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Rebuilding a Yamaha Rx135 4-Speed (1997) aka 'Rustique'

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  • Rebuilding a Yamaha Rx135 4-Speed (1997) aka 'Rustique'

    After an agonizing wait, I've decided to take the plunge and rebuild my Yamaha Rx135 4Speed that stepped out of the factory gates in 1997.
    Today however, she's in quite a bit of bother. A far cry from how she must have been a decade and a half ago.

    Click image for larger version

Name:	Rustique - XBhp.jpg
Views:	1
Size:	104.2 KB
ID:	1973441

    This above image is among the last set of pics i have of her. Rusted in multiple places, the plan is to rebuild her to riding spec.
    Looking forward to sharing this journey and learning from everyone about this fine machine.

    Cheers

  • #2
    Thread Approved
    Advice is a form of nostalgia.
    Dispensing it is a way of fishing the past from the disposal, wiping it off, painting over the ugly parts and recycling it for more than it's worth.

    Antz Travelz!! | South India Exploration Ride | Leh Triplog (Work in progress)

    Comment


    • #3
      Originally posted by firbie View Post
      After an agonizing wait, I've decided to take the plunge and rebuild my Yamaha Rx135 4Speed that stepped out of the factory gates in 1997.
      Today however, she's in quite a bit of bother. A far cry from how she must have been a decade and a half ago.

      [ATTACH=CONFIG]80768[/ATTACH]

      This above image is among the last set of pics i have of her. Rusted in multiple places, the plan is to rebuild her to riding spec.
      Looking forward to sharing this journey and learning from everyone about this fine machine.

      Cheers
      Welcome to the Two Stroke Forum, a bit more elaborate details of the bike & the owner which is obviously you, will help seniors here to pour in their suggestions, with mediocre details like what you've posted will not fetch you any suggestions or results.

      Hearty Congrats on your build though..
      Whenever there is a Rainbow in the sky, I know it's u mastering the art of Cornering. U will always be remembered brother, R.I.P Arun.

      The 5 Speed Restoration
      The Z Restoration


      /2001 Yamaha Rx 135 5 Speed/ 1999 Yamaha RXZ 135/ 2012 Honda Dio/ ?

      Comment


      • #4
        Hello Firbie - All the best for your restoration process. If you are not familiar on the road map to rebuild, take a look at restoration threads to get an idea and also might help to learn something.
        RX100 1996 | Karizma 2004 | Karizma-R 2011 | RXZ 1999 | RX 135 1998 | RX 100 1993 | CBF150 2005 - 2011

        2012 - Meghamalai | Kuttralam | 2011 Ooty | Munnar | 2010 Point Calimere | Horsley Hills | Yercaud

        Comment


        • #5
          Brief History of My Yamaha Rx135 4Speed (1997) aka 'Rustique'

          Originally posted by antz.bin View Post
          Thread Approved
          Thanks for the speedy approval @antz.bin

          Originally posted by dual disc 200 View Post
          Welcome to the Two Stroke Forum, a bit more elaborate details of the bike & the owner which is obviously you, will help seniors here to pour in their suggestions, with mediocre details like what you've posted will not fetch you any suggestions or results.
          Hearty Congrats on your build though..
          Originally posted by SriramEfunds View Post
          Hello Firbie - All the best for your restoration process. If you are not familiar on the road map to rebuild, take a look at restoration threads to get an idea and also might help to learn something.
          Dualdisk & Sriram,
          thanks a ton for the warm welcome and the kind wishes. I have been more of a lurker on the forum this far. So it is glad to be posting again

          About the bike:


