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**Bismaya** · 04-21-2019, 09:04 AM

Re: Project IND-SUZUKI AX100

Never seen a nylon bushing before. Seems like that must have been a hard part to source. How's the paintjob and stickering so far? All finished?

**Naveen Reddy** · 04-21-2019, 09:49 AM

Re: Project IND-SUZUKI AX100

Originally posted by Bismaya View Post

Never seen a nylon bushing before. Seems like that must have been a hard part to source. How's the paintjob and stickering so far? All finished?

Painting and stickering is done I suppose have already posted a picture of the same

**prasath_xbhp** · 04-22-2019, 01:23 PM

Re: Project IND-SUZUKI AX100

Originally posted by avhad sitaram View Post

Bro max 100 forks oe is not super easy though[emoji33] ,
I searched almost six months only for oe fork tubes and no luck[emoji1].

so have u got them or not?. I also need 1 or 2 sets of TVS OE front forks for MAX100R. what is the price of 1set(OE)?

**Naveen Reddy** · 04-22-2019, 07:07 PM

Re: Project IND-SUZUKI AX100

Started the engine and noticed a bit of clutch noose.. I lately realised that while opening up the bike the mechanic who's not so pro used an Ellen key to lock the gear wheel basket and caused a bit of drnt on the gears.

Managed to source a brand new clutch kit and primary wheel

That's the damage on one of the tooth

**avhad sitaram** · 04-22-2019, 10:32 PM

Re: Project IND-SUZUKI AX100

Originally posted by Naveen Reddy View Post

Started the engine and noticed a bit of clutch noose.. I lately realised that while opening up the bike the mechanic who's not so pro used an Ellen key to lock the gear wheel basket and caused a bit of drnt on the gears.

Managed to source a brand new clutch kit and primary wheel [ATTACH]249175[/ATTACH]

That's the damage on one of the tooth
[ATTACH]249176[/ATTACH]

Lz dont ever use any metal or wooden object to lock the teeth of primary drive gear and primary driven gears.

The best way to tighten the primary gear is use dedicated connecting rod holder tool. If that is not available use straight rod of soft metal and lock the connecting rod.

I have not used any one of the above method instead i used a jugaad to tighten primary gear to descent torque. Just fit the magnet rotor into its place and hold it using magnet holder tool. Now you are all set to give torque to primary gear. Hope this help you.

**avhad sitaram** · 04-22-2019, 10:35 PM

Re: Project IND-SUZUKI AX100

Originally posted by prasath_xbhp View Post

so have u got them or not?. I also need 1 or 2 sets of TVS OE front forks for MAX100R. what is the price of 1set(OE)?

No luck bro...instead i used aftermarket good quality stuff. But it wont even close to oe one.

**avhad sitaram** · 04-22-2019, 10:40 PM

Re: Project IND-SUZUKI AX100

Originally posted by Naveen Reddy View Post

Started the engine and noticed a bit of clutch noose.. I lately realised that while opening up the bike the mechanic who's not so pro used an Ellen key to lock the gear wheel basket and caused a bit of drnt on the gears.

Managed to source a brand new clutch kit and primary wheel [ATTACH]249175[/ATTACH]

That's the damage on one of the tooth
[ATTACH]249176[/ATTACH]

Pls place the old primary gear and a new one side by side and observe the difference. There should be lot of difference in outer diameter of both. Old primary gear eventually worns out and becomes smaller in size which our naked eyes cant differentiate and we think that its all ok but its not probabaly.

**Naveen Reddy** · 04-23-2019, 12:18 AM

Re: Project IND-SUZUKI AX100

Originally posted by avhad sitaram View Post

Lz dont ever use any metal or wooden object to lock the teeth of primary drive gear and primary driven gears.

The best way to tighten the primary gear is use dedicated connecting rod holder tool. If that is not available use straight rod of soft metal and lock the connecting rod.

I have not used any one of the above method instead i used a jugaad to tighten primary gear to descent torque. Just fit the magnet rotor into its place and hold it using magnet holder tool. Now you are all set to give torque to primary gear. Hope this help you.

I agree .. while opening up the bike I have seeked support from a small mechanic and we have stripped it down

Setting up the bike is by a very professional guy who has all tools and even a compressor and air gun

----consecutive posts auto-merged-----

Originally posted by avhad sitaram View Post

Pls place the old primary gear and a new one side by side and observe the difference. There should be lot of difference in outer diameter of both. Old primary gear eventually worns out and becomes smaller in size which our naked eyes cant differentiate and we think that its all ok but its not probabaly.

