Re: Suzuki Samurai restoration

Yes,If you are willing to sacrifice some fuel efficiency for that.Samurai and Max engines are designed with efficiency in mind and are not really meant for performance,so when you start modding,efficiency takes a heavy toll..But you can do it anyways and gain 2 to 3Bhp from it.It's still not going to beat a stock RX100.


First of all,You need to make sure that the engine,Air filter,spark plug,CDi,carburettor,clutch plates,chain&sprockets and all are in great shape for adequate power delivery.

After completing proper maintenance,You can go for Mild porting and polishing,don't go too much. best place to do it is at Bangalore.You can install a Shogun Core and upjet your carburettor for better power.

I'd also suggest you to use a 16" Yezdi wheel at the back.You need to get the rim and tire,Just use the old hub and spokes,cut it to fit the length from hub to rim (any bicycle repair guy will be able to do it) and you are done.You will notice better acceleration,but slightly reduced top-end.

With these mods installed,You will get 35-40kmpl efficiency,down from the 55 to 60kmpl that they usually deliver.


Or if you are willing to spend,You can search for an AX100 block piston kit,along with its triple reed valve,use a bigger carburettor, combine with port&polish and Shogun core,and you will have noticeably much more power,maybe matching an RX100 but efficiency will drop below 35kmpl.

All the best.Choose wisely

Re: Suzuki Samurai restoration


replied in bold

Re: Suzuki Samurai restoration

Guys, can we replace fork downtubes of Samurai 2001 model with downtubes of pulsar classic model ?
Is it a direct fit or not ??

Re: Suzuki Samurai restoration

No,It's not a direct fit.If you want a Pulsar Disc setup,then change the full front end (Forks,Stem,Disc,Caliper,Master Cylinder,Lever,Hub.etc) to that of the Pulsar.

Re: Suzuki Samurai restoration

Hello guys...
Suggest me a o-ring chain, sprocket kit for Samurai

Re: Suzuki Samurai restoration

Why do you need a o-ring chain sprocket honestly? Just stick with the regular one.

Re: Suzuki Samurai restoration

Dear Friend (TVSian)

I'm Bhaskaran living in Bangalore and I'm crazy Fan of Suzuki Shogun and RX100.. I born and brought up from middleclass agricultural family (Tamilnadu).. when i completed my education and moved to Bangalore in search of job (1998) i suppose to have a Bike to get a job there . So i requested my father to help me to get a bike (Huge money for him it was) for me and my request was RX100 or Suzuki Shogun. But what i got was Suzuki Samurai (Because of finance as well his friends suggested that samurai is economy in fuel).

Anyhow i was happy to get a new Japanese Motor and started enjoying it ..

To make it short its my first vehicle (For my entire family) and till now i have it with goo shape.. currently I can afford to upgrade to a good bike , I'm not really willing to do because of my love towards the 2 stroke machines (Shogun/RX100).

Now i have decided to restore my Samurai (1998 Model) as new with all possible power improvements.
Please please help me to achieve my dream if you can.

1. Suzuki AX-100 Cylinder Kit is available in Alixpress china will it be worth to try or is there any other way to source it in India?

2. AX-100 and Supra bike had same Cylinder block or different ?

3. What is mean by Shogun core (please forgive my poor knowledge) ? is it mandatory to change the core to get good result ?

4. If i fix AX-100 Cylinder Kit on samurai engine still i need to do porting & polishing ? if yes can you refer me any good mechanic in bangalore ?

5. Do i need to use powerbox ? can i use the normal manifold ?

6. which carburetor do u recommend.

When you find time please respond me .

With Best Regards
Baskaran.V

Hello Experts !

can anyone please through some light on my queries please 😀

Apologies for the late reply, Like you, I am a big fan of the Shogun but not so much of the RX100. Samurai is a wonderful bike, better built than the Max 100R while it shares all the mechanical aspects with it.

1) AliExpress is banned in India now (unfortunately), If you want an AX100 Cylinder, look at used options in India (scrapyards,online sellers.etc) taken from scrapped bikes, should be available. Don't get the new ones you see with some sellers, they are crap.

2) Supra and AX100 blocks are different, especially the ports, both made more power than the Samurai.

3) Shogun Core, it is the internal flute-like thing with a cone, that is inserted in the exhaust. It's purpose is to reduce the sound, but Shogun's flute acted kind of like an expansion chamber and the sound was awesome. Performance side, it's most likely not going to work due to the fact that it's designed for a Shogun's block so it takes the info of Shogun's exhaust port size, duration, RPM.etc and not the data of Max/Samurai/Supra/Shaolin's engines, so it's not going to do any benefits on the performance, it does sound awesome though.

4) Not really, But I'd suggest you to port your current Samurai block, and get a new OE Max 100R block piston kit at TVS (Yes, still in production) for the future. Make sure to get it done at someone who knows what he is doing. AX block's advantage is the triple reed setup and bigger ports, made slightly more power. So if you can't source one, you can go for modding your current block, but whatever you do, get a new block piston beforehand.

5) You will need Supra's manifold, tube and powerbox which are damn near impossible to source or old stock/used ones are crazy expensive these days, very few people are making custom ones (@tuners_craft at Insta) but I'm not sure if it's available today. So stick to the stock intake manifold for now, but go for the powerbox setup if you can find the Manifold,pipe and powerbox.

6) You can try using Shogun's VM22 carb, should help in performance. But do spend time jetting it correctly. Ported AX block with Shogun Carb will net you the best result here.

But like I said earlier, Bikes like Samurai & Max are not meant for performance mods as their base character was,is & will always be about being a frugal, reliable everyday runner and not a performance machine. Stuff like a good AX block that's not damaged/sleeved with good quality piston & rings,good Shogun carb with OE Jets and no damage, in itself can be a headache, then comes the R&D part of you spending countless time and money on installing it and making it run correctly.

So the best and straightforward way, is to stick to stock and enjoy the bike for what it is, you'll be able to save tons of time & money and use it to actually ride the fully rebuilt bike. If you want performance and if you are in a position where you can safely spend extra money & time on fuel,oil & maintenance, simply go for an RXG/RX135 or a Shogun and enjoy the extra performance.

Hope it helps, apologies again for the late reply.

Dear Friend!
First of all my sincere thanks to you for such a brief and clear write up !! Thanks a lot..

Sure I went through your reply line by line and I’m reconsidering myself to keep the engine untouched as of now (Let me think) , but at least I decided 100 percent that the outer look of the bike will be shogun 😁 with stickers and headlight visers etc.. that will give some happiness to me.

As of now , I completely teared down the bike and removed the paint from all parts (took me good amount of time almost 20 days ) .. and buying all the parts which needs replacement..

next step:
1. Need to find a good place to get it painted for reasonable price in Bangalore (yet to find the palace , if you know anyone do let me know).

2. Few more spares I need i.e Silencer , chain cover and Bore kit ..

will update further.. and attaching few pics of the work ...

Cheers!

On the cosmetics as well, I would suggest you to stick to Samurai design. It will help in resale value when you are in a position to get a real Shogun, as it preserves the originality of the bike.

Looks like you have teared down the engine as well, clean the crankcases well, change all the washers,circlips,bearings and seals.etc
Make sure that the gears are not damaged & are in good shape. Get the crank rebuilt and rebalanced, or change it as a whole & get the clutch rebuilt.