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**sanjithjoseph** · 10-23-2011, 10:41 PM

Me got few problems with my ride..

1) Even if the ignition is off the engine is not getting stopped. Lights and all are not working when the ignition is off but It is possible to start the bike without switching on the ignition. Key set is the new original one which is set during the restoration of the bike.

2) Gear shifting from neutral to first is too hard. And sometimes it produces a sound like 'trrrrrrrrrrrrrrr....' while attempting to shift the gear to first gear. This problem I have noticed during the last all Kerala Xbhp g2g n ride.

Friends, what may be the problem? How can I fix these?

**kb100** · 10-25-2011, 07:18 AM

Originally posted by sanjithjoseph View Post

Me got few problems with my ride..

1) Even if the ignition is off the engine is not getting stopped. Lights and all are not working when the ignition is off but It is possible to start the bike without switching on the ignition. Key set is the new original one which is set during the restoration of the bike.

2) Gear shifting from neutral to first is too hard. And sometimes it produces a sound like 'trrrrrrrrrrrrrrr....' while attempting to shift the gear to first gear. This problem I have noticed during the last all Kerala Xbhp g2g n ride.

Friends, what may be the problem? How can I fix these?

the ignition problem might be due to faulty earthing of the lock

since yours is a newly rebuilt bike some resistance will be encountered while shifting gears also do get the clutch properly adjusted

**sanjithjoseph** · 10-25-2011, 10:10 PM

Originally posted by kb100 View Post

the ignition problem might be due to faulty earthing of the lock

since yours is a newly rebuilt bike some resistance will be encountered while shifting gears also do get the clutch properly adjusted

Thanks Sarin, few days back me took the bike to another mechanic who is near to my office when I saw the pilot headlight bulb is not working.
He told me the bulb holder is in worse condition and temporarily he made the bulb to glow by cutting a wire and made it to touch the reflector part of headlight...Any chance for that to be the reason for the first problem? Or any disturbance in the wiring while doing all those!..?

Regarding the gear shifting problem I will check it by adjusting the clutch.

Thanks a lot again... Sarin...

**sixspeedtwin** · 10-26-2011, 12:28 AM

Originally posted by sanjithjoseph View Post

He told me the bulb holder is in worse condition and temporarily he made the bulb to glow by cutting a wire and made it to touch the reflector part of headlight...Any chance for that to be the reason for the first problem? Or any disturbance in the wiring while doing all those!..?

Get the "Socket Chord Assy" for the Pilot Lamp .... that should fix it ...

Better still, If u have not done so already, Get the entire wiring harness replaced .. is not too expensive, and is tops, a half day job for the RX100

**yamdoot** · 10-26-2011, 03:33 AM

Originally posted by sanjithjoseph View Post

Me got few problems with my ride..

1) Even if the ignition is off the engine is not getting stopped. Lights and all are not working when the ignition is off but It is possible to start the bike without switching on the ignition. Key set is the new original one which is set during the restoration of the bike.

2) Gear shifting from neutral to first is too hard. And sometimes it produces a sound like 'trrrrrrrrrrrrrrr....' while attempting to shift the gear to first gear. This problem I have noticed during the last all Kerala Xbhp g2g n ride.

Friends, what may be the problem? How can I fix these?

1. bad wiring and earthing or even a faulty switch.

2. try adjusting the clutch play on the engine cover. If it doesnt improve,the gears might not have been fitted properly . things like the shifter drum and shifter forks. Did you also check the clutch bell before the rebuild?

**sanjithjoseph** · 10-26-2011, 11:59 PM

Thankyou all for the help...

Checked the bike at PSN Yamaha,Cochin

Problem 1: Got solved, They told me that the black wire came out of the socket and was not tight..

Problem 2: I asked him, whether it is because of any other reasons like clutch adjustment and all(which are mentioned by you all here).The mechanic at PSN Yamaha told me that the gear lever fitting used in my bike are non OE ones. And because of it the gear lever position is wrong... will be OK once those fittings are replaced with OE ones and he will check the clutch adjustment too, If its not getting ok we will go more detail. And he added 90% chance is the problem with the non OE fittings used for the shift lever.

Actually what happened during the restoration is, My mechanic told me to change the gear shift lever and fittings. But the fittings was not available at YASS shop on that day. Since the 90% work of the bike was completed and me in a hurry to get the bike back from workshop, purchased non OE fittings from a local shop (was lucky to collect the OE gear shifter from YASS shop). Latter after some 2 r 3 week got 2 sets of fittings from YASS shop into the OE parts Im collecting for my bike.

