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Suzuki max 100r restoration DIY

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  • #1

    Suzuki max 100r restoration DIY

    Hello everyone,
    I have 1998 suzuki max 100r and bike is in a very bad condition. I wish to restore it like a factory version. All works will be done by me at home.
    Its my collage bike and i have loads of memories with her.
    After restoration of rx 100 few years back i was unable to see my collage bike resting idle in my garage. Today i decided to restore it all by myself. I need all your suggetions and help. After reading all the restoration threads from years my its my turn to restore my nostalgic bike to a stock glory.
    Tags: None
  • #2
    Re: Suzuki max 100r restoration DIY

    Topic approved.

    It will be great if you could explain what specific help you need.
    (Been There Done That) x 3.25

    Comment

    • #3
      Re: Suzuki max 100r restoration DIY

      Thanx for the quick aproval sir. I need some of the maintenance tips and mainly service manual. Their are many owner of suzuki samurai, max 100 and max 100r who want to restore this humble machine. Its my attempt to create atleast one thread for these bikes so many old bikes of this make can have a reference and i too get some good knowledge through sharing.

      Comment

      • #4
        Re: Suzuki max 100r restoration DIY

        Sorry but by mistake i have created two threads on the same topic plz delete one

        Comment

        • #5
          Re: Suzuki max 100r restoration DIY

          Originally posted by avhad sitaram View Post
          Sorry but by mistake i have created two threads on the same topic plz delete one
          These bikes don't require a service manual until you are going for an engine/Carb rebuild. I have restored couple of Shoguns and trust me they are pretty easy to restore.

          I suggest, Dismantle the bike make a list of things that can be repaired and a similar list of things to be Replaced. You would need a helper to bag and tag everything, if you work like an energiser bunny you cannot keep a tab of things yourself. So I suggest take things out one by one and bag and tag the articles. Take detailed videos, this can not only help you to see how to take things apart and put it back, it will also help you in helping future DIY restorers.

          Buying Plated stuff is easier than getting old stuff plated, Buy new rims, new brake pads, Replace all bearings. Check the reed valve, if necessary replace it. Ideally you should start putting things back once you get everything you need. Mudguard and handle is cheaper to buy new, Don't think new tank and panels are available these days.

          If you have any further questions feel free to contact me.

          Pramod
          Cigarettes are like squirrels... perfectly harmless until you put one in your mouth and light it on fire.

          Wanna learn more about 2 Stroke DIY maintenance? Subscribe to https://www.youtube.com/yamakaze

          Comment

          • #6
            Re: Suzuki max 100r restoration DIY

            Thnx a lot [MENTION=73502]yam[/MENTION] for the suggetions. It will be a complete restoration. From engime side i have collected block piston std, clutch bell oil seal kit engine packing kit, bolts of crank drive and clutch bell, clutch plates and pressure plates, engine oil drain bolt, reed valve gear changer...will soon assemble it

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            • #7
              Re: Suzuki max 100r restoration DIY

              New wiring harness, starting coil, ignition coil, cdi and spark plug all oe collected...only i am unable to find out is crankcase bearings. Required some suggestions regarding the bearing set...i have no part catalouge...so rely only on the observations

              Comment

              • #8
                Re: Suzuki max 100r restoration DIY

                Originally posted by avhad sitaram View Post
                New wiring harness, starting coil, ignition coil, cdi and spark plug all oe collected...only i am unable to find out is crankcase bearings. Required some suggestions regarding the bearing set...i have no part catalouge...so rely only on the observations

                Take the old bearings and get new ones.

                Pramod
                Cigarettes are like squirrels... perfectly harmless until you put one in your mouth and light it on fire.

                Wanna learn more about 2 Stroke DIY maintenance? Subscribe to https://www.youtube.com/yamakaze

                Comment

                • #9
                  Re: Suzuki max 100r restoration DIY

                  [MENTION=73502]yam[/MENTION] which brand of bearing set is good. I am unable to upload the snap as the app does not allowed the photo sizes more than 19 kdŸ˜Ż

                  Comment

                  • #10
                    Re: Suzuki max 100r restoration DIY

                    Removed the engine from bikeClick image for larger version Name: IMG20180905112615.jpg Views: 1 Size: 91.5 KB ID: 1961576

                    Comment

                    • #11
                      Re: Suzuki max 100r restoration DIY

                      Removed clutch cover, magnet cover, block piston setClick image for larger version Name: IMG20180905112601.jpg Views: 1 Size: 80.1 KB ID: 1961577Click image for larger version Name: IMG20180905104358.jpg Views: 1 Size: 69.5 KB ID: 1961578Click image for larger version Name: IMG20180905104401.jpg Views: 1 Size: 82.3 KB ID: 1961579Click image for larger version Name: IMG20180905104419.jpg Views: 1 Size: 93.7 KB ID: 1961580Click image for larger version Name: IMG20180905112553.jpg Views: 1 Size: 90.3 KB ID: 1961581

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                      • #12
                        Re: Suzuki max 100r restoration DIY

                        Today i went for hunting tools and spares, collected philips head screwdriver 02 nos, socket set and driver, nose plier, plastic hammer, adjustable wrench, ball point steel hammer, flat head minus screwdriver, multimeter, could not find flywheel magnet puller and the clutch holding tool.

                        Comment

                        • #13
                          Re: Suzuki max 100r restoration DIY

                          Collected the required tools some general tools and magnet puller clutch holding tool. Clutch holdimg tool was not available in.my city so i have made one out of old pressure plates and it works nicely again DIY. Click image for larger version Name: IMG20180914190815.jpg Views: 1 Size: 77.3 KB ID: 1961638Click image for larger version Name: IMG20180915192519.jpg Views: 1 Size: 54.0 KB ID: 1961639Click image for larger version Name: IMG20180914191121.jpg Views: 1 Size: 51.5 KB ID: 1961640Click image for larger version Name: IMG20180914185525.jpg Views: 1 Size: 77.6 KB ID: 1961641

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                          • #14
                            Re: Suzuki max 100r restoration DIY

                            Stripped down the entire body parts. frame is rusted in some parts and thick coat of mud+oil/grease everywhere on it. Washed out entire parts in three different sessions. This is where all the detergent, dishwashers, shampoos and other ckeaning agents fails miserably. My entire day was busy with that slush and cleaning agents. My wife told me that if you work like this for me then i can hire you as a kaamwali for lifetime[emoji33]. After three to four wash of detergent i cleaned the frame with kerosene and diesel. Next step will be paint removing.Click image for larger version Name: IMG20180906094830.jpg Views: 1 Size: 103.0 KB ID: 1961642Click image for larger version Name: IMG20180907085242.jpg Views: 1 Size: 62.4 KB ID: 1961643Click image for larger version Name: IMG20180907090310.jpg Views: 1 Size: 91.6 KB ID: 1961644Click image for larger version Name: IMG20180907090603.jpg Views: 1 Size: 59.0 KB ID: 1961645Click image for larger version Name: IMG20180907092411.jpg Views: 1 Size: 70.7 KB ID: 1961646

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                            • #15
                              Re: Suzuki max 100r restoration DIY

                              SKF bearings are great.

                              Pramod
                              Cigarettes are like squirrels... perfectly harmless until you put one in your mouth and light it on fire.

                              Wanna learn more about 2 Stroke DIY maintenance? Subscribe to https://www.youtube.com/yamakaze

                              Comment

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