Re: TVS Suzuki Max 100R - Good First Bike ?

I think either you have a busted carb or that your tank seems to be leaking fuel.

Was the exhaust note your only aim behind using the Shogun muffler? It's a powerhouse in itself on the Shogun and removing it alone reduces the output by a 1.5 to 2HP. Performance wise there won't be any difference on the Max 100 as your bike isn't supposed to deliver Shogun like performance. It's built for commuting.

Re: TVS Suzuki Max 100R - Good First Bike ?

Busted Carb ? But that should also mean other problems like missing,starting trouble,bad performance.etc right ? The bike doesn't have any of these symptoms.I also only recently cleaned and rebuilt the carburettor.Also regarding the Tank,I have replaced my tank with another Max 100R's one,long back.Because the tank that came with this bike,was rusted badly.This current tank has no major rust inside or outside.I am running on premix also so the oil in petrol tank will also help it remain rust free.

Yes,I changed to Shogun muffler to get a better exhaust note than stock.Also this muffler is not OE but a replica with similar dimensions as OE Shogun muffler.Yes,I have also heard many people say that this muffler was basically an inbuilt expansion chamber.I haven't ridden my bike for too long to judge,but from initial riding,I found that the bike to be slightly more peppy!

Re: TVS Suzuki Max 100R - Good First Bike ?

Low mileage can be allotted a lot of factors pertaining to damaged air screw, damaged air screw washer, mutilated pilot jet, damaged pilot jet seat, air leaks in the manifolds etc. Rebuilding isn't enough or so isn't the cleaning if you haven't checked whether the above are in mint condition or not.

Missing on the other hand is due to something obstructing the pilot circuit, say for example dust. Or it may be due to insufficient fuel getting into the bowl which can be caused due to an obstructed float jet. Starting issues can occur due to improper air flow into the carb, a damaged dc slide or obstruction in air jets as well (again).

Throttle problems rise due to problems with imulsion tube, main air jet or wearing off of the main jet washer.

Re: TVS Suzuki Max 100R - Good First Bike ?

Thanks for the information.I will try and Invest in a good used/new carburettor and will install and see if it improves.

Re: TVS Suzuki Max 100R - Good First Bike ?

good journey buddy they are build like tanks.

Re: TVS Suzuki Max 100R - Good First Bike ?

Ofcourse! That's the reason why these machines still runs like charm for decades!

UPDATE

I was experiencing some wierd problems with the bike where even with good amount of fuel,It used to lose power and switching it to reserve and then back to main fixes it.This is an occasional problem that occurs rarely.I'm guessing that the fuel tap and filter needs to be cleaned.

In sheer curiosity as to why people quote Max and Samurai gave above 50kmpl but mine,even after complete maintenance,never touches even 40kmpl and sometimes dips below 34kmpl,I learned something new in the carburettor from a member in the Shogun WhatsApp Group.I have attached an image of the slide setting in the carburettor.If you notice the small clip thing as number 8 part,It will be sitting in the slots present in the needle which is the number 9 part.Ideally,A bone stock bike should have this clip sitting on the 2nd slot from top of the clip.Mine was sitting on the 4th slot.The thing is that the higher the clip sits,The lower fuel is being sent into the engine.The upper you put the clip the lower the needle will go in the jets.The more the needle goes into the jets,The more fuel gets thrown in.The lower you set the clip, the needle will be up.it will put more fuel in the block.The clip prevents it from going more than the clip's position.4th clip should have caused the bike to lose a little bit of power in lower end I guess.Now put back the carburettor and start tuning,You should tighten the AFR screw and go one full turn out.

So I've done what he said,Filled 2.67lt of petrol with 50ml Oil premixed (3250KM ODO),and already experiencing better low end power,starts in a single kick in the morning without choke,consistent power delivery.etc.

I'd be a little mad if that tiny clip in the wrong position was the factor that caused low efficiency,and not all the other variables like air filter,spark plug,carburettor's condition,fuel's condition,exhaust's condition,clutchplates,chain and sprockets.etc because I've already done aaaaaalllllll that hahahhaa!

Have attached a recent photo of the bike as well

Re: TVS Suzuki Max 100R - Good First Bike ?

The Oil Tank which I replaced,The float wasn't working.Luckily I identified this before Oil got completely empty.I also had the old oil tank,so removed the working float and installed on the new oil tank and now it's working fine.Sourced Shell Advance VSX 2T Oil,500+500ml at ₹300.

I also cleaned the Fuel tank by draining all the petrol.It had so many small debris present,so removed them and also cleaned the petrol tap with its filter.

But I feel that fuel tank needs an extensive cleanup but due to lack of time,I did a basic job.Next,I'm planning to drain out the fuel,do a pressure wash and then let it dry...will do that soon!

