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I bought another Suzuki Shogun

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  • I bought another Suzuki Shogun

    As the threads title says, I bought another Shogun.

    Why did I buy one?

    After restoring one which I ended up selling later, More details here (I bought a Suzuki Shogun to Restore. UPDATE: Back with me again!). I always wanted one. Fast forward to 2016, I was bestowed up an opportunity to restore one, The restoration took me 45 days. Here is the end result

    The second one was the final nail in the coffin, that was running so beautifully that I wanted one even more. So my endless search began. All were either too heavily priced or were Samurai to shogun convert(Cosmetics )

    In the mean time the prices for shogun spares began skyrocketing. A cylinder kit was retailing above 20k on facebook and OLX.

    On a desperate Monday evening I was just casually surfing OLX and I found a shogun, The price was right, The registration number was visible in the ad. The first think I did was to verify if the bike is a shogun and if the paperwork current.

    It checked both of those boxes, The Bike had fitness till Dec 2020 and the tax was valid till Nov 2019. Immediately send him a message in OLX asking his number, The guy was responsive, also told him that I will only be free on a Saturday.

    Was eagerly waiting for Saturday to arrive, Frantically checking each day if the bike is sold.

    On Saturday went and saw the bike, liked it(it is rough) paid the full amount and bought the bike. Did 3 rides from the owners place to mine in My RX 100 and in the "new to me" shogun. Dropped the RX 100 at my place and took the shogun with me as pillion, Dropped the owner back to his place, it was night already so the ride back home was uneventful, the bike performed well and the rear brakes had a lot of play so took it easy.

    As soon as I came home, I wanted to make a list of things that were wrong, So here it is;

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    The mechanicals and electrical:

    1. The bike had a Max 100 silencer the owner had the original exhaust
    2. None of the lights except the headlight were working.
    3. It had no horn
    4. The Christmas tree instrument cluster was dead
    5. The tacho was stuck at 14k RPM
    6. the speedo was not working
    7. It was not idling well
    8. had no rear brake
    9. No battery.
    10. The wiring kit was a rats nest
    11. The engine kill switch or the ignition kill switch were not working
    12. Max 100 tail lights
    13. Rear indicators missing
    14. Local headlight beam
    15. Front shock was leaking
    16. Rear RX 100 Seat
    17. Carb was leaking
    18. The air-filter was bone dry
    19. both tyres were shot
    20. rear indicator brackets were missing
    21. The flute was stuck in the exhaust
    22. Both the switches are broken



    The Cosmetics:

    1. The tail section was missing,
    2. The paint was all screwed,
    3. The visor had a small crack and the glass was missing.
    4. It had max 100 rear mudguard,
    5. The side panels were broken
    6. The front mudguard was broken
    7. Rims had pitting
    8. Hubs were painted silver
    9. Both the mirrors are missing
    10. Seat is all gone


    The good stuff

    1. Its a shogun and its black
    2. The tank had zero rust
    3. The cylinder though I lift it, is a .25 as per the seller and is powerful
    4. All the locks open with one key and its a metal key
    5. The bike runs straight, signs of no major accident
    6. Good at a extremely mouth watering price
    7. Engine has new oil seals and clutch plates
    8. chain and sprocket look ok
    9. the gear change is smooth
    10. All bearing are good and no unwanted noise from the engine or wheels
    11. The mask is original and not a cheap fiberglass replica


    The game plan

    The game plan is to do a complete ground up restoration including a complete engine check-up to see if a rebuild is required. If yes then a pin to pin restoration.

    Full paint(same colour) full cosmetics, Front end upgrade with old apache forks and rotor and other brake gear with Fiero F2 hub.

    Keep watching this space.

    Pramod

    Shogun in my garage(sorry for the crappy pic)
    Last edited by xBhp; 03-01-2019, 12:02 PM.
    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

  • #2
    Re: I bought another Suzuki Shogun

    Thread approved.

    Comment


    • #3
      Re: I bought another Suzuki Shogun

      Completely glued to this thread sir! I am a huge fan of your work.The Shogun is my dream bike! I own it's little brother,the Max 100R.The issues in this Shogun closely resemble the ones that I had on my bike.It is nice that the engine pulls well and doesn't have any abnormal noises,also the fact that it isn't pulling to any side and going straight.The Complete Cosmetic Kit,right from the front visor to the tail is available (including tank and panels) are available I think.Switching back to the Shogun exhaust would transform the sound and would aid the performance also.

