@ Nithin it wouldn't be an costly affair at all only the bore costs an arm and a leg rest is still sourceable at affordable prices, if you say converting 5 speed is a costly affair then what will you say to the guyz who get rx 100 or 135's at 40k+ if you ask me that would not be worth the $$, in the end it depends on one's passion and love on his bike or his set up for them the cost wouldn't be a matter.

I know a guy in the forum who has bought a 135 for a pricey amount and converting it to 5 speed, recently we happened to open the 4 speed engine for the conversion and came to know that the engine was never opened after it was fitted in the factory for 7 long years the owner had clocked 12k+ and shut fill drive, every single part in the engine as mint as u can get, its running on standard bore and the bore mounts on the crankcase had rusts on it, had a tough time removing it LOL enough said if i go on i will end saying the owners name here..

^^ yup that they are.. ITs ok to run a 5 speed gearbox on a 4 speed bore, the final drive ratio is the same, infact the 5 gears give you better traction and gearing!

@raghu - You have painted the whole engine block black. would you be looking at restoring it back to silver? or keeping it as is..
I haven't painted anything. It was the same when I bought it. Any how it requires painting so I was thinking how about going in for silver. Because, I would like to paint the tank with Black and sticker it similar to the stock one.

the FE is nearly same for both bikes 4S and 5S.
ok. In that case, it all depends on the availability of the parts.

- Also the overall condition of the bike is good.

- Check the chassis for rusting and corrosion. If any, get the paint stripped, cleaned, and repaint the chassis.

- Check the wiring for cuts, brittleness, and general quality. If necessary, replace entire wiring harness to have a more efficient electrical system

- All head lamps, indicators bulbs, lenses etc can be replaced to give it a fresh look.

- Check front fork springs, and you can overhaul the front forks with new seals, fresh shocker oil.

- Check tank for rusting - you can get it repainted, or exchange it for a new tank in the local market.
There is a small dent in the tank apart from this tank is good. I would like to remove the dent and get it painted.
COming to the engine -

- If you are running last oversize, then best bet is to go for a new cylinder , but beware, majority of your budget could be the cylinder, but then once you get a new block, it will be peaceful riding for ages. ~ 6-7k minimum what i can find.
I really don't mind going in for a new cylinder so that it would last long.
Many times I thought of selling it and going in for another RX which is in a perfect condition. But then I knew it is very difficult to find the RX with perfect condition. So then I thought it would be better to rebuild the existing with new engine so that it would last longer and I get the pleasure of riding a new bike.
- cheaper option would be to get it sleeved, and then bored to stock. But then that will only be for running about, and the engine will never perform like stock bike.

- Change bearings on crankshaft, get it rebalanced.

- Change oil seals on engine, also check condition of clutch housing, clutch plates.

- Replace clutch actuation springs, and the clutch housing springs for a better response.

- Get the carburettor serviced thoroughly. Also change the reed valve if never done so in many years.. It will help a lot with the performance.

- When the engine is opened, the cylinder should/would be cleaned to remove all carbon deposits in the ports.

- Also check condition of chain, sprockets etc.

- You are running a box type swingarm at the back -

First query - where did u get it?? i want one too!!
- As I said earlier, it was the same when I bought it. Is it any way better than the stock ones? Is so would like to retain it.
Second one - check the swingarm bushes for wear and tear, and then check the rear suspension for proper damping. replace if necessary.

- Replace all cables, speedo, throttle, choke, brake etc... ( if cracked or brittle).

- Change brake shoe springs, and cam lobes ( as aargee found out for his braking issue). This will help improve your braking.

These are just some general points to be taken into consideration. But go mechanical first, and visual later...
Yes what you said is right.

^^ for the jerking issue you can use the heavier magneto plate from the RX135. That will add mass to the crank, and smoothen out this issue.

just managed to get a 1997 RXG for 13000/-

mech told me that the engine is recently resleeved.

Oil tank is slightly rusted

wheels are from herohonda

which is the best tyre for wet conditions as monsoon is at our door steps?