          Mine is a Yamaha Rx135, a 4Speeder who'll be 15 this year

          Her existing setup is as follows:
          • Block/Piston: 1st Oversize ART Piston in an un-sleeved block
          • Crank Replaced in 2005, running with crank rod of 'unknown' origins
          • Suspension: Rear Suspension replaced with OEM Escorts Shock-Absorbers. Front suspension running the same as 15 years ago, with bi-monthly oil & oil seal changes. Both, the Oil as well as the Oil Seals used are OEM Yamaha India parts
          • All Cables barring the Choke cable are OEM Yamaha
          • Speedometer is OEM Pricol
          • Light & Ignition pod are non-OEM make due to unavailability of OEM Parts
          • Wiring Loom - Replaced last month with MINDA OEM Wiring Kit
          • Fuel Tank - Replaced with Yamaha OEM last month
          • Running OEM Fuel Filter
          • Carburetor is the same that came with the bike 'Mikuni', runs standard 17.5/165 Jets & needle set at half-point (OEM Yamaha, replaced earlier this year)
          • Spark Plug is NGK Japan, OEM Yamaha
          • Oil Pump functions normally, oil being used is Yamalube. A small amount is also added to the fuel tank at every top up to prevent engine from running fully dry
          • Clutch & Pressure Plates are Yamaha OEM Replacements from the YBX (i think) 4 Stroke bikes
          • Engine was rebuilt last year for 1st Piston Oversize with all OEM Bearings & Oil Seals
          • Rims are Hero Honda & Tires were replaced earlier this year to Michelin Sirac 2.75*18 & 3.0*18, front & rear
          • Sprocketing is 16T up front, unsure whether it is (34/37 or 38T at the rear), both sprockets again being OEM Yamaha
          • Exhaust is the same 15 year old one, with an OEM Yamaha (36Lxxx) Core being added last year. The bend pipe sadly is non-OEM


          The Journey in a nutshell:

          In the past 7 years since she's been with me, there have been 2 cosmetic builds and countless 'mechanical' ones. Lack of knowledge, about this forum, sources of information on the parts & highly restricted finances had meant that i was to suffer endlessly. Having being butchered and pillaged by almost every mechanic i have been to, the journey has been nothing, if not a nerve wracking one.

          It was some time last year when i had my first cut of luck that things began to change for the better. I was to begin her rejuvenation process at the beginning of the year, but lack of funds for parts & the subsequent monsoons meant that it had to wait till now.


          A Mechanic's Tale:


          I finally have a mechanic who has agreed to let me work in his garage for a few hours every night and help me with the rebuild process. 'Mahesh' is a rare breed as far as mechanics come. Loyal to his Enfields, he has been my go-to guy for all things Royal Enfield. With the patience of a sage, he is a sight to see when working. Unassuming fella, he's at his workshop, coaxing the best out of Bullets 7 Days a Week. Yes, that's not a typo, this guy loves his bikes so much, he only takes a leave when there's a family celebration or when he's short of parts to finish off the job. Both scenarios are extremely rare and he's possibly got access to the entire range of RE OEM Spares.

          He usually is reluctant to take on bikes of other makes as "running around for parts saps him out of his energy". Thankfully, after much coaxing, he's agreed to assist and guide me in my Rebuild process.


          The 2012 Rebuild Begins:


          Been shoring up my war-chest of OEM Yamaha Parts for some time now. Brought the wrong ones, brought too many, brought too little, lost many a pretty penny, but its all added up. This rebuild process is all about bringing the bike to Factory specs with Yamaha OEM parts being used to the extent possible. The Engine has been mechanically rebuilt just a few months ago and is turning over decently. Hence, it is only going to see a good paint job. The internals shall be worked upon once a few critical parts are in hand, the funding for which, shall take a while.

          I managed to do a partial strip down of the bike last night. As of now, the Grab rail, exhaust assembly, fuel tank, carburetor, wiring loom, meter pod & headlight assembly have been dismantled. Fingers crossed on getting the garage space to finish the job tonight.

          I get in about 90 mins to 2 hours after office to work on the bike and the timeline for the rebuild is about a month.

          Shall keep updating with doubts, queries & my thoughts on the rebuild as time goes by

          To Be Continued....

          Thank You for a patient read
          Cheers

          Comment


          • #6
            Wonderfully written the story so far. Well, though you have not shared as which part of this country you belong to, however, keep us posted on the cosmetic work. Also, I'm sure you are into right forum for the rebuild. Here there are many who have restored more than one bike and their knowledge gained over the experience will translate into productive approach. Keep us posted.
            RX100 1996 | Karizma 2004 | Karizma-R 2011 | RXZ 1999 | RX 135 1998 | RX 100 1993 | CBF150 2005 - 2011

            2012 - Meghamalai | Kuttralam | 2011 Ooty | Munnar | 2010 Point Calimere | Horsley Hills | Yercaud

            Comment


            • #7
              NEatly penned history and specs! All the best for the build!
              Rx is a Phoenix!!! It always rise from ashes!!

