as for me, i've seen one 5spd rx100 setup just like insane_x97 mentioned. while i asked him what exactly did he do, he said something like replacing the gears or something like that.

also my other cousin rides a 135 4s which he converted to 5 speed recently. he is also unsure of what exactly the mech did. but from the look of it, he runs a stock gearbox. so will be really helpful if someone explained it. i am not going to plonk it on my 100 as it will be hard to revert to stock. just want to know how its done. thanks in advance.

good to see a fellow mallu modding a bike

yeah, i've noticed that "KL-2" before.

Now thats some hard core chop job on that block. i'm still figuring out the pics. Btw, where did you get the piston from (store/place pls) & how much for.

piston is of the make SAM-KRG. it is a first oversize shogun piston(52.75). sourced it from a local rebore shop. they stock these pistons as they'll have to supply pistons together with the block after a rebore job. cost is 550 for the piston kit.

are you planning to do such a job?

Been outta town for some days without web access so missed this thread. I must say this is a great and successful effort Navin! Simply amazing. Many can take inspirations from your project. Congratulations!!

thanks nitesh.

Nice work dude,

A year back i tried the same technique with some uneducated metch and guess what? ended up with some strange Problems like vibration after 60kmph and some extra noises . unfortunately no one was able to recognize the issue so i repalced with a New OEM Bore kit.



now after reading your project may be i can make out the issue and also get some help from you.


i dint get one thing here,have you gone for piston intake holes? or its as it is?

Same thing for me too except with Suzukis...After completely servicing my Suzuki MAX100R, I'm loving it more than my Suzuki Fiero....

piston is not at all altered, means it does not have the holes. yes, i read your thread before i did this mod. well, i had my set of problems. the intake holes are there to increase the charge flow at high rpm/ increased intake duration. without that it will just go flat at the top end(which is exactly what happened to your rx, also i dont know what exactly the mech did. did he alter the block or went for a longer conrod?). you need to do some homework before you do such a thing, and one thing with local mechs are that they do dont do this homework. what i did was alter the ports to increase the midrange and low end power and went pretty high on compression(this is a delicate process which requires precision in calculation and machining. you cant go super high on compression because of our cheap low octane fuel and also have to take into account rod stretch at high rpm. if you mess up something, the cyl block will be useless). it took some hair pulling before i got everything sorted out the way i wanted it to be. lathe shop (stupid) guys almost messed it up for me, but i improvised. also i'm on taller gearing. so i can put that increased midrange power to good use. the best part is, it delivers 35-40kmpl in normal conditions. also i did some other small tricks to go with this engine mod. overall it is a reliable and torquey setup.

two strokes has that effect on you.

I will PM you..

@Navin,
Your mod job is awesome bro. I want to test ride your RX 110. I would like to do the same mod job on my RX 100 too . Because, my ride's mid range is not that much responsive as you already know.

but your 100's top end is really good. i am pretty convinced about that from our last g2g.

Amazing stuff Fatality - just because you say you've achieved this all on your own !! Transfer bridge looking good too . I think cutting RX100 piston sized intake ports on ur piston would be a good idea. The ports that have been exposed will be covered by the gaskets so no need to worry. yup ur right your chambers end can design is poor at muffling sound. slicing a junk 4 speed bore will give you better results. Superb effort - enjoy

ps: why the extra effort to hide porting / pipe ? super fast eh ?

Very nice job there how much did it cost you including the EC ; was the FE figures checked with stock silencer or the EC