Tweet
You live in Salaria 
You're my neighbor !
Will drop by when I come home for vacations : )
You're my neighbor !
Will drop by when I come home for vacations : )
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Shanghaing/
I over-torqued one of the banjo bolts securing the oil pump outlet to the clutch cover and ended up shearing it. I went around looking for one but couldn't find it. I took a couple of bolts of the same size to a lathe shop and the guy told me that he couldn't do it. So I thought why not give it a try myself.
so, with a pair of vice grip pliers doubling up as a bench vice and my trusted Skil electric drill and a 2mm Bosch HSR drill bit, i fashioned this. I ended up breaking the drill bit but i had my banjo bolt.
@rabbit13: you have a PM.Last edited by rookieraj; 03-27-2012, 09:06 PM.Comment
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WOW ! great DIY...you are improving and innovating day by day...Originally posted by rookieraj View Post
I over-torqued one of the banjo bolts securing the oil pump outlet to the clutch cover and ended up shearing it. I went around looking for one but couldn't find it. I took a couple of bolts of the same size to a lathe shop and the guy told me that he couldn't do it. So I thought why not give it a try myself.
so, with a pair of vice grip pliers doubling up as a bench vice and my trusted Skil electric drill and a 2mm Bosch HSR drill bit, i fashioned this. I ended up breaking the drill bit but i had my banjo bolt.
@rabbit13: you have a PM.When Was The Last Time,You Did Something For The First Time.Comment
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@Rookie, Superb DIY! Vice grips come in handy and are a good addition to personal tool kits.1985 Yamaha RD350 HT
1989 Ki-Honda 110
1994 Suzuki Shogun
1997 Yamaha RX135
2008 Yamaha FZ
Suzuki Supra Powerup
IND-SUZUKI AX100
Hero IMPULSE
TVS NTORQ
No Cams, No Valves, No Headaches.Comment
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Originally posted by rookieraj View Postand guess who told me about the vice grip pliers Doc?
.. Thanks!
1985 Yamaha RD350 HT
1989 Ki-Honda 110
1994 Suzuki Shogun
1997 Yamaha RX135
2008 Yamaha FZ
Suzuki Supra Powerup
IND-SUZUKI AX100
Hero IMPULSE
TVS NTORQ
No Cams, No Valves, No Headaches.Comment
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Rookie! You have got to show us pics of what the bike looks like now!!!!True blue smoke makes the devil's blood run coldComment
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Wah!! Jahaanpana!! Tussi great ho!! Thats's what went through my mind when I saw the pics rookieraj sir. Stupendous! From the pic posted by yamdoot sir I see that the compression ratio is really high(11.3). Have you got the same numbers? And did you use the three bond gasket like psr sir said?Last edited by harishkumarko; 04-29-2012, 04:35 PM.Tour De Thekkady
The Return of the KB
The Run-in Adventure
150cc doing 100+ is great!
100cc doing 100+ is awesome!!
150cc cornering like hell is great!
100cc cornering like hell is awesome!!
THAT'S WHY I RIDE A RTZ!!Comment
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Status Update
As mentioned earlier, i got the engine to fire but no matter what i did the oil leaks wouldn't stop.
So, i stripped down the engine, bought some grinding paste and started hand lapping the mating surfaces of the crankcase halves and the clutch cover on a glass pane. the process was taking so long that i decided to do something else. i saw a video on youtube and accordingly i pasted emery paper on a granite slab and hand lapped the parts on it. it was a gradational process ie first with 220 grit and thereafter with 400 and 600 grit. i then assembled the engine again.
no oil leaks so far and i'm keeping my fingers crossed.
@harishkumarko: i have yet to buy a compression gauge. three-bond gasket sealant is not readily available so i used anabond 696.Comment
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Wow.. Really commendable! . Must've required a lot of patience.Originally posted by rookieraj View PostLast edited by yamdoot; 04-30-2012, 08:23 PM.1985 Yamaha RD350 HT
1989 Ki-Honda 110
1994 Suzuki Shogun
1997 Yamaha RX135
2008 Yamaha FZ
Suzuki Supra Powerup
IND-SUZUKI AX100
Hero IMPULSE
TVS NTORQ
No Cams, No Valves, No Headaches.Comment
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They say necessity is the mother of invention....First the banjo bolts and now this....you are following the lines of Edison...I am eagerly waiting to see what next ? and learn some more from you...Originally posted by rookieraj View PostWhen Was The Last Time,You Did Something For The First Time.Comment
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The hardest thing to accept in life is the TRUTH..Originally posted by rookieraj View PostAnna, its also said that an empty mind is the devil's workshop.
and you learning from me? khayaal achcha hai (its a good thought to amuse yourself with):
When Was The Last Time,You Did Something For The First Time.Comment
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Re: My KB125 Rebuild
Hi rookie
Awesome thread, read it all since last night and now.
I am also starting work to get my 18 yr old KB100 RTZ to new state.
Have posted a few queries on kb100's thread.
Am glad I got here, so much information in these threads, and not to mention the Manual from PSR.
Thinking of starting a thread of my own, but I am not sure whether the pace of my work will justify a thread at all.
Again, great effort.
kb100, you, PSR - give me confidence to aim to do all work myself.
(anyhow these stupid mechanics will do more damage than good to my handsome RTZ)
RegardsComment
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Re: My KB125 Rebuild
It is always the First step that is difficult to take, but once that is done you will be another master here......and seeing that you had already done that, wish you Good Luck...Originally posted by KB100RTZ View Post
Mechanics will always mess up when fitting the Rotary Disc Valve...so be there, and take a look at the Manual to know the proper position for fitting the Valve.When Was The Last Time,You Did Something For The First Time.Comment
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