Disclaimer:

• I am no restoration expert, just a somewhat crazy, silly, irrational petro-head, yearning for the next adventure, if not on the roads – then for the roads!
• If you seek some rational ratification from my post, you won't find it - This is totally an irrational decision of a crazy biker.

Prologue:

Some craziness does hit you in mid-life crisis, especially once you lock yourself up in a tiny room for hours slogging on a computer.

One of the solaces, I’ve discovered is binge browsing, and in that process came across a 1999 model TVS – Suzuki Samurai bike, for those who don’t know – it’s a 98.2 CC, 7.8 Bhp, Single Cylinder, 2-Stroke Bike – that was made in joint collaboration with TVS & Suzuki Motorcycles.


Why a Samurai? It’s not a RX, Shogun or a Shaolin ?

A typical mid-life crisis hit, when you suddenly get emotional to some bleak childhood memory. In my case a 20 year old memory, when out of experiences driving a Gypsy, Zen and 800 – I believed, anything with Suzuki written on it is super cool and fast! I had almost convinced my dad to get me a Samurai, but at the last moment he had a change of mind and bought me a Bajaj Bravo.

My Buying Process:

Saw the bike online, seller first wanted to sell it off as whole and then decided to pull it apart and sell it for parts! Something clicked, without even seeing the bike – decided to close the deal. – Guess some childhood memories cost !

Total time to buying decision: <10 Mins! - The bike was delivered to me during the lockdown.


Condition of the Bike:

The bike has an expired digital RC on the Vahaan Portal, and is a total project bike – in need of a grounds up restoration. Most of the things that could go bad, have gone bad on this bike.

Below is my 9 stage approach to restoring this bike:

Stage – 1 Analysis:

The Good:

• Chassis is quite okay, only a little surface rust
• Bike starts with some effort and Revs
• All bits and pieces are there in varying conditions.
• 2T Pump is present on the bike, but is disconnected.
• All gears engage

The Bad:

• Fuel tank is gone beyond repair (Currently working with M-seal)
• Mudguard has surface rust
• Wiring is kaput
• Switches are all lose and needs changing
• Meters do not work
• Clutch action is suspect - Clutch bell has play
• Front rim is cracked and rusted
• Locks are all broken
• Headlight is okay but not OEM
• Mirrors are missing
• Choke does not work
• Brakes are weak
• Wheel bearings are shot
• All rubber parts show signs of age and rough usage.

Stage 2: Planning

The bike would be restored in two phases – mechanical and cosmetic. First preference would be for mechanic restoration, getting everything working and running as it should and then would address the cosmetic bits.

1. Mechanical phase: Get everything in running order, repair/replace whatever is necessary.
2. Documentation: Arrange for proper documentation of the bike, if successful – only then do a proper cosmetic restoration or I sell off this bike to some enthusiast.
3. Cosmetic Restoration: Strip the bike completely and do a quality future proof paint job.

Stage 3: Preparation

• Listing out what parts seem to be immediately needed
• Finalizing the mechanic who can work on this machine
• Estimating the total budget for the build
• How would be paperwork be arranged? – Still in progress

Stage 4: Procurement

Procuring parts from reliable sources with good references on the internet – I could not visit the Karol Bagh Market owing to the pandemic, I am sure would have saved a lot in that process. Parts sourced from various sources over Facebook and word of mouth references.

• All cables
• Wiring assembly
• Lock Set
• Packing kit
• Gaskets
• Shell transmission oil
• 2T oil – Motul
• Engine flush
• Clutch plate
• Brake shoes
• Front wheel Rim
• Actually a long list of parts

(I will update contact details of the various sellers I got my parts delivered from, for the benefit of the entire community)

Stage 5: Bring the bike in running condition to ascertain the way forward.

1. All cables changed
2. Wiring harness changed
3. Lockset changed
4. Meter case changed and meter repaired
5. Carb cleaned and packings changed
6. Chassis cleaned and spray painted - somehow rust protection.
7. Silencer cleaned and muffler changed to Shogun.
8. Brake liners changed
9. Wheel Bearings changed
10. Front RIM changed
11. Wheel aligned
12. Cone set greased
13. Tank repaired with M-Seal and is holding on ok, but will be changed.
14. New battery installed.
15. Wheel bearings and hub rubber replaced

Stage – 6: Evaluation & Road test.

1. The bike starts erratic, troublesome when parked overnight - but starts on first kick when engine is warm.
2. 2T pump seems to work and there is smoke under acceleration
3. acceleration is slow, mechanic says it's due to clutch bell slipping.
4. Bike hits 60 easily, kind of struggles to go to 80
5. Breaks work well
6. Horn needs to be changed
7. All electricals are working
8. One of the side panel locks is not working
9. All plastic panels need to be replaced - I was thinking if I can have the back panels fabricated by a denter, would it work?
10. Panels have been repaired

Stage 7: Pending work:

1. The clutch bell is lose and needs attention.
2. Engine compression is slightly weak, mechanic says changing the ring will solve it.
3. Engine bearings need changing
4. Horn needs changing
5. Leg-guard has been ordered and is awaited
6. Slight leak from the silencer needs attention
7. Front fork needs some tinkering
8. The bike needs better lights.
9. Paper work!
10. The center stand and side stand kind of act funny – I mean it’s not properly balanced.
11. Fuel tank is to be procured.

Stage 8: Paper work or sell off the bike?

Get the paper work (extension of 5 years) – if not, find another bike with papers, make this a donor bike and sell off other parts.