Re: Suzuki Samurai restoration

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Do go through these threads as well -





All the best

Re: Suzuki Samurai restoration

I've read both the threads. I guess the difference is that in both the above threads the bike seemed to be in working condition. Mine seems to be in working condition but just wont start. And also I'd like to know any places in Mumbai where I can source parts from. Anybody from Mumbai who knows such places kindly help out!
Another thought me and my friends had was to install an RX100 japanese block in it. I wanted to know whether or not it's doable. If yes then where can I get the part in Mumbai?

Re: Suzuki Samurai restoration

For any 2 stroke to start, you need 3 things, air Fuel and 3rd and most important; spark. If you are planning to do it yourself then I suggest you take out the spark plug and connect the plug cap to the plug while its out and kick couple of times to see if its sparking, few things to note while doing it is you should not be holding the plug in the hand as the shock you get from the plug are quite powerful, second thing is equally important, the plug should be resting against some metallic part of the bike to provide the plug a suitable ground. if its sparking move to the next bit if not then you have a faulty ignition system.

Troubleshooting the ignition system

Step1. Take the plug out and remove the plug cap(by turning it anti clockwise) now hold this HT lead a few MMs away from the metallic parts of the bike and start kicking to see if that produces a strong spark, if yes you have a faulty spark plug or little less likely a faulty plug cap, if this solves the spark issue install a new plug/cap and try starting the bike, it should come to life, if not then move to step 2

Step 2. Checking the ignition lock, you don't have much options here but if you have a working neutral light you can isolate the lock issue easily. if the lock is faulty the neutral light wont come on when you try kick starting, if it does then move on, else spray generous amount of WD40 and see if that make a difference

For the next set of steps you need to swap parts to check if there is an issue with the components, these components are the coil and the CDI.

If there is no ignition problem or one of the previous troubleshooting solves the issue then you can move on to the next component, which is checking if the system is receiving fuel.


Troubleshooting fuel issues

Old fuel disintegrates over a period of time and gums up the jets, so even if the bike starts its advisable to get the carburettor thoroughly cleaned and rebuilt.

Step 1, disconnect the fuel inlet tube and see if there is a fuel flow, be careful while doing it and avoid spilling fuel on the bike or yourself. Keep the fuel tap closed when you disconnect the tube, if there is fuel flow then move to next step if there is none, your filter/fuel tap is clogged, replacing it might solve the problem.

Step 2, disconnect the rubber hose that connects the carburettor to the air filter and place your palm on the opening behind the carburettor where the hose was connected, kick couple of times and your palm should be wet with fuel, if not, your carb needs a rebuild, if its wet then try kicking for a couple of minutes and the bike should start, if not then safely drain old fuel and get fresh fuel and try to start again.


If all this fails you need to get it to the mech. Note, please take pics of each part you are taking apart so that you know what goes where, Suzuki bikes are highly fiddly so expect bruised knuckles and fingers
There are a lot of shops in Mumbai where you can source parts, body parts should be easily available, engine parts are also farily easy as most of the parts were shared by shogun, samurai, shaolin, AX 100, max 100 and ind suzukis. Make a list of things you need and then go looking for it.
Its a extremely stupid idea to fit a rx 100 engine, one the suzukis have a single cradle chassis and yamahas have a double cradle chassis, so its not going to be easy, second the bike would no longer be road legal since the engine number and the make of the engine would be different, plus this would also ruin the bike in terms of valuation and character.

Re: Suzuki Samurai restoration

very nice instructions by yam. . I have a 2002 Suzuki MAX100R and am also looking to do a complete restoration myself. please post pics of your samurai soon. eager to see in its condition. . do you plan to do just a restoration or some modifications after?

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yam has answered correctly to this question. I thought of buying the piston-cylinder kit for my MAX100R. Since samurai and MAX100R share the same kit, I'm posting this pic for your reference.

Re: Suzuki Samurai restoration


Here are a few pics!

Re: Suzuki Samurai restoration

Clean that carb throughly. I suspect its a carb issue.

Sent from my XT1033 using xBhp Connect mobile app

Re: Suzuki Samurai restoration

have you restored the bike yet?. plz update the status of the restoration work....

Re: Suzuki Samurai restoration

Suzuki Samurai 1998 Model fully restored with all OE Spare parts

Re: Suzuki Samurai restoration

Looking amazing.Hats off! Great work on the bike!

Re: Suzuki Samurai restoration

Can you help me with the source from where you managed these parts?

(To All): I'm planning to do modifications to my Samurai, something like a Basic Cafe Racer. If anyone of you can provide me any guidance regarding the same, I'll be grateful.
Inspired by this:


Thanks,
Sumit

Re: Suzuki Samurai restoration

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