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**avhad sitaram** · 09-20-2018, 03:21 PM

Re: Suzuki max 100r restoration DIY

OE spokes for tvs rims are not available anymore. [MENTION=25995]srikany[/MENTION] [MENTION=50781]BOSS[/MENTION] bros where i can found brass nipples and which spokes are good enough eg hero and honda

**avhad sitaram** · 09-20-2018, 03:40 PM

Re: Suzuki max 100r restoration DIY

[MENTION=73502]yam[/MENTION] its a second time such incident happens between us, first regarding swing arm painting and second about rims[emoji1] [emoji1]

**avhad sitaram** · 10-08-2018, 10:48 AM

Re: Suzuki max 100r restoration DIY

Restoration work came to standstill as end of my leave, hope it will resume when i got leave, so atleast 80 days no chance to proceed[emoji54] .

Meanwhile the hunt for some critical spares and particularly the workshop manual started in WOT.

Contacted suzuki motorcycles various sites NO luck[emoji54]
Contacted Tvs motors multiple times, send aleast 50 mails, got the response say very good response but they refuses to send it other than ASS, Tvs demands to raise a request through the dealers and dealers refuses to raise one.
Attemped several times on online forum but no luck.
Become member of various ax 100 clubs in search of this manual but no luck only found some parts catalouge and others only in spanish.
In meantime srikany appeared with a parts catalouge he promptly send it to me. I am very grateful to [MENTION=25995]srikany[/MENTION] for the much required help.
I steadily loosing my hopes for a service manual. If any of member got some clues that where i can get a copy of service manual that will be great help.

**avhad sitaram** · 12-31-2018, 07:05 PM

Re: Suzuki max 100r restoration DIY

Finally got the leave and restoration work will resume on 02 jan 19. Everything is scattered in different places, how to deal with that mess is a real challenge now.

**ayrus** · 12-31-2018, 08:10 PM

Re: Suzuki max 100r restoration DIY

I wanna tag [MENTION=72230]TVSian[/MENTION] in this post. He has a preowned MAX 100R. He is changing and fixing everything that wasn't in the perfect condition when he got his hands on the bike.

Do have a look at his thread https://www.xbhp.com/talkies/thumper...irst-bike.html

Pardon me if I was a bit too nosey.

Cheers mates

**avhad sitaram** · 12-31-2018, 11:39 PM

Re: Suzuki max 100r restoration DIY

[QUOTE=ayrus;1363039]I wanna tag [MENTION=72230]TVSian[/MENTION] in this post. He has a preowned MAX 100R. He is changing and fixing everything that wasn't in the perfect condition when he got his hands on the bike.

Do have a look at his thread https://www.xbhp.com/talkies/thumper...irst-bike.html

Pardon me if I was a bit too nosey.

Cheers mates

[/QUOTE [MENTION=96476]ayrus[/MENTION] thanx for the pointer and I know Bharath and his efforts to upkeep the bike. Here is nothing that is nosey imo.

Will update on restoration as soon as I reach home and start working on the bike. I left my bike in bits and pieces at home three months back. Plan is to make it fully serviciable and proper roadworthy in a month of time. Lots of work is pending and I need some spares to restore it to complete stock.

**TVSian** · 01-01-2019, 12:09 AM

Re: Suzuki max 100r restoration DIY

Originally posted by ayrus View Post

I wanna tag [MENTION=72230]TVSian[/MENTION] in this post. He has a preowned MAX 100R. He is changing and fixing everything that wasn't in the perfect condition when he got his hands on the bike.

Do have a look at his thread https://www.xbhp.com/talkies/thumper...irst-bike.html

Pardon me if I was a bit too nosey.

Cheers mates

Thanks for the tag ji [emoji4][emoji120] This bike deserves that love and care.So well built.Feels great to Un-screw things screwed by previous owners lol

**ayrus** · 01-01-2019, 06:14 PM

Re: Suzuki max 100r restoration DIY

The Max 100R was the bike on which I learnt how to ride a geared motorcycle. It is an impressive bike. Maintained properly, it can perform close to today's 125cc commuter bikes. Sometimes, I felt that this bike needs an additional cog (was it just me??).

The Max 100R I've ridden belongs to my dad's elder brother. I was about to get it, but in an interesting turn of events, I got an Apache 200. But then, even when I ride the Max 100R today, it doesn't feel like a downgrade. It does lack braking and stability (honestly, I shouldn't be comparing these 2 bikes at all) but is definitely more flickable and easier to filter through traffic.

**TVSian** · 01-02-2019, 01:24 PM

Re: Suzuki max 100r restoration DIY

Originally posted by ayrus View Post

The Max 100R was the bike on which I learnt how to ride a geared motorcycle. It is an impressive bike. Maintained properly, it can perform close to today's 125cc commuter bikes. Sometimes, I felt that this bike needs an additional cog (was it just me??).

The Max 100R I've ridden belongs to my dad's elder brother. I was about to get it, but in an interesting turn of events, I got an Apache 200. But then, even when I ride the Max 100R today, it doesn't feel like a downgrade. It does lack braking and stability (honestly, I shouldn't be comparing these 2 bikes at all) but is definitely more flickable and easier to filter through traffic.