              Comment


              • #8
                Gud Luck for the build..
                Happy & Safe Riding to All

                Comment


                • #9
                  Wonderfully penned down, Congrats on the build. Keep us posted pls.
                  Whenever there is a Rainbow in the sky, I know it's u mastering the art of Cornering. U will always be remembered brother, R.I.P Arun.

                  The 5 Speed Restoration
                  The Z Restoration


                  /2001 Yamaha Rx 135 5 Speed/ 1999 Yamaha RXZ 135/ 2012 Honda Dio/ ?

                  Comment


                  • #10
                    Yamaha Rx135 4-Speed Rebuild Update: Strip Down

                    Originally posted by SriramEfunds View Post
                    Wonderfully written the story so far. Well, though you have not shared as which part of this country you belong to, however, keep us posted on the cosmetic work. Also, I'm sure you are into right forum for the rebuild. Here there are many who have restored more than one bike and their knowledge gained over the experience will translate into productive approach. Keep us posted.
                    Originally posted by dpak89 View Post
                    NEatly penned history and specs! All the best for the build!
                    Originally posted by vimalnair4u View Post
                    Gud Luck for the build..
                    Originally posted by dual disc 200 View Post
                    Wonderfully penned down, Congrats on the build. Keep us posted pls.
                    Thanks for all the wishes guys.
                    @Sriram, I am from Mumbai (somehow missed out on that - silly me)

                    Now for the Updates on the strip-down:

                    Although, i'd have liked to go revv happy on the rebuild, i could only spare an hour post office hours to work on her. So, after 8.5 Hours of sweat, toil and loads of grime n grease, spread over a week, step 1 was finally complete. The bike is now in her individual pieces.

                    It has been a slow crawl this far. She has bared all before me and it is not a pretty sight. All the butchering and cheating by the earlier 'mechs' that she'd suffered over the years came out in all its painful detail.

                    I shall now begin a close inspection of all the parts and am sure that there are going to be tons of things to share, ask about and learn from everyone.

                    Going to try clicking snaps but it gets kind of difficult when the grime takes over.

                    Thanks for your time and hope to see you'll in the next round.

                    Cheers and ride safe
                    Last edited by firbie; 09-22-2012, 08:26 AM. Reason: corrected typo

                    Comment


                    • #11
                      Queries Galore: Yamaha Rx13 Carburetor, Gears, Gladiator Disk Brakes & More in Mumbai

                      Hi guys,
                      I'm back with the next installment of my rebuild tale. The earlier plan was to leave the engine untouched, but what's life without a few extra twists? Looking forward to suggestions and knowledge on the following:

                      • Upgrading to 5Speed Gearbox:
                        The current 4-Speed gearbox is the stock one and hasn't been changed as far as i know. She was alright at lower rpm but when the revs climbed, it felt like she would love to run a 'lil more relaxed. Adding that 5th cog would give her the headroom that she seems to need.

                        Thing is that, much as i would like to go in for a brand new 5Speed 'box, both, the availability and costing are beyond my means. The next option would be a used 5Speed Gearbox or a conversion kit).
                        What are the pros and cons of both options, in terms of Reliability, Suitability, Costing, availability,etc.
                      • The Carburetor:
                        The current condition of the carburetor can be seen from the images
                        Top Half View - Yamaha Rx 135 Carburetor 4TL-01Bottom Half View - Yamaha Rx 135 Carburetor 4TL-01 Combined View - Yamaha Rx 135 Carburetor 4TL-01
                      Considering that the jets & needle are OEM & replaced recently, i don't really see the need for a replacement. However, I do wish to clean the gunk and muck that has settled in on the body.

                      I did discover soda-blasting and came across this site that speaks about the benefits of the same. It also has a pictorial account & a short video on the DIY equipment & process that can be seen here: AircooledTech's Tools-On-The-Cheap - DIY Soda Blaster

                      What are the benefits, risks & feasibility issues of following this method? Can this be done out here?