Re: TVS Suzuki Max 100R - Good First Bike ?

Hey TVSian, very happy to see ur MAX100R....are u running STD pistons or oversize ones?. have u changed the oil seals in the gearbox?. i'm asking because my MAX100R is in very bad shape currently...and I'm planning to do a complete work on the engine/gearbox....

Re: TVS Suzuki Max 100R - Good First Bike ?

Hey! Sorry for replying late.Yes,My engine hasn't been rebored even once.Piston is STD.Also I haven't touched the gearbox apart from replacing clutch and pressure plates,But before putting the cover,they used some sort of sealant paste and then put the cover back in.The bike is in good shape,But I have some noise coming from engine,which I believe is related to the Connecting rod or Crank,which will be checked soon.

But if your bike is in very bad shape,Best is to rebuild the engine and gearbox.Totally,It wouldn't cost more than ₹6K including new parts,labour,lathe (if crank work needed) and new seals,ask them to balance crank and install it when rebuild starts.Replace all bearings and seals.Make sure Oil Provisions are clean and not choked so critical parts will get proper oil all the time.

If you are going to restore it,Do it completely in one go unlike me.You will save good amounts of money and time.Do a rust removal and paint job on the frame and tank,Do a full electrical checkup,replace wiring harness.etc.

All the best [emoji16][emoji106]

Re: TVS Suzuki Max 100R - Good First Bike ?

sure thanks bro....My bike is a 2002 model we bought it in 2011...the previous owner was my dad's friend. back then it was in very good condition all the body work and the mechanicals but now its not...its my fault I've not taken enough care on it. Another reason is its my primary bike for commuting is rush hour traffic doing almost 30kms a day. and i'm not a light/kind rider either I would open the throttle just hear the sound of the 2stroke engine accelerating touching 60-70kmph often. even after all that its still with no issues major at all...yes the engine response has dulled down but its going solid. After all its a 2-stroke eh?. .

I'm checking if its possible to fit the following shogun parts on the MAX100R :- ( points 5-8 )

1. High Performance Iridium Spark Plug. ( I've read from an RX expert that Iridium plugs don't make much difference but i'll give it a try )
2. New CDI Unit.
3. Mikuni VM20 Japan Caburretor for AX100/Shogun ( Keep as an extra spare )
4. Nippon Ignition Coil ( Japan )

5. Shogun Piston ( TKRJ Brand ) ( Imported ) ( Don't know if shogun piston can be fitted but I will check )
6. Shogun Chain-Sprocket
7. Shogun Silencer ( Or just fit the Shogun flute inside the MAX100R exhaust )
8. Fibre Clutch Plates for AX115 ( Shogun ) ( Imported )

I've sent you a PM check that also...

Re: TVS Suzuki Max 100R - Good First Bike ?

Oh Nice.I feel that the bike will keep running even if all the other parts feel like they can fall off anytime lol.Before I got my bike,I rode a good amount of Max 100R's and Samurai's which,all were almost dead with dead electricals,nothing working,but the engine,but all of them ran without too much fuss.So yeah,The engine is bulletproof in these things,if you take good care on lubrication and stuff as I feel that's kind of a weak point in TVS-Suzuki engines all around.

To get back Engine Response,You can do some basic+some unique services like cleaning your fuel tank and use fresh fuel (25ml oil per litre of petrol,assuming your oil pump is working and you have oil in oil tank),fuel tap and filter,Clean and retune your carburettor,Change Air Filter,Open Engine head and clean the carbon deposits,Open exhaust and decarbonize it,Install a new Bosch Spark Plug,then ride it around.I think you will definitely notice the difference.It brought me a ton of difference.


Regarding the Shogun Parts :

1) Nope,Not worth it.You are better off with normal NGK Plugs.In fact,You can get like 5 plugs for the price of one iridium plug lol.Max 100R is a commuter and not a racebike,you won't have any noticeable improvements.

2) You can go for it if your current CDi isn't working fine.But yes,While you are at it,Replace the wiring kit and check the coils and RR Unit if they are working fine.

3) Yeah,OK,But it won't fit the stock intake manifold though.

4) Original one.Little hard to find and expensive.But if you get it,Go for it.

5) Will NOT fit.Even if you change the whole thing with Cylinder of that of the Shogun,It WILL NOT fit on the crankcase block rods.Better,if you want more power,Go for AX100 Block + Triple Reed Valve,I think it's available for sale,obviously used one.You need to source an Intake Manifold though,which,the VM20 Carb will fit in.Bike should make close to 10Bhp now.But mileage will be some 30kmpl,since it's your daily commuter,see if it's economically viable for you before you go ahead and get it changed.

6) Stick to stock.Shogun's gearing ratio is entirely different and the chain sprockets are decided based on the gearing of the bike.