Very well said.No it's just not you,Me too! I also (really really) miss the 5th gear.I learnt riding on my dad's Thunderbird and even after 2 months have passed,I still search for the 5th gear.Yeah,The Apache RTR 200 is on a completely another league and ironically,I have both in the garage - The 200 and the Max 100R and honestly,I love the Max 100R more,for it's ease of riding,simplicity,classic charm,2 stroke thrum.But yeah,We just cannot compare these bikes.What's for sure is that the Max 100R has its own charm!

**ayrus** · 01-02-2019, 01:47 PM

Re: Suzuki max 100r restoration DIY

Originally posted by TVSian View Post

Very well said.No it's just not you,Me too! I also (really really) miss the 5th gear.I learnt riding on my dad's Thunderbird and even after 2 months have passed,I still search for the 5th gear.Yeah,The Apache RTR 200 is on a completely another league and ironically,I have both in the garage - The 200 and the Max 100R and honestly,I love the Max 100R more,for it's ease of riding,simplicity,classic charm,2 stroke thrum.But yeah,We just cannot compare these bikes.What's for sure is that the Max 100R has its own charm!

One thing I find anmoying in this bike is the gear shift pattern. It took some time for me to get used to the gear shift patterm in the other bikes and when I come back to this bike, I have to think for a moment before gear changes but it becomes natural within 1 or 2 kms. I downshifted from 4th to 3rd at around 45 kmph (thinking it was the Apache and I was upshifting) and opened the throttle. It just pulled without any lag or hestation which is unimaginable in today's bikes of similar cc; it is something that only a 2 stroke engine can do (of course, that is the difference between an engine firing every revolution and every alternate revolution). But having ridden a more stable bike with better brakes, it is scary for me to push beyond the 60 kmph mark.

**TVSian** · 01-02-2019, 01:53 PM

Re: Suzuki max 100r restoration DIY

Originally posted by ayrus View Post

One thing I find anmoying in this bike is the gear shift pattern. It took some time for me to get used to the gear shift patterm in the other bikes and when I come back to this bike, I have to think for a moment before gear changes but it becomes natural within 1 or 2 kms. I downshifted from 4th to 3rd at around 45 kmph (thinking it was the Apache and I was upshifting) and opened the throttle. It just pulled without any lag or hestation which is unimaginable in today's bikes of similar cc; it is something that only a 2 stroke engine can do (of course, that is the difference between an engine firing every revolution and every alternate revolution). But having ridden a more stable bike with better brakes, it is scary for me to push beyond the 60 kmph mark.

It was the polar opposite for me.I simply loved the all down shift pattern and I often think why all manufacturers are not doing this and keeping the neutral in the middle of two gears.But yeah,It took me sometime to get used to this.I learned on a one down 4 up bike so this took quite sometime to get used to.Yeah lol beyond 60kmh/r this isn't the bike you want to be on.Mine shivers at that speed but the engine has a nice booming sound at 60kmh/r and I love it! Cruising is best done between 60 and 70kmh/r!

I suggested a Fiero/Gladiator disc setup but dad is holding it as he says the disc setup is like 50% of the value of the bike [emoji23] also the fact that in city traffic,we will very rarely reach 60kmh/r.So yeah.

**ayrus** · 01-02-2019, 02:00 PM

Re: Suzuki max 100r restoration DIY

Originally posted by TVSian View Post

It was the polar opposite for me.I simply loved the all down shift pattern and I often think why all manufacturers are not doing this and keeping the neutral in the middle of two gears.But yeah,It took me sometime to get used to this.I learned on a one down 4 up bike so this took quite sometime to get used to.

The reason to have the neutral between 1 and 2 is to prevent ending up in neutral while downshifting multiple gears at once. I've ended up in neutral in bikes like the Max 100R, Glamour, Splendor (all up or all down pattern bikes). In USA, it is mandatory for all motorcycles to have a 1 down the other gears up pattern.

**kb100** · 01-03-2019, 05:27 PM

Re: Suzuki max 100r restoration DIY

Originally posted by ayrus View Post

The reason to have the neutral between 1 and 2 is to prevent ending up in neutral while downshifting multiple gears at once. I've ended up in neutral in bikes like the Max 100R, Glamour, Splendor (all up or all down pattern bikes). In USA, it is mandatory for all motorcycles to have a 1 down the other gears up pattern.

AFAIK there is no such rule

**ayrus** · 01-03-2019, 06:10 PM

Re: Suzuki max 100r restoration DIY

Originally posted by kb100 View Post

AFAIK there is no such rule

https://mechanics.stackexchange.com/...d-second-gears

I just said what was said in this article but I did misinterpret some part of it.

**avhad sitaram** · 01-04-2019, 11:14 PM

Re: Suzuki max 100r restoration DIY

Update
Today i dismantled the front fork assy, very hard to remove inner tube from a outer one but finaly managed to separate the things apart. Cleaned the parts purchased new oil sesl and oe springs for it. Engine casings and cyclinder head recieved after high temp powdercoating. Looks very nice. Purchased vernier caliper, filler gauge, front fork oil seal installer, impact driver and long bits for it.

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Suzuki max 100r restoration DIY

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