I did't expect this kind of problem with non OE gear lever fittings.

To fix the problem today, those parts are not available at PSN Yamaha. Anyway Im lucky that I have those parts with me. Mechanic told me to bring the OE fittings and he will set them, most probably its going to solve the problem. What do you all think? Is it going to solve the problem?

**SriramEfunds** · 10-27-2011, 11:51 AM

Originally posted by sanjithjoseph View Post

I did't expect this kind of problem with non OE gear lever fittings.

I went through the similar situation during my restoration. During that time, had kept my shift pedal unchanged. Not sure why. Then some xbhphian and known circle pointed out the old depleted chrome needs to go!
There were no stock available that time. So had to go buy from local shop and believed it to be OE. Only realized that it will never be the same.
Though there were no clutch problem, but I had to use the toe for up and down shifts. Later... no recently say 4 months back got hold of OE and now it looks angled and I use it my toe and heel shifts without issue. The point I'm trying to say here is, OE makes a difference.

**sanjithjoseph** · 10-27-2011, 09:59 PM

Originally posted by yamdoot View Post

No chroming or buffing. Simply send it for Zinc plating/ galvanizing to give them a new, original look. Should not cost you more than Rs. 50.

As suggested by you I have given them for galvanizing and got them back today. They charged Rs 30/-

Originally posted by FATAL1TY - X View Post

congrats on the rebuild. its perfect.

Thanks Navin..

Originally posted by sixspeedtwin View Post

Get the "Socket Chord Assy" for the Pilot Lamp .... that should fix it ...

Better still, If u have not done so already, Get the entire wiring harness replaced .. is not too expensive, and is tops, a half day job for the RX100

Got the 'Wire Harness Assy' and 'Socket Chord Assy' today from YASS. Price 410/-. Thanks mate for guiding me..

Originally posted by SriramEfunds View Post

I went through the similar situation during my restoration. During that time, had kept my shift pedal unchanged. Not sure why. Then some xbhphian and known circle pointed out the old depleted chrome needs to go!
There were no stock available that time. So had to go buy from local shop and believed it to be OE. Only realized that it will never be the same.
Though there were no clutch problem, but I had to use the toe for up and down shifts. Later... no recently say 4 months back got hold of OE and now it looks angled and I use it my toe and heel shifts without issue. The point I'm trying to say here is, OE makes a difference.

True...

**sanjithjoseph** · 10-29-2011, 10:15 PM

Galvanized Tools

BEFORE

AFTER

**Rxboy** · 10-31-2011, 08:50 AM

@sanjithjoseph sir,i am requesting you to please share your bike owners manuals scan with us.and i am unable to download the owners hand book pages that you attached in the thread.i am in the search of the manuai from last 1 year still no luck.thanks in advance.

**driftjockey** · 10-31-2011, 10:05 AM

Originally posted by sanjithjoseph View Post

BEFORE

AFTER

treasure!

**sanjithjoseph** · 10-31-2011, 11:44 PM

Originally posted by Rxboy View Post

@sanjithjoseph sir,i am requesting you to please share your bike owners manuals scan with us.and i am unable to download the owners hand book pages that you attached in the thread.i am in the search of the manuai from last 1 year still no luck.thanks in advance.

Sure,Give me some 2 or 3 days.. I will scan the whole pages.
Your name?. You can call me Sanjith.

Originally posted by driftjockey View Post

treasure!

Yes..I have't seen the original RX100 tool set written 'RAJDOOT' with anyone else these days.

And I have got the RX100 side signal lights too in which its embossed 'RAJDOOT' (Replaced and kept safe during the restoration).
In Brake lights too I can see 'RAJDOOT'.

**Rxboy** · 11-01-2011, 07:49 AM

Originally posted by sanjithjoseph View Post

Sure,Give me some 2 or 3 days.. I will scan the whole pages.
Your name?. You can call me Sanjith.

much thanks to you sanjith,now i am feeling relaxed and waiting for your hand book uploads eagerly.
And you can call me RAUNAK

**driftjockey** · 11-01-2011, 08:41 AM

Clean your bike regularly to keep the originals safe.

**sanjithjoseph** · 11-01-2011, 11:08 PM

Originally posted by driftjockey View Post

Clean your bike regularly to keep the originals safe.

Sure Dhanush...always clean and the metal parts are shining . I don't use to take her to the road all the day...may twice or once in a week to my office and with a max speed limit of 60kmph enjoying musical note

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The very Old RX100 (1986, Japan)

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