7) You can just install Shogun's Flute inside the Max 100R's exhaust like I've done.You will love it.The tone will get optimised automatically as you ride.But if you are in an area that is kind of cramped,or have cops all around,catching vehicles for nothing,Please install Glasswool because it's a little loud lol.

8) Hmm,I got OEM plates just before this came,I didn't know this existed.I think I may try this one when I replace the plates next time later in the future.I think they will last really long because they are built for the power with the AX115 made.Our bike produces much lesser than that,so lower stress for the plates so they might be able to last really long.

My humble suggestion,is to stick to OEM.You can save a lot of money,which you can use to get the bike look like new,with the process of rust and old paint removal,new paintjob on the frame,engine head,cylinder,L and R covers,side panels and other miscellaneous items.Then you can also fix the electricals if they are messy.The bike will only become more reliable,peppier and more fuel efficient and most importantly....it becomes an absolute classic beauty!

All the very best [emoji120]

Re: TVS Suzuki Max 100R - Good First Bike ?

yes I agree with you on all points...MAX100R is for commuting and reliability...I know how reliable the original AX100 is . shogun is fundamentally a RX100 beater at the cost of reliability. For my MAX100R, I bought side panels and wiring harness also abt an year back also new headlight unit w/o bulb. I also have a minda speedometer unit waiting to be fitted during the restoration.

I'll try to get the following items,

2. New CDI Unit.
3. Mikuni VM20 Japan Carb
4. Nippon Japan Ignition Coil.

so regarding the shogun parts,

7. Shogun silencer or flute
8. Fibre clutch plates for AX115
9. Fibre reed valve.

3. So if the Mikuni VM20 Japan carb will not fit the intake manifold, what can we do?. I just wanted an extra spare carb to keep for the future.
9. I forgot to mention the fibre reed valve in my previous post. I don't know if a fibre reed valve exist for the suzuki 2 strokes. But it is available for Yamaha RXZ. check the below pic. How much of a difference will it make?. you've already suggested to stick to stock as possible but I'm just curious.



PS: I mean I know the AX100 carb is japan and MAX100R carb is indian. but I assumed they are all same specs...does it mean the AX100 carb is not a direct fit on the MAX100R?. My long-time local mech told me that for moped racing purposes( during the old 2T days ), tuners prefer to use IND-Suzuki AX100 carbs because of their japan make and material quality...none of the other 2T bike carb can be used for that purpose...TVS-Suzuki AX100R, MAX100R and RX100 included will not do the job.

Re: TVS Suzuki Max 100R - Good First Bike ?

I can help you source almost all the above mentioned parts.Just send me a PM.

3) Get the Stock Max 100R carburettor.It's available literally everywhere.18mm and will fit directly.It will be of big help when you need it.

BUT

If you still want that AX Carb,You can install AX Manifold and then install AX Carb.

Forget that fibre reed valve ji.Yamaha,it's available but for Suzuki it's not available.It's because RX,RXK, Shogun and Shaolin : they are consist of 4 petals - In our bikes,the intake is too small.It won't fit even on the AX Block.But if you had a Shogun or Shaolin,That fibre reed valve is a direct fit.

Yes,The VM20SS was very famous in moped racing due to it's great performance and reliability.But we aren't going to race our Max 100R [emoji14]

Re: TVS Suzuki Max 100R - Good First Bike ?

UPDATE :

Good news! That Carburettor Pin adjustment WORKED ! I got about 38kmpl now and that was with the carburettor AFR Screw at 1 turn out.Now I've made the mixture linear at 1.25 turns out to get better efficiency.Bike starts easily,but takes time to warm up but then behaves normally,Performance remains the same.Engine idle RPM went up as I made the mixture linear so I adjusted the idle screw as well.Hoping to reach the 40kmpl mark next time.Filled 2.69lt of fuel with 50ml Oil at 3591KM ODO.Hoping to reach a range of 3605KM ODO,Before getting to reserve of 2 litres.

I have to inspect the engine noise.I think it might be related to the piston rings too.I hope I can get it fixed without involving significant costs.

Re: TVS Suzuki Max 100R - Good First Bike ?

UPDATE

I went to a different Mechanic and made him listen to the engine.He said that the engine needs a rebore and the rings have gone bad.I had this noise since day 1 with this bike which I thought,would go away with normal maintenance.But It persisted.He listened to it and immediately told me that the engine needs to be rebored.He suggested me that going straight to 0.5mm would be better than 0.25 as the work is supposedly done better.He quoted ₹1000 for the work and said it will take a full day to be done.

Right now,My exams are going on,so I will be needing the bike for many small trips like for sourcing books and stuff.So I have to do it later.

He also told me that rebore means proper compression will be there and so engine might become more efficient and noticeably more powerful in the same time....which is a really nice thing!

Will update you guys on more information soon!