I don't mind you riding the RD, provided you are willing to travel . Let me know if your Gun requires any support. I would be glad to help.


Pramod

Went to a veteran mechanic for his opinion about what should be done on my 'gun. He started the bike and the moment he started he said that the bearings are gone and the block needs either to be rebored or replaced.
I Knew that something is wrong with piston as there was a piston noise while riding it and i thought it would go away after a rebore. The moment he said the engine needs a overhaul...I was shocked! He is the type of guy..who doesn't charges more and know his job very well. I completely trust him..he has about 45 years of experience and he repairs only bullets...He previously used to work on rd's,jawa,rajdoot and all other vintage bikes. I asked that can you make an exception and repair my gun? He said collect all the necessary parts like oil seals,bearings,clutch plates and other small bits.Generally,One has to wait for 3-4 months for taking his appointment for fully restoring bullets.
As of now, I don't have the any funds as all of my savings went into buying the gun. I have recently graduated(Mechanical Engineer) and currently looking for job.
So the rebuild will be postponed. Will collect the required parts and then start the rebuild.
Also confirmed that the silencer is of shogun and not samurai.

Couple of things about 2 strokes, They just don't die, unless they are run without 2T oil, so you have as long as you need to save up to fix your gun. Start collecting small bits first. The oil seals are same for shogun and Samurai, if I am not wrong the clutch plates are also same. Start collecting parts slowly. Replace the Tank if rusted and get the rest re sprayed. The cylinder would cost you a bomb if you are going new, so start spare hunting, there are many shops which still has NOS kits, what ever you find in local shops, buy.

Also get the size on the cylinder checked, it can help you decide weather you need a new cylinder kit or can rebore the present one.

Pramod

Will start the spare hunt in few days. The small bits like packing set,oil seals,clutch plates are available in local shops in mumbai. Can you tell me the bearing number and how much bearings will be needed to fix the engine?
Will check the condition of the cylinder and decide whether it can be rebored or fixed. If it needs a rebore which pistons i should go for?

I don't remember the bearing numbers, but it would be available at bearing shops, pistons are not a major issue if you will run them in properly and your application doesn't require frequent drags, but if it does then you need to look for ART pistons, Mahle and SAM pistons are also not as bad as people say. make sure the reboring is done at a precision lathe and the clearances are set correctly, else it will stick and seize. Before you hunt for the pistons remove the cylinder and check the size they are presently on, if there is no major scoring and the pistons look all right you might just need the rings. Also get the compression checked, Most bikes I have seen getting rebored are not due to piston/cylinder scoring but due to crank noise, if the cylinder and piston is fine then just get the crank rebuild and ride on.

Pramod

Update on my Rebulid!!!
Sir,As you said check the block for scoring marks,So i went to my local mechanic...He opened the block and bam! the piston was really in a bad shape. I have attached the photos of my block and piston. He said that it will need a rebore and also found out that the Piston was not of the standard size. It was running on 0.5mm OS and was of Sam make.
I later searched on the internet whether 0.75 mm piston were available. To my surprise found out that Sam made these odd sized piston....As ART had only .5mm and 1mm OS.
So in the evening I messaged you Whether to go for .75mm or the last size 1mm. I was totally confused as in my city no local shops kept even a single spare of tvs-suzuki models. So next day went to Thane city,as there was one shop who deals in all the old models stuff. Asked him For .75 sam pistons and he was forcing me to buy some cheap local brand name METRO Pistons which he was ready to give me for Rs-250/-.
I Asked him if he can arrange me the size which i wanted. Paid him some advance and got it on the next day. Collected the piston,front fork oil seals and fork oil and got the bore job done in thane itself as My mechanic said that 2 stroke bore job is not done in my city. Later that night got the the piston fitted and did the basic service like changing the oil,Lubricating all the bits. The Front shock were little too soft..so opened it for overhauling and saw that some bush or some spring has gone kaput. I have attached the pic of the required part...Please provide your input...So,just attached it back as it was as i was not sure if i can find that part anymore. Also got the tail light bulb fitted.
The bike is running great now...adding 40 ml of oil to 1 litre of petrol..as advised by my mech...The engine is heating a bit after riding it for 15-20 mins..
Regarding the change of bearings...my mech says that abhi engine khone ki jarurat nahi hai...abhi aur jaan baaki hai.
Now,looking forward to add the square orange indicators, stickers for the front fairing and lock set.