      All the very best sir [emoji120][emoji120]
      [My Motorcycle]

      2001 TVS-Suzuki Max 100R

      Comment


      • #4
        Re: I bought another Suzuki Shogun

        Pramod, lovely to read that you going to restore another gun! Not many I get to see/hear a full fledged restoration of gun. All the best for your restoration.
        Keep the blue smoke floating!!!!!
        RX100 1996 | Karizma 2004 | Karizma-R 2011 | RXZ 1999 | RX 135 1998 | RX 100 1993 | CBF150 2005 - 2011

        2012 - Meghamalai | Kuttralam | 2011 Ooty | Munnar | 2010 Point Calimere | Horsley Hills | Yercaud

        Comment


        • #5
          Re: I bought another Suzuki Shogun

          Originally posted by TVSian View Post
          Completely glued to this thread sir! I am a huge fan of your work.The Shogun is my dream bike! I own it's little brother,the Max 100R.The issues in this Shogun closely resemble the ones that I had on my bike.It is nice that the engine pulls well and doesn't have any abnormal noises,also the fact that it isn't pulling to any side and going straight.The Complete Cosmetic Kit,right from the front visor to the tail is available (including tank and panels) are available I think.Switching back to the Shogun exhaust would transform the sound and would aid the performance also.

          All the very best sir [emoji120][emoji120]
          Thanks For those encouraging words, Its a dream bike for many.

          Originally posted by SriramEfunds View Post
          Pramod, lovely to read that you going to restore another gun! Not many I get to see/hear a full fledged restoration of gun. All the best for your restoration.
          Keep the blue smoke floating!!!!!
          Thanks Sri, I have a couple of bikes lined up for restoration.

          Meanwhile, Here is the list of things needed.
          1. New headlight dome
          2. New wiring kit
          3. new cables
          4. New bar Handle
          5. New Grips
          6. New Yokes
          7. New switch gear(both sides)
          8. New clutch leaver(chrome)
          9. Front brake master cylinder(Apache-New/used)
          10. Front rotor(Apache-New/used)
          11. Front Caliper(Apache-New/used)
          12. Front Brake hose(Apache-New)
          13. Brake fluid Dot 3
          14. Chrome Front Brake leaver
          15. Speedo Worm
          16. Speedo cable
          17. Hub Spacer
          18. Axel(Shogun)
          19. New visor Glass
          20. New indicators 4Nos
          21. Side panels
          22. New Battery
          23. Rear Panels
          24. New seat
          25. Rear Mudguard
          26. Tail light assembly
          27. Rear Brake shoes
          28. Rear mudguard reflector
          29. Front tyre(Non Ribbed 270X18))
          30. Rear Tyre(Michilin Sirac Street 300X18)
          31. Rear Mudflap
          32. Front mudguard
          33. Sticker Kit
          34. Rubber kit
          35. Side stand
          36. Center stand
          37. Misc Bulbs
          38. Oil level sensor
          39. Engine screw kit
          40. Air filter screw kit
          41. Air filter element
          42. Carb rebuild kit
          43. Reed valve
          44. New rims(Hero Honda)
          45. Crash Guard(Bar/Butterfly)
          46. Packing kits
          47. Piston Rings(if needed)
          48. 12mm 1 inch Bolts(20 NOS) + Washer nuts(20)
          49. 10MM 1/2 Inch bolts (20)+ Washer nuts(20)
          50. New axels
          51. New engine mounting bolts
          52. 10mm Alen key bolts 1.25-1.5 inch 4 Nos


          I have made an exhaustive list, Hoping I do not miss anything.

          Here is a video of everything wrong with my shogun.



          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: I bought another Suzuki Shogun

            Pramod, most of the spares should be available. I see many restoring their gun to full glory. I'm sure you have the right contacts in your phone book to get these.
            Bangalore is the one of the place where you can get good help.
            RX100 1996 | Karizma 2004 | Karizma-R 2011 | RXZ 1999 | RX 135 1998 | RX 100 1993 | CBF150 2005 - 2011

            2012 - Meghamalai | Kuttralam | 2011 Ooty | Munnar | 2010 Point Calimere | Horsley Hills | Yercaud

            Comment


            • #7
              Re: I bought another Suzuki Shogun

              Phew! That is an exhaustive list of parts required!
              Last edited by TVSian; 03-06-2019, 06:25 AM.
              [My Motorcycle]

              2001 TVS-Suzuki Max 100R

              Comment


              • #8
                Re: I bought another Suzuki Shogun

                Originally posted by SriramEfunds View Post
                Pramod, most of the spares should be available. I see many restoring their gun to full glory. I'm sure you have the right contacts in your phone book to get these.
                Bangalore is the one of the place where you can get good help.
                Most of the parts are procured. Details in the videos below

                https://www.youtube.com/watch?v=s1pfhc57MVo
                https://www.youtube.com/watch?v=4qUeBrtB350

                Another important question i get asked all the time is, How to identify a shogun from other Suzuki vehicles such as samurai and Max 100, Yes people are converting their max 100s as well to look like shoguns.

