Since '02 xBhp is different things to different people. From a close knit national community of bikers to India's only motorcycling lifestyle magazine and a place to make like-minded biker friends. Join us

Castrol Power 1

Always use both brakes to reduce speed.

Our Partner

Announcement

Collapse
No announcement yet.

Project catastros (rx rebuild)

Collapse
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

  • Project catastros (rx rebuild)

    Lets face it. Apart from a few old timers, and very few young ones, the riders today have moved to 4-strokes. They started with 2-strokes and moved to 4-strokes because of various reasons. Mileage and maintainance were among the primary causes. Some were just not able to handle the dragons.

    My story is a bit in reverse. I started with 4-strokes. But somehow I was never content with their looks and performance. In every measurable sense they are better than 2-stroke bikes but they always have and will lack the charm of the old time dragons.

    This brings me to my current topic. My rx100 was converted to a rx135 ages ago. But due the great mechanic who did the conversion the bike never ran properly. I did about 10,000 kms on her before realising that I should start on a proper rebuild of the bike if I wish to enjoy her company in the way it was supossed to be.

    So I set about dismantling the bike. To my horror, 90% of the bike was found unusable in someway or the other. I felt like weeping. The cylinder was damaged. The crank was destroyed. Clutch was fubar. Gearbox was rattling. Crank case leaked oil. Chassis parts were unrecoverable.

    This led me to start the project catastros. Complete rebuild of the bike. From pin to pin. As of now, the only parts remain from the original bike are the chassis and the crankcase. Rest everything, I mean everything is being changed or augmented. As far as looks are concerned, I have gained a new found appreciation for stockish looks during my rd rebuild. So the bike would be close to stock in looks. It takes various cues from different versions of rx though. The build is being done by me at home as I have found that trusting mechanics with detailed jobs always leads to disasters.

    The build is in its final stages where only assembly remains. Due to my constraints of time and space, I am unable to take pics of all spare parts. However I do have pics of the build process. I will post pics of the progress today on this thread. Any and all suggestions and comments welcome.

    Sent from my GT-I9001 using xBhp Connect mobile app
    Last edited by Bibhu; 03-06-2014, 12:45 PM.
    HYPERTHRUST CLEARED AND COUNTING
    5.....4.....3....2.....1

    sigpic

  • #2
    Re: Project catastros (rx rebuild)

    Topic Approved

    Awesome stuff. Await the build pics and details
    Biking is not about what you have between your legs, its all about how well you use it!!!!!!!

    Give your details here if you want to help your fellow xBhpian stranded in your city

    Touring Blog: Cycling in Mongolia!

    Comment


    • #3
      Re: Project catastros (rx rebuild)

      Congrats Bibhu. Much awaited thread.

      Nissan Sunny XVD | Toyota Corolla | Suzuki Ritz
      Yamaha RX135 4s-->5s | Yamaha RX100 | Yamaha RXG | Yamaha Ray | TVS Scooty Streak | Duke 390
      2000 Yamaha RX135 5s (Sold) | 1998 Yamaha RX135 4s (Sold) | 1997 Yamaha RXG (Sold) | 1994 Yamaha RX100 (Sold)

      Comment


      • #4
        Re: Project catastros (rx rebuild)

        Congrats Bibhu... Will keep a close watch on the thread...

        Comment


        • #5
          Re: Project catastros (rx rebuild)

          Very well !! Subscribed !!
          Stop at RED and go at GREEN !!!

          Comment


          • #6
            Re: Project catastros (rx rebuild)

            Thank you mr. Monk for the approval.

            Sent from my GT-I9001 using xBhp Connect mobile app
            HYPERTHRUST CLEARED AND COUNTING
            5.....4.....3....2.....1

            sigpic

            Comment


            • #7
              Re: Project catastros (rx rebuild)

              [QUOTE=Bibhu;1046043
              So I set about dismantling the bike. To my horror, 90% of the bike was found unusable in someway or the other.

              The build is being done by me at home as I have found that trusting mechanics with detailed jobs always leads to disasters.


              Sent from my GT-I9001 using xBhp Connect mobile app[/QUOTE]

              welcome to the club
              Kawasaki KB100/enduro/125 substitute parts list http://www.xbhp.com/talkies/508615-post105.html

              Comment


              • #8
                Re: Project catastros (rx rebuild)

                Thumbs up and Best of luck!!!!!!!
                BORN TO RIDE!!

                Comment


                • #9
                  Re: Project catastros (rx rebuild)

                  Thank you for your wishes guys. I am posting pics of the day the bike was being dismantled.

