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**xBhp** · 04-15-2019, 01:43 PM

Re: Suzuki Samurai restoration

Thread approved.

**AshwinYuvRaj** · 04-15-2019, 11:13 PM

Re: Suzuki Samurai restoration

Originally posted by xBhp View Post

Thread approved.

Thanks for quick approval. Give me some suggestions based on your experience.

**TVSian** · 04-16-2019, 10:21 AM

Re: Suzuki Samurai restoration

Originally posted by AshwinYuvRaj View Post

Hi,

I am restoring my dad's old Suzuki Samurai with some simple upgrades listed below:
1. Front disc brake & a Victor GL Swingarm for rear
2. Shogun headlight mask+visor with Splendor headlight
3. Engine - Reboring to 1st over size, mild porting, Enlarging reed area, using Ax100 reed 3 petal one, Supra manifold with power box
4. Exhaust - Stock exhaust with Shogun muffler

I have some queries with this restoration.

1. I have purchased Pulsar classic forks, can we simply plug the downtube of pulsar into stock tubes ?
2. Using a victor swingarm causes any issue ? Or if i use stock swingarm suggest a suitable o-ring chain
2. Best headlight bulb for an Samurai
3. Does enlarging reed area gives more power ? As i read somewhere on a forum

Waiting for experts advice

Thanks,
Ashwin Yuvraj[ATTACH]249060[/ATTACH]

Hi,All the very best for the restoration!

1) You can get a Pulsar Disc setup up front.Easily available.Should cost you under 5K for the total work.Victor Swingarm would be nice! Worthy investment.I am not sure about the downtube thing,I think it needs slight modifications.

2) Not sure why.It kind of messes with the looks.But if you like it,Go for it.If you want the round type,Go for Roadking headlight.Headlight bulb,I'm using 35w normal.You can go upto 45w.

3) But Supra Manifold is very difficult to source.The powerbox,The Samurai engine isn't designed for it,so You might face misfiring with that boost bottle/power box.I also had this idea for my bike,but experts who had experience with it,adviced me to not go for it.As far as I know,It isn't possible to enlarging the reed area to accomodate for a bigger reed.Samurai isn't designed for Shogun-levels of power but for great efficiency with one of the best fuel efficiency numbers in its times.I don't know how it will react or behave with such mods.Best to keep it stock and you will really appreciate it's frugal nature!

4) Awesome.I've also done the same for my bike.It's a little loud,but is nice! If you are in places were cops are a little more sensitive,Wrap a layer of Glasswool in end.But be very careful with handling Glasswool.It's lethal stuff.

Best of luck for rebuild [emoji106]

**AshwinYuvRaj** · 04-16-2019, 11:24 PM

Re: Suzuki Samurai restoration

Originally posted by TVSian View Post

Hi,All the very best for the restoration!

1) You can get a Pulsar Disc setup up front.Easily available.Should cost you under 5K for the total work.Victor Swingarm would be nice! Worthy investment.I am not sure about the downtube thing,I think it needs slight modifications.

2) Not sure why.It kind of messes with the looks.But if you like it,Go for it.If you want the round type,Go for Roadking headlight.Headlight bulb,I'm using 35w normal.You can go upto 45w.

3) But Supra Manifold is very difficult to source.The powerbox,The Samurai engine isn't designed for it,so You might face misfiring with that boost bottle/power box.I also had this idea for my bike,but experts who had experience with it,adviced me to not go for it.As far as I know,It isn't possible to enlarging the reed area to accomodate for a bigger reed.Samurai isn't designed for Shogun-levels of power but for great efficiency with one of the best fuel efficiency numbers in its times.I don't know how it will react or behave with such mods.Best to keep it stock and you will really appreciate it's frugal nature!

4) Awesome.I've also done the same for my bike.It's a little loud,but is nice! If you are in places were cops are a little more sensitive,Wrap a layer of Glasswool in end.But be very careful with handling Glasswool.It's lethal stuff.

Best of luck for rebuild [emoji106]

Thanks for your kind comments brother...
I've already sourced pulsar front end, Victor swingarm, Supra manifold and power box.
Regarding headlight i prefer to have clear lens glass, will check if it looks good...if not will go for stock shogun setup.

**AshwinYuvRaj** · 04-18-2019, 01:09 AM

Re: Suzuki Samurai restoration

Guys, can we use Gladiator alloys on Pulsar classic forks ???

**TVSian** · 04-18-2019, 06:43 AM

Re: Suzuki Samurai restoration

Originally posted by AshwinYuvRaj View Post

Guys, can we use Gladiator alloys on Pulsar classic forks ???

No.Please use the respective setups as it is.Pulsar setup is most preferred for its affordable cost and good performance.

**AshwinYuvRaj** · 04-18-2019, 11:48 AM

Re: Suzuki Samurai restoration

Originally posted by TVSian View Post

No.Please use the respective setups as it is.Pulsar setup is most preferred for its affordable cost and good performance.

Yes bro... I agree, even i have purchased a Pulsar front end setup. But I'm planning for Tubeless tyres, thats why checking for Alloy rims compatibility.

