch replacements. Accelerator assembly replacement. Replacing all springs.
                      Dont forgot to replace all Oil seals,O-Rings and Valve Stem Oil Seal.

                      Stage 2:Adding Karizma alloys, if possible the entire Karizma disc assembly.
                      Wont it be costly?


                      Stage 4: Replacing Tyres
                      Did you decided which one to get? I can help you in this section.

                      Stage 5: After completing the running in, will add K&N and upjet.
                      Again i wont recommend this mod,Still if you want,Go for it and i have a used K&N RC1060 with me,used just one week.Changed to stock filter due to non availability of jets.So if you are interested,PM me!

                      Some questions: Should I go for synthetic oil after engine rebuild? If yes, which one?
                      After engine overhaul,You will have new piston rings and other metal parts(if anything need replacement),So a small there will be a small run in period, So mineral oil will be best for completing the first 500 after engine overhaul.Just my thought.


                      Will post pics before the work begins. :-)
                      Waiting for it.

                      Comment

                      • #12
                        Thanks Aneesh for all the input.
                        Karizma alloys and disc assembly won't be costly. I will source it from a known friend for very less.
                        Suggest me the best tyres.
                        PM me the price for K&N.
                        Will complete the run in with Mineral oil.

                        Comment

                        • #13
                          Originally posted by rockstar1630 View Post
                          Some questions: Should I go for synthetic oil after engine rebuild? If yes, which one?
                          Yea buddy go for fully synthetic engine oil.Instead start using Motul 300V FL the best synthetic available for bikes.Your bike would love it
                          In A War Only Men DIE!!

                          Hero Honda CBZ (43500kms) Running on Motul 3100 20w50 Semi Synthetic.
                          Fiat Linea Emotion Pack Petrol (17350kms) Running on Castrol Edge Titanium 5w40 Fully Synthetic.

                          Comment

                          • #14
                            ^^ It's never appropriate to use synthetic oil on a new/rebuilt engine. Use mineral for the run in and then switch over to SS/FS. For reasons take Google's help :-)

                            Dude rockstar, long time no update?
                            Contribute to the environment.

                            Comment

                            • #15
                              Originally posted by nirvaana View Post
                              ^^ It's never appropriate to use synthetic oil on a new/rebuilt engine. Use mineral for the run in and then switch over to SS/FS.
                              +1^^^ Run on mineral, atleast 6000kms and after that switch to SS or FS in case of a new engine. For an overhauled engine,500kms is enough,for safety make it upto 1k
                              Last edited by Aneesh@4GHz; 09-15-2012, 05:21 PM.

                              Comment

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