Re: 1995 - RX100 Restoration

Thread Approved

Re: 1995 - RX100 Restoration

The below are the parts Purchased and remaining work are in progress.

1. Chrome Plating
2. Repainting etc.

Re: 1995 - RX100 Restoration

[MENTION=24526]kjayakannan[/MENTION] - All the best for your restoration. Good to see you logging your restoration here. Really appreciate many newbies wanted to restore will take cue from this thread and learn.

Do not hurry, take your time and get them restored at your own pace. All the best.

Re: 1995 - RX100 Restoration

From my experience I can share the following two cents: -

If you are installing a brand new bore, might as well install Crankshaft & Connecting rod if the current one is out of spec. Else, just use the same.

I would say if the current frame is fine with no major rusting/bends use the current frame. Else, use the new one inspite of the hassles involved in punching number and RTO approval, etc.

Disc set up is a personal choice. I ride RX100 & Duke 390 on alternative days to work and I have no issues with RX100's stock drum brake. As long as we know our and bike's limitation it should be fine

Please do not get the silencer re-chromed if its in decent shape. Basically, re-chromed parts cannot stand neglect/abuse as well as the original part from factory.
Give it to a detailer who will be able to restore it to good shape.

Don't do anything to new parts just use them as is.

Regarding Head, Crankcases better to buff to aluminium finish. Would depend upon personal choice I guess but buffing to look all shiny makes the bike look like a vessel

Re: 1995 - RX100 Restoration

Thanks Sriram. Your inputs are always in great help for me.

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Thanks Nitin. will describe my work done so far below.

Re: 1995 - RX100 Restoration

Update 1: Silencer Work

Let me start with my silencer work first. Taken my old silencer for chrome plating. He quoted 1800. /- for decarb and chroming excluding welding works.

With in 2 days after decarb of silencer he called me for inspection and approval before proceeding the welding works. I saw the silencer inside and the 2 of the holes are torn and outside there was a hole where main stand touches. So thought of leaving the silencer not to proceed further since it won't give proper beat as per my understanding.

My searching started for next silencer either used or new one which is quoted 2100 /-. But somehow I am not interested in new one and the reason being it is make of RX135. Two guys from north they quoted 2500 and 3500 for 86 model of it and concern of transport and condition cant be check it like in person.

Then finally my mech sourced the old one 86-88 model but not sure the exact year. After decarb of second silencer and dipping in acid found small tiny holes at end of it and fixed by the copper welding on it. And then finally chrome plating done.

Below is the picture of my old silencer - first one and then next one is sourced by mechanic.

Cost involved:
Used one - 1500 /- (approx and havent settled yet)
Chrome - 1800 /-
Welding - 400 /-

I am thinking I have gone mad but let us wait till the output comes after restore.
Lot of lessons learnt during this process of silencer plating when I personally visit the workshop. will definitely give the feedback after testing the results.

Lessons learnt:

1. 86-88 Model silencer has the bigger size 6 holes in the first layer and second layer has around 3 holes and you can see thoes through from first layer whereas 135's doesnt have any hole in first layer and 90s has small size of 6 holes present.
2. 86-88 makes silencer weighs heavier than the 90's make ~ around .5 kg may be
3. while plating they do decarb using kerosene and after they inspect the damage of holes outside and inside. And sometime after dipping in acid you have to be carefull to watch those damages. These damages can be identified only after these two steps. before that you cant recognize it.
4. Generally these rechrome process reduce the metal strength and its weights to be frank. we dont have choice if you want old silencer.
5. Chrome plating always high or equal to new silencer price in market.

Re: 1995 - RX100 Restoration

Update 2: Buffing Crank case and Head

Next work buffing of head and crank cases with aluminium.

Cost involved:
Buffing Head - 600 /-
Buffing Crank case - 750 /-

Some how I am not convenienced the process of buffing and the reason its not covered each place inside of head. What i meant is when you spray paint, it will cover each corner of the head. Look the top view of the picture of head and inside of it.But not like here and it is just by applying the aluminium by rotating the various size of wheels to buff.

Here the output of both head and crank case. They requested me to clean them using petrol before fitting.

Re: 1995 - RX100 Restoration

Update 3: Nuts & bolt plating

Next work is plating the nuts and bolt.

He quoted three times of actual cost in general. So I gave the small parts of nuts and bolt which was weighing 1.5 kg.

Cost involved:
Nuts & bolt - 900 /- (per kg is 600 and other place after I heard it is 350/- )
Spokes 36 - 325 /-

Remaining parts are like front and rear axles, new set of wheel rim, break pad, handle bar, gear shift lever and rear break rod all are he quoted Very very high. one example he quoted 1200 for handle bar and I got the heart attack.

So I will not sugesst this place for chrome plating

Shine metal finishers in Muduchur Road Chennai. Cost is so high 2-3- 4 times than others and price of the parts. unless you dont have other option.

Then I gave it to other place and waiting for them.

Re: 1995 - RX100 Restoration

Update 4: Frame punching.

Yes. I was in dilemma to go for new one with number punching or repaint the old one. Old one is in good condition except the place where the battery touches got rusted and hole present due to acid from battery.

Also considering the cost of repaint work, sand blast , welding and then repaint will involves more amount work if you do yourself.

So finally decided to punch the new frame procured. I was really satisfied with the outcome of result and look at the numbers punched. it was perfect.

Cost involved:

Punching : 1000 /-
New frame : 4900 /-

Yamaha dealer quoted 1500 /- with submission of all the RTO required documents.

To be frank it just 50 rupees manual work job in 2 minutes.

Don't ask me why this much of and this is how it is..

Re: 1995 - RX100 Restoration

Hi J.K,

Somehow I missed the thread for over a month.
All the very best for the restoration.

Get the punched area sprayed with paint, else it will start to rust.
PS: Font doesn't match with the OE spec, any idea if dealer has the proper punch?

Re: 1995 - RX100 Restoration

Thanks Mr.Boss. Sure will do paint before fitting. Regarding font, I gave it to them for punch and I was not there and not sure they have the all size of punch.
Does it matter the fonts has to be in same size with OE? since the bike is on my name only. Point to be noted for next restoration if I get a chance for RX135 5 speed.

but anyway I am going to use it on my native occasionally and not on daily commute.

Re: 1995 - RX100 Restoration

Clarification 1:

After crank case and head buffing , how to clean them properly inside of it. Just petrol wash is enough?

What are the pre installation steps for engine
1. Polish the new bore and piston before
2. Do we need to heat the crank to install bearings?
3. Do we need to clean/polish the crank rod assembly? if so better method?
4. Head clean?

if it can be done by ourself, then I would like to do myself before giving it to mech for assemble the engine. Please your thoughts!

Re: 1995 - RX100 Restoration

Update 5: chrome plating the rims and other axles

The parts are done by plating are

1. Rims
2. Break Rod
3. Break pad
4. Headlight Rims
5. Handle Bar
6. Nuts and Bolt.
7. Axles

Re: 1995 - RX100 Restoration

Clarification 2:

New Piston Goetze make comes with Bore






New Bore






New piston Rings




Mahle Piston Qn:

Adarsh Motor offering the STD Mahle piston with 1000 /- . It is embossed escorts in it.
Is this Original Mahle and work of spending ?
How about the performance?
Will this fit exactly and same size only. or better to go with same pair meant with Goetze which comes with Bore.