                  Sent from my GT-I9001 using Tapatalk 2
                  Attached Files
                  HYPERTHRUST CLEARED AND COUNTING
                  5.....4.....3....2.....1

                  sigpic

                  Comment


                  • #10
                    Re: Project catastros (rx rebuild)

                    Click image for larger version

Name:	uploadfromtaptalk1394099973270.jpg
Views:	1
Size:	108.6 KB
ID:	1875848Click image for larger version

Name:	uploadfromtaptalk1394100058935.jpg
Views:	1
Size:	108.1 KB
ID:	1875849

                    Engine being opened. Note the condition of the crank.
                    Sent from my GT-I9001 using Tapatalk 2
                    HYPERTHRUST CLEARED AND COUNTING
                    5.....4.....3....2.....1

                    sigpic

                    Comment


                    • #11
                      Re: Project catastros (rx rebuild)

                      Click image for larger version

Name:	uploadfromtaptalk1394100198649.jpg
Views:	1
Size:	107.1 KB
ID:	1875850

                      This is how the bike was before the build. The genious mechanic decided to cut off the exhaust clamp to fit the rear sets. The bike was supposed to be a cafe racer. But ended up being an abomination. Imbalanced and ungainly.

                      Sent from my GT-I9001 using Tapatalk 2
                      HYPERTHRUST CLEARED AND COUNTING
                      5.....4.....3....2.....1

                      sigpic

                      Comment


                      • #12
                        Re: Project catastros (rx rebuild)

                        Seems like Mechanic tried some interesting modifications.
                        BTW, need some info on the parts used
                        - what tyre size where they (front I suppose 2.75, rear???)
                        - Gladi kicker?
                        - T-stem, from which bike?

                        Nissan Sunny XVD | Toyota Corolla | Suzuki Ritz
                        Yamaha RX135 4s-->5s | Yamaha RX100 | Yamaha RXG | Yamaha Ray | TVS Scooty Streak | Duke 390
                        2000 Yamaha RX135 5s (Sold) | 1998 Yamaha RX135 4s (Sold) | 1997 Yamaha RXG (Sold) | 1994 Yamaha RX100 (Sold)

                        Comment


                        • #13
                          Re: Project catastros (rx rebuild)

                          Originally posted by Mr.Boss View Post
                          Seems like Mechanic tried some interesting modifications.
                          BTW, need some info on the parts used
                          - what tyre size where they (front I suppose 2.75, rear???)
                          - Gladi kicker?
                          - T-stem, from which bike?
                          Modifications were mine mostly. Front and rear 17 inch rims. 2.75x17 front and 100/90x17 rear. The swingarm is from pulsar classic. Shox from gladiator. Footpeg system from classic cbz.

                          Whole front end from pulsar, with pulsar 150 clip on type bars. Kick is from yamaha crux. The mods themselves werent the issue. The execution of them however was very poor and lacked finish.

                          Now the rims are back to 18 inches due to the lack of top end the 17 inche rims caused. Tyre sizes now are 2.75x18 and 3.00x18. Swingarm and shox are stock. Although i am thinking about using rd shox in the rear.

                          Sent from my GT-I9001 using xBhp Connect mobile app
                          Last edited by Bibhu; 03-06-2014, 07:14 PM.
                          HYPERTHRUST CLEARED AND COUNTING
                          5.....4.....3....2.....1

                          sigpic

                          Comment


                          • #14
                            Re: Project catastros (rx rebuild)

                            The pulsar front end was retained. Although the T stem was changed to a classic pulsar one as it is closer to yamaha T stem.

                            Sent from my GT-I9001 using Tapatalk 2
                            HYPERTHRUST CLEARED AND COUNTING
                            5.....4.....3....2.....1

                            sigpic

                            Comment


                            • #15
                              Re: Project catastros (rx rebuild)

                              After the engine was dismantled, it was found that the block was scored. Connecting rod was damaged. Main bearings were fused. Gb bearings had given up due to age. There was an oil leak from the case as only 50-100 ml of oil was recovered from the gb.

                              Due to this lack of oil the main and drive shaft along with the gears were damaged. The clutch housing had come off from the secondary gear and one finger in the clutch hub had cracked.

                              I found the reason for such massive damage was the neglegence of my mech. He did not put the dowel pins in the crank case and just screwed them together. Which had got loose and offset in time and leaked all the oil out. Also he fit a cracked 2t pipe connecting the pump and carb. Thus no oil flowed to the carb and the top end got damaged as a reasult.

                              So the whole engine was written off as a total loss and I began the process of planning to install a new(relatively) engine altogether.

                              Sent from my GT-I9001 using xBhp Connect mobile app
                              HYPERTHRUST CLEARED AND COUNTING
                              5.....4.....3....2.....1

                              sigpic

                              Comment

                              Working...
                              X