                      • Coil Plate:
                        The Coil Plate assembly and associated wiring loom is now about 15 years old.
                        The individual coils on the plate assembly have been replaced over the years and their origin is unknown.
                        The Rectifier, i think, is a HH one while the OEM Magnet is in good shape.
                        Minda makes OEM Coil Plate wiring as can be seen from the mention of the 'Magnet wire for Rxg' in their catalog
                        Model Number of Magnet Wire & Wiring Harness by Minda for Yamaha Rx135

                        However, i am still looking for a retailer in Mumbai who can source the same for me.
                        Also, can the individual coils involved be sourced individually or do they have to be purchased along-with the entire Coil Plate assembly?


                      • Gladiator Disk Brake Assembly:
                        When upgrading to the Gladiator's Disk Brake Assembly, aside from the disk brake components & the front suspension (fork, t-stem)?
                        Do we have to use the associated parts at the wheel end (spacers & stuff) or can we use those from the existing Rx135 Front Suspension setup?

                        Secondly, how do we get the speedometer & odometer working with the Gladi setup & Rx Speedometer?
                        Would the speedo/odo cable being used here would be from the Rx Parts Bin or the Gladi Parts bin? Is there some adapter that must be used in such cases?


                      • Spokes & Spoke-Nuts:
                        I had purchased OEM Spokes & Spoke Nuts and was told that these would mate with the Rx Rim & Gladi Hub.
                        However, the guy who fits the stuff said that the spokes are mismatched and hence won't fit.
                        I would hate to use non-oem or poor quality stuff that would rust in no time and detract from the overall quality & appearance of the build
                        A mech did advise me to look for Stainless Steel Spokes, but my search this far has been non-fruitful
                        Any advice/thoughts on this?


                      • Bolts, Nuts & Washers:
                        Quite a few bolts sheared off during the just concluded strip-down of the bike and it was then decided that new Bolts, Nuts & Washers would be used in the rebuild.

                        Looked around for a 'kit' and found all local stockists to be having just one single brand of such a 'kit'. However, the quality of the bolts, nuts & washers is abysmal.

                        Someone has even suggested making my own custom set, however, the technicalities & costs involved in such an exercise would be prohibitive and hence, undesirable.

                        Awaiting possible solutions and leads on good quality nut/bolt/washer kits that are specific to the Yamaha Rx series. The stuff should hold good for about 5 Years, will probably replace the same after that period is over


                      I have tried to be as clear as possible while penning down my doubts. Looking forward to hearing what you have to say about it all.

                      Thank you again for your patience in reading this long post
                      Cheers

                      Comment


                      • #12
                        Originally posted by firbie View Post
                        Thanks for the speedy approval @antz.bin




                        Dualdisk & Sriram,
                        thanks a ton for the warm welcome and the kind wishes. I have been more of a lurker on the forum this far. So it is glad to be posting again

                        About the bike:


                        Mine is a Yamaha Rx135, a 4Speeder who'll be 15 this year

                        Her existing setup is as follows:
                        • Block/Piston: 1st Oversize ART Piston in an un-sleeved block
                        • Crank Replaced in 2005, running with crank rod of 'unknown' origins
                        • Suspension: Rear Suspension replaced with OEM Escorts Shock-Absorbers. Front suspension running the same as 15 years ago, with bi-monthly oil & oil seal changes. Both, the Oil as well as the Oil Seals used are OEM Yamaha India parts
                        • All Cables barring the Choke cable are OEM Yamaha
                        • Speedometer is OEM Pricol
                        • Light & Ignition pod are non-OEM make due to unavailability of OEM Parts
                        • Wiring Loom - Replaced last month with MINDA OEM Wiring Kit
                        • Fuel Tank - Replaced with Yamaha OEM last month
                        • Running OEM Fuel Filter
                        • Carburetor is the same that came with the bike 'Mikuni', runs standard 17.5/165 Jets & needle set at half-point (OEM Yamaha, replaced earlier this year)
                        • Spark Plug is NGK Japan, OEM Yamaha
                        • Oil Pump functions normally, oil being used is Yamalube. A small amount is also added to the fuel tank at every top up to prevent engine from running fully dry
                        • Clutch & Pressure Plates are Yamaha OEM Replacements from the YBX (i think) 4 Stroke bikes
                        • Engine was rebuilt last year for 1st Piston Oversize with all OEM Bearings & Oil Seals
                        • Rims are Hero Honda & Tires were replaced earlier this year to Michelin Sirac 2.75*18 & 3.0*18, front & rear
                        • Sprocketing is 16T up front, unsure whether it is (34/37 or 38T at the rear), both sprockets again being OEM Yamaha
                        • Exhaust is the same 15 year old one, with an OEM Yamaha (36Lxxx) Core being added last year. The bend pipe sadly is non-OEM


                        The Journey in a nutshell:

                        In the past 7 years since she's been with me, there have been 2 cosmetic builds and countless 'mechanical' ones. Lack of knowledge, about this forum, sources of information on the parts & highly restricted finances had meant that i was to suffer endlessly. Having being butchered and pillaged by almost every mechanic i have been to, the journey has been nothing, if not a nerve wracking one.