                Identity a shogun without looking closely. How not to get cheated while buying a shogun and not to end up with a samurai or a max 100#Yamakaze Join the Yama...



                Below is the status of the list

                Pending items

                1.New headlight dome
                4.New bar Handle
                5.New Grips
                6.New Yokes
                7.New switch gear(both sides)
                8.New clutch leaver(chrome)
                9.Front brake master cylinder(Apache-New/used)
                10.Front rotor(Apache-New/used)
                11.Front Caliper(Apache-New/used)
                12.Front Brake hose(Apache-New)
                14.Chrome Front Brake leaver
                15.Speedo Worm
                16.Speedo cable
                17.Hub Spacer
                18.Axel(Shogun)
                20.New indicators 4Nos
                22.New Battery
                23.Rear Panels
                24.New seat
                25.Rear Mudguard
                27.Rear Brake shoes
                28.Rear mudguard reflector
                29.Front tyre(Non Ribbed 270X18))
                30.Rear Tyre(Michilin Sirac Street 300X18)
                32.Front mudguard
                35.Side stand
                36.Center stand
                37.Misc Bulbs
                38.Oil level sensor
                39.Engine screw kit
                40.Air filter screw kit
                41.Air filter element
                43.Reed valve
                44.New rims(Hero Honda)
                47.Piston Rings(if needed)
                48.12mm 1 inch Bolts(20 NOS) + Washer nuts(20)
                49.10MM 1/2 Inch bolts (20)+ Washer nuts(20)
                50.New axels
                51.New engine mounting bolts
                52.10mm Alen key bolts 1.25-1.5 inch 4 Nos

                Items already procured

                1. New wiring kit
                2. new cables
                3. Brake fluid Dot 3
                4. New visor Glass
                5. Side panels
                6. Tail light assembly
                7. Rear Mudflap
                8. Sticker Kit
                9. Rubber kit
                10. Carb rebuild kit
                11. Crash Guard(Bar/Butterfly)
                12. Packing kits
                13. KB 100 RVMs
                14. Front mudflap
                15. Clutch plates

                I have a busy weekend planned ahead, Saturday will be mostly parts procurement day, Sunday will be the dismantling day.



                Pramod
                Last edited by yam; 03-06-2019, 10:39 AM.
                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: I bought another Suzuki Shogun

                  I'm a big fan of the shogun, i tried to buy one back in 2011 but unable to do so.....I currently have a 2002 Suzuki MAX100R and the 1984 IND-Suzuki AX100(Japan) and looking forward to restoring them both.

                  If u can get the Shogun meter assembly(PRICOL) and the sticker kit I'll buy it from you...I'll PM you my number.
                  My Motorcycles :-

                  IND Suzuki AX100 ( 1984 )
                  TVS Suzuki Fiero ( 2000 )
                  TVS Suzuki MAX100R ( 2002 )

                  Hero Splendor Plus i3S ( 2018 )

                  Be Passionate about your BIKE and Ride Safe...


                  Comment


                  • #10
                    Re: I bought another Suzuki Shogun

                    Originally posted by prasath_xbhp View Post
                    I'm a big fan of the shogun, i tried to buy one back in 2011 but unable to do so.....I currently have a 2002 Suzuki MAX100R and the 1984 IND-Suzuki AX100(Japan) and looking forward to restoring them both.

                    If u can get the Shogun meter assembly(PRICOL) and the sticker kit I'll buy it from you...I'll PM you my number.
                    I am not sure if i can help you. The shogun meters are not available any more, Stickers are available almost everywhere, It would be better if you can go around in your area and check.

                    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


                    • #11
                      Re: I bought another Suzuki Shogun

                      How to repair the apache Master cylinder and Caliper





                      Rebuilding the apache master cylinder for the shogun, the video ended abruptly after the memory card was full, but covers most of it hence uploading it anywa...






                      Apologies for the abrupt ending, however it covers the entire procedure. I could have bought the caliper and master cylinder new but this channel won’t be a ...




                      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


                      • #12
                        Re: I bought another Suzuki Shogun

                        The most important thing is the ease of usage of this forum, There is absolutely none.

                        The application is extremely buggy and i have never seen a single attempt to fix it. I have not been able to share youtube videos here and I am convinced that it would be of no use since its buggy and it might even not get a single view due to the bugs. I am not planning to post anymore content here till the time someone fixes these bugs.

                        I am expecting a PM once the bugs are fixed, Hope that is soon.

                        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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