**AshwinYuvRaj** · 04-18-2019, 11:56 AM

Re: Suzuki Samurai restoration

Stripped chassis... getting ready for tinkering & then painting.

**TVSian** · 04-18-2019, 12:10 PM

Re: Suzuki Samurai restoration

Originally posted by AshwinYuvRaj View Post

Yes bro... I agree, even i have purchased a Pulsar front end setup. But I'm planning for Tubeless tyres, thats why checking for Alloy rims compatibility.

Alloys don't really go along with the looks of these classic motorcycles but looks are objective,so you might like it.

**AshwinYuvRaj** · 04-19-2019, 12:05 AM

Re: Suzuki Samurai restoration

Originally posted by TVSian View Post

Alloys don't really go along with the looks of these classic motorcycles but looks are objective,so you might like it.

Yes bro... Even spokes are my choice too...

Having problems with fork top bolt, can we use Pulsar classic top plate on Samurai ?

**kb100** · 04-19-2019, 12:20 AM

Re: Suzuki Samurai restoration

Originally posted by AshwinYuvRaj View Post

Guys, can we use Gladiator alloys on Pulsar classic forks ???

try and source the suzuki heat/zeus front end and alloys , that should be a direct fit and will be cheaper to procure

**prasath_xbhp** · 04-19-2019, 04:28 PM

Re: Suzuki Samurai restoration

Originally posted by TVSian View Post

3) But Supra Manifold is very difficult to source.The powerbox,The Samurai engine isn't designed for it,so You might face misfiring with that boost bottle/power box.I also had this idea for my bike,but experts who had experience with it,adviced me to not go for it.As far as I know,It isn't possible to enlarging the reed area to accomodate for a bigger reed.Samurai isn't designed for Shogun-levels of power but for great efficiency with one of the best fuel efficiency numbers in its times.I don't know how it will react or behave with such mods.Best to keep it stock and you will really appreciate it's frugal nature!

I agree with TVSian that sticking to stock setup is the wise desicion. But I want to discuss a few points.

1. Supra also has same reed valve like Shogun and Shaolin right?.

2. What is that Boost Bottle/Power Box? Shogun and Shaolin also have this?

3. I don't know abt supra manifold, but shogun manifold is available for sale in Kaveri Auto Parts in Facebook Rs. 650/- ( See the image below )

4. Specially manufactured bore for Shogun is available for sale for Rs. 7500/-. ( Is it worth it? ) ( Can it be installed directly on to the MAX100R/Samurai crankcase? ) ( See the image Below )

**TVSian** · 04-20-2019, 06:32 AM

Re: Suzuki Samurai restoration

Originally posted by prasath_xbhp View Post

I agree with TVSian that sticking to stock setup is the wise desicion. But I want to discuss a few points.

1. Supra also has same reed valve like Shogun and Shaolin right?.

2. What is that Boost Bottle/Power Box? Shogun and Shaolin also have this?

3. I don't know abt supra manifold, but shogun manifold is available for sale in Kaveri Auto Parts in Facebook Rs. 650/- ( See the image below )

4. Specially manufactured bore for Shogun is available for sale for Rs. 7500/-. ( Is it worth it? ) ( Can it be installed directly on to the MAX100R/Samurai crankcase? ) ( See the image Below )

[ATTACH]249127[/ATTACH]

[ATTACH]249128[/ATTACH]

1) No,Supra's Reed Valve design is similar to that of the AX100.Not the Shogun or Shaolin.

2) Boost bottle/power box is there to improve low-end performance and aids for smoother throttle transitions.The Supra SS had it I think.Not sure.The SS was the predecessor to the Shogun.

3) Don't need boost bottles on Max or Samurai.You will end up spending so much money for an engine that misfires a lot.

4) 'Specially Manufacturered' could just be a marketing term,We need to know the make before coming to a conclusion.AFAIK,Nothing beats an ART Setup for Shogun.ART kits are still in production but costs a bomb.And NO,Shogun block will NOT fit in the crankcase of Max 100 or Samurai.Best you can get is an AX100 or Supra block for better performance,Both,are rare and can cost a lot.

**AshwinYuvRaj** · 04-20-2019, 10:45 AM

Re: Suzuki Samurai restoration

Originally posted by TVSian View Post

1) No,Supra's Reed Valve design is similar to that of the AX100.Not the Shogun or Shaolin.

2) Boost bottle/power box is there to improve low-end performance and aids for smoother throttle transitions.The Supra SS had it I think.Not sure.The SS was the predecessor to the Shogun.

3) Don't need boost bottles on Max or Samurai.You will end up spending so much money for an engine that misfires a lot.

4) 'Specially Manufacturered' could just be a marketing term,We need to know the make before coming to a conclusion.AFAIK,Nothing beats an ART Setup for Shogun.ART kits are still in production but costs a bomb.And NO,Shogun block will NOT fit in the crankcase of Max 100 or Samurai.Best you can get is an AX100 or Supra block for better performance,Both,are rare and can cost a lot.

Very informative. Bro...
Suggest some simple modifications to make Samurai peppy to ride.?

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Suzuki Samurai restoration

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