I am replacing both clutch and primary.. never one old and one new match

**avhad sitaram** · 04-23-2019, 12:39 AM

Re: Project IND-SUZUKI AX100

Originally posted by Naveen Reddy View Post

I agree .. while opening up the bike I have seeked support from a small mechanic and we have stripped it down

Setting up the bike is by a very professional guy who has all tools and even a compressor and air gun

----consecutive posts auto-merged-----

I am replacing both clutch and primary.. never one old and one new match

I am not talking about mix and match the primary gear[emoji1]. I am just stating the fact that we cant figure out the worn out primary gear coz it worns out in such away that there teeth seems to all ok eventhough they are heavily worn out. To experience this you have to just observe the old on vs new one. New one is actualy bigger in outer dia. The primary gear is the one which worn out so quickly but in such a way that it evenly reduces its outer side, when we place new and old primary gear we immediately notice their sizes.

If your mech has all the tools to assemble it then its a ill practice to place a allen key like object to lock the primary drive gear and primary driven gear instead of using connecting rod holding tool.

I just wish to contribute your rebuild nothing else.

**Naveen Reddy** · 04-23-2019, 07:10 AM

Re: Project IND-SUZUKI AX100

Originally posted by avhad sitaram View Post

I am not talking about mix and match the primary gear[emoji1]. I am just stating the fact that we cant figure out the worn out primary gear coz it worns out in such away that there teeth seems to all ok eventhough they are heavily worn out. To experience this you have to just observe the old on vs new one. New one is actualy bigger in outer dia. The primary gear is the one which worn out so quickly but in such a way that it evenly reduces its outer side, when we place new and old primary gear we immediately notice their sizes.

If your mech has all the tools to assemble it then its a ill practice to place a allen key like object to lock the primary drive gear and primary driven gear instead of using connecting rod holding tool.

I just wish to contribute your rebuild nothing else.

That's good information bro.. appreciate your suggestions. I got what you saying about the primary gear.

We have started the bike late night yesterday and it is buttperfect sounds mint..

Now my other . thought is whether or not to pickup max 100r exhaust.. there's one brand new old stock for sale. I already have two exhausts that belong ax100 which need re chrome plating

One major difference is with the exhaust end can tip. On ax100 it is welded and painful to clean. Only the muffler pipe can be removed and I have seen many folks cutting the bend pipe to clean.. was wondering why not use castic soda

Anyways I am planning to pick that new exhaust as it looks exactly same

**prasath_xbhp** · 04-23-2019, 12:30 PM

Re: Project IND-SUZUKI AX100

i have bought the TVS OE primary driven gear back in 2015 for my MAX100R....just to be future-spare-proof for our beloved 2 strokes.....

**Naveen Reddy** · 04-23-2019, 02:55 PM

Re: Project IND-SUZUKI AX100

Originally posted by prasath_xbhp View Post

i have bought the TVS OE primary driven gear back in 2015 for my MAX100R....just to be future-spare-proof for our beloved 2 strokes.....

Yes it is good to treasure few important parts

**Naveen Reddy** · 05-01-2019, 08:32 PM

Re: Project IND-SUZUKI AX100

Introducing the Suzuki AX100. A project that was in mind for a decade and finally made it.
I would like to thank every person who helped during this Journey. Had to over come many pain points while sourcing the parts and finding the best skilled force. Tried my best to get as close as it was in the 80's when rolled out of factory.
let me know what you think of the build guys

**TVSian** · 05-02-2019, 05:50 AM

Re: Project IND-SUZUKI AX100

Has come out incredibly well! Looks like it just rolled out of the showroom! Please upload more pictures and also share the cost! Thanks

**Bismaya** · 05-02-2019, 07:47 AM

Re: Project IND-SUZUKI AX100

Originally posted by Naveen Reddy View Post

Introducing the Suzuki AX100. A project that was in mind for a decade and finally made it.
I would like to thank every person who helped during this Journey. Had to over come many pain points while sourcing the parts and finding the best skilled force. Tried my best to get as close as it was in the 80's when rolled out of factory.
let me know what you think of the build guys

That looks so much more beautiful than a Max 100.

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Project IND-SUZUKI AX100

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