Re: Zeus - A story of RX-Z restoration

22/5/2014:-

Woke up late past alarm, still had enough time to complete few tasks for the day. Impatiently rushed to wheel truing shop to see if he's open, Ah! there he was and was ready to take up the job. Dash home and brought tyres and rim real quick. Felt glad that something is going good for me and have self kept timelines to complete the restoration in next 3 days.





While he was working on the rims and spokes, I sprinted to nearby Yamaha showroom and bought lube as advised.





Pictures of clutch case covers how the RPM worm gear plonked.






Random pictures taken during the day.

Mask Center clamp



Pad to plonk between mask and headlight inner guard, helps reduce vibration


Handle standing - to help pull while drawing main stand.



Update:-

Body parts- painted, sticker job done, clear coat done.
Wheel truing done.
Need to drill holes on the visor
I'm going to use the old Sprocket hub as it is in good condition


Still to come..

1.I'm not sure what is missing in my list, but will soon know..
2. Anger
3. Frustration
4. Joy
5. Sleeplessness
6. Happiness
7. Tired

Re: Zeus - A story of RX-Z restoration

which one are you talking about?

Re: Zeus - A story of RX-Z restoration

Fruitful day....

Zeus in progress. It was a roller coaster ride to me. It was 10 am, early morning to me, received a call from mechanic that tail piece is missing. Panic stuck, immediately called up the painter and confirmed he remembered me keeping inthe car. What do I do now?
Rushed to the shed and saw the frame proudly flagged with tail piece. It was mixed up with boxed and that brought me a relief.
Started to assemble the body first then engine as the cases needed some blasting due to black paint all over outer case. Took to Ambattur abd refresh the skin.



Had lunch on the way back, started to fix front wheel steering etc. Steering was missing few important parts, though had racer kit and T- stem, those were nut and ball racer cover. Spent time roaming and finally got the old packing stuff, thank God. They came for Rs.25 and Rs 1.35 but I gave Rs. 27/- [emoji16]



Successfully steering front fork legs were plonked and thought I got it all. Then came the front wheel, I had bearings, spacers, worm gear, adaptor plate oil seal, wheel axle, nut castle even coter pin.

Well, there was something to haunt me still. Wheel collar was of gladiator and wasn't a fit. Decided to shave off few millimeters. Luckily we still had time, so we rushed to the lathe, also carried the visor abd mask as they needed a drill too.
Got done all lathe work and gathered all except engine and put on bike to see how it looks, good. Front wheel now went between fork legs and wheel collar sat just right. Tomorrow is another D-day, power plant rebuild. Some random pictures of the day....




Just wanted to share a piece of information here. Practically speaking, there is a slight difference between inner tube and pump of bikes after 2003 catcon model and of those previous era. Here is the picture of pump inside the inner tube as shown below, long one is the latest RX135 series and the short one from pre 2000-1 model.


Inner tube difference....taller one belongs to latest model


Random pictures of the day...



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Re: Zeus - A story of RX-Z restoration

can you post an additional pic of the speedo console , never seen that type before, the speedo dial looks cool, also when you finish the work ,wax the painted parts that will really bring out the sheen and depth

Re: Zeus - A story of RX-Z restoration

Sri I still remember the front wheel inner collar problem you had and how we corrected it.If you need help I am free to help you...
Good luck.

Re: Zeus - A story of RX-Z restoration

ummm this speedometer was import i think i m right ??? its rxs speedometer

Re: Zeus - A story of RX-Z restoration

Yes I believe it's from RXS 100, eBay UK :-)
Am I right [MENTION=22265]SriramEfunds[/MENTION] ?

Re: Zeus - A story of RX-Z restoration

yeap

Re: Zeus - A story of RX-Z restoration

Zeus, I liked the name you've given for the project. Couldn't find much story in fb after you posted the teaser pic, so I searched for it here. Loved reading the dedicated and passion which you have put forward for the project. :-)

Sent from 'La Suisse'

Re: Zeus - A story of RX-Z restoration

Sri

Awaiting for the final Pic. Good restoration


Cheers !!
Karthi

Re: Zeus - A story of RX-Z restoration

Applogies, work at office and with restoration kept me away. Nagging issues persists. Fluttering, bend pipe not aligning, oil pump skeptical, powerbox forgot at home...

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Re: Zeus - A story of RX-Z restoration

5/27 - Fixed the fluttering issue. My old carb had 20 pilot jet and it was very rich and the reason why it was causing the issue. After going to 17.5 pilot, things settled down slowing and behaved normal.
The steering stopper on the T-stem had already made a dent on the frame hence it looked punched a depth over years. So filled out by weld job and now the top crown plate doesn't dare nearing the tank.

5/29 - There will always be something titbits coming up to be fixed or look into. Well, I've finished my restoration of RX-Z


Engine

Koyo Engine Bearings
HTA ARS - Engine Oil seals
OE Clutch plates
OE Crankshaft assembly
RX-Z 5speed cylinder (0.75)
RX-Z 5speed head cylinder
RX-Z 5speed gearbox
RX-Z 4speed carburetor
NSK bearings for wheels
OE 5speed chain sprocket
Oil - gearbox - Yamalube
Oil - 2T Engine oil - Yamalube
RX-Z OE Crash guard
RX-Z OE mirrors
RD125 LC Disc brake set up
TZR Master Cylinder

Wheels

Front - 2.75 x 18 - Rim - Sandhar - CEAT Secura F85+
Rear - 3.00 x 18 - Rim - Sandhar - Michelin M45

Electricals

12v - 2.5ah - Exide
35/35w headlight
OE Horn

Paint job

It was carried out in a very average garage with Dupont paint

Most of the items were bought atleast more than 6 months and some even a year before.

During the restoration..




Today, happened to click few pics, though they are very candid shot. I'll need to spend time with bike and take pics in coming days.

Re: Zeus - A story of RX-Z restoration

[MENTION=22265]SriramEfunds[/MENTION] : fantastic job done there. On the side corners,The ceat F85 has got grip grooves of different pattern than the center tread. Would be nice to hold good grip while hard turns.

Re: Zeus - A story of RX-Z restoration

Congrats Sriram.
"Awesome" isn't sufficient for this restoration.

Re: Zeus - A story of RX-Z restoration

Sriram....Love the completed Restoration, since I saw the condition when you bought it. Your pictures DO NOT do justice to your Restoration...The bike looks Stunning in Person....Only a dedicated person like you could have done such a beautiful ,restoration..