                        It was some time last year when i had my first cut of luck that things began to change for the better. I was to begin her rejuvenation process at the beginning of the year, but lack of funds for parts & the subsequent monsoons meant that it had to wait till now.


                        A Mechanic's Tale:


                        I finally have a mechanic who has agreed to let me work in his garage for a few hours every night and help me with the rebuild process. 'Mahesh' is a rare breed as far as mechanics come. Loyal to his Enfields, he has been my go-to guy for all things Royal Enfield. With the patience of a sage, he is a sight to see when working. Unassuming fella, he's at his workshop, coaxing the best out of Bullets 7 Days a Week. Yes, that's not a typo, this guy loves his bikes so much, he only takes a leave when there's a family celebration or when he's short of parts to finish off the job. Both scenarios are extremely rare and he's possibly got access to the entire range of RE OEM Spares.

                        He usually is reluctant to take on bikes of other makes as "running around for parts saps him out of his energy". Thankfully, after much coaxing, he's agreed to assist and guide me in my Rebuild process.


                        The 2012 Rebuild Begins:


                        Been shoring up my war-chest of OEM Yamaha Parts for some time now. Brought the wrong ones, brought too many, brought too little, lost many a pretty penny, but its all added up. This rebuild process is all about bringing the bike to Factory specs with Yamaha OEM parts being used to the extent possible. The Engine has been mechanically rebuilt just a few months ago and is turning over decently. Hence, it is only going to see a good paint job. The internals shall be worked upon once a few critical parts are in hand, the funding for which, shall take a while.

                        I managed to do a partial strip down of the bike last night. As of now, the Grab rail, exhaust assembly, fuel tank, carburetor, wiring loom, meter pod & headlight assembly have been dismantled. Fingers crossed on getting the garage space to finish the job tonight.

                        I get in about 90 mins to 2 hours after office to work on the bike and the timeline for the rebuild is about a month.

                        Shall keep updating with doubts, queries & my thoughts on the rebuild as time goes by

                        To Be Continued....

                        Thank You for a patient read
                        Cheers
                        Fantastically written my friend... Welcome to the world of 2 strokes and all the best for the restoration.
                        From the information you provided you have a tons of goodies in the bike..
                        Yamaha RX100 (1993)
                        Yamaha RX135 (2000)
                        Bajaj Pulsar 150 (2004)
                        Yamaha FZ-25 (2017)
                        TVS N-Torq (2018)

                        "Owners Pride Neighbors Envy"

                        Comment


                        • #13
                          Originally posted by Dinesh.P View Post
                          Fantastically written my friend... Welcome to the world of 2 strokes and all the best for the restoration.
                          From the information you provided you have a tons of goodies in the bike..
                          Thanks a ton buddy. The goodies hunt is still on. Hoping to have a few missing pieces of the puzzle soon, and then i can finish the build.

                          Will keep you'll updated

                          Cheers

                          Comment


                          • #14
                            Where are you exactly in Mumbai? So that We can help you with some spareparts shop where you can get Rx spares?
                            Happy & Safe Riding to All

                            Comment


                            • #15
                              Rustique comes back to life

                              Hi Everyone,

                              Reviving a dormant thread after a long time.
                              Loads has happened in the months that have gone by and am happy to share that Rustique has come back from the dead to start her Second Life.

                              I prefer the stock look a lot and had decided upon the same. But there have been many a twist and turn in this tale. As she has crossed the 15 Year mark, her paperwork has lapsed and work is in progress to bring it up-to-date.

                              Shall share my views on this journey soon, and i hope that the updates will come quicker than last time around.

                              Thank you for your patience,
                              Cheers

                              Comment

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