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**avhad sitaram** · 01-04-2019, 11:19 PM

Re: Suzuki max 100r restoration DIY

Tomorrow i will lace both front and rear wheels spokes, colour and clear coat on rear swing arm, front mudguard inner side, paint the rim outer side after lacing it assemble the front forks.

**avhad sitaram** · 01-04-2019, 11:32 PM

Re: Suzuki max 100r restoration DIY

So far in two days work speed ups planning to complete it as soon as possible, oe seat assy is no longer available so is the seat plate. I wish to do engine work as good as possible. Collected engine oil seal kit, engine packing kit, crankcase bearings, counter shaft lh bearing, driben shaft bearing, crankset, clutch bell, clutch plates , driven plates, kick paul assy, kicker spring and new block piston set.
Hopefully tomorrow i will start to dismantle the engine[emoji7] very excited.

**avhad sitaram** · 01-07-2019, 06:06 PM

Re: Suzuki max 100r restoration DIY

Update-
1) Wheels front and rear laced up along with new ceat tyre and tubes.

2)Front fork assy assembled, new springs and oil seal installed, stickered and three coats of clear lacquer applied to it.

3) Dismantled the engine
Removed old bearings and oil seals, cleaned crankcases in four different sessions, collected all the skf bearings(as per Yam quote), thrust washer(kick bearing), new kick paul.

4) Two coats of clear lacquer applied on powdercoated chassis.

Any suggestions regarding this restoration from experienced members particularly on engine rebuild are highly welcome as its my first ever engine rebuild.

Now the next task is to install bearings of crankcases, counter shaft and driven shaft along with the oil seals.

Looking forword for any recommondation.

**avhad sitaram** · 01-07-2019, 06:48 PM

Re: Suzuki max 100r restoration DIY

Some pics during dismantling of engine as I am the only to do work and take snap, sry for the poor quality mobile pics as it was a night time 0200 hrs.

Impact driver is the thing which really leaves a strong impact on rebuild it works out on the jammed nuts effortlessly.

**Anuj Agarwal** · 01-07-2019, 11:22 PM

Re: Suzuki max 100r restoration DIY

I'm super glued to this particular thread, in simple words sir YOU ARE SUPER AWESOME AND A TRUE BIKER AT HEART [emoji813] keep the posts coming âş

**avhad sitaram** · 01-07-2019, 11:42 PM

Re: Suzuki max 100r restoration DIY

Originally posted by Anuj Agarwal View Post

I'm super glued to this particular thread, in simple words sir YOU ARE SUPER AWESOME AND A TRUE BIKER AT HEART [emoji813] keep the posts coming âş

Thanx for the kind words bro

**avhad sitaram** · 01-12-2019, 09:46 PM

Re: Suzuki max 100r restoration DIY

Some pic of engine during assembly

**TVSian** · 01-12-2019, 11:10 PM

Re: Suzuki max 100r restoration DIY

Originally posted by avhad sitaram View Post

Some pic of engine during assembly[ATTACH]246730[/ATTACH][ATTACH]246731[/ATTACH][ATTACH]246732[/ATTACH][ATTACH]246733[/ATTACH][ATTACH]246734[/ATTACH][ATTACH]246735[/ATTACH][ATTACH]246736[/ATTACH][ATTACH]246737[/ATTACH][ATTACH]246738[/ATTACH][ATTACH]246739[/ATTACH][ATTACH]246740[/ATTACH]

Coming along very nicely!
Question : Are you porting and polishing the block or will you be keeping it completely stock ?

**avhad sitaram** · 01-12-2019, 11:15 PM

Re: Suzuki max 100r restoration DIY

Originally posted by TVSian View Post

Coming along very nicely!
Question : Are you porting and polishing the block or will you be keeping it completely stock ?

Only mild polishing for a better throttle response thats it else everything stock

**avhad sitaram** · 01-13-2019, 03:35 PM

Re: Suzuki max 100r restoration DIY

Got new pricol oil pump old stock, it looks eyecatching. New but very old stock kick bearing(thrust washer), new metal sest plates, new oe suzuki 2002 manufactured fuel tank and side panels, shogun old stock silencer along with old flute, yamaha rx shock absorbers rear, amaron battery.

**avhad sitaram** · 01-17-2019, 08:52 PM

Re: Suzuki max 100r restoration DIY

Some more pic of engine rebuild

**TVSian** · 01-17-2019, 10:25 PM

Re: Suzuki max 100r restoration DIY

Originally posted by avhad sitaram View Post

Some more pic of engine rebuild
[ATTACH]246921[/ATTACH][ATTACH]246922[/ATTACH][ATTACH]246923[/ATTACH][ATTACH]246924[/ATTACH][ATTACH]246925[/ATTACH][ATTACH]246926[/ATTACH][ATTACH]246927[/ATTACH][ATTACH]246928[/ATTACH][ATTACH]246929[/ATTACH][ATTACH]246930[/ATTACH]

Just so beautiful to see it man [emoji7]

About the Coil,Did you replace the entire thing,or did you rewind ? I think my lighting coil is weak,that's why I'm asking.

**avhad sitaram** · 01-17-2019, 10:36 PM

Re: Suzuki max 100r restoration DIY

Originally posted by TVSian View Post

Just so beautiful to see it man [emoji7]

About the Coil,Did you replace the entire thing,or did you rewind ? I think my lighting coil is weak,that's why I'm asking.

Thanx for the words buddy, I have replaced primary ignition coil only, lighting coils are fine no need to replace it only varnish dipped it and used as it is.

Your lighting coils might be alright, try to resolve the other probable issues first eg loose connections and drop in voltage to shorted connections. If you found other things correct then proceed for lightIng coil checkout..

**TVSian** · 01-17-2019, 10:37 PM

Re: Suzuki max 100r restoration DIY

Originally posted by avhad sitaram View Post

Thanx for the words buddy, I have replaced primary ignition coil only, lighting coils are fine no need to replace it only varnish dipped it and used as it is.

Your lighting coils might be alright, try to resolve the other probable issues first eg loose connections and drop in voltage to shorted connections. If you found other things correct then proceed for lightIng coil checkout..

OK sure,Thanks a lot ji

Happy to see your work coming along.I also have a full rebuild planned for my bike in the near future,provided that 2Ts don't get banned before that lol.I shall check for shorted connections first,like you said.

**Shogunsamurai** · 01-17-2019, 10:43 PM

Re: Suzuki max 100r restoration DIY

Originally posted by avhad sitaram View Post

Some more pic of engine rebuild [ATTACH]246921[/ATTACH][ATTACH]246922[/ATTACH][ATTACH]246923[/ATTACH][ATTACH]246924[/ATTACH][ATTACH]246925[/ATTACH][ATTACH]246926[/ATTACH][ATTACH]246927[/ATTACH][ATTACH]246928[/ATTACH][ATTACH]246929[/ATTACH][ATTACH]246930[/ATTACH]

Nice work Bro. Now i don't think there is much left to do on your bike. Just bolt everything up. Much awaited to see the bike in its full swing. And man do something with your inbox. It is full. Can't send any more messages.

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Suzuki max 100r restoration DIY

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