update

Finally completed the running-in of the bike,yet to open up the throttle fully (waiting for a hartal) ,she runs fine now except for the reluctance to idle ,

changed the rear tyre to ceat gripp and rides better than the earlier m86

half the bikes electricals are now directly connected to the battery....the other half got eaten by rats

will post more after opening her up fully

Good keep the ownership thread flowing. BTW, what engine oil & 2T are you using?

engine oil is castrol active 20w40 , 2t oil is mixed with the petrol from the pump itself

2T oil is generally mixed with petrol using an oil pump & not as mixing oil & petrol in the fuel tank - is that what you mean? I didn't understand the statement - "2t oil is mixed with the petrol from the pump itself".

the oil is mixed with petrol in the fuel tank itself as the oilpump was ruined by the mech, im not sure of the brand of 2t oil as it varies with the fuel pumps ,the ones i visit use mak 2t semi synth ,wanted to try out valvoline 2t semisynth but couldnt as the oilpump was shot

I too rebuilt my 1989 KB100 about 2 years back, its sad that is now parked at my home town in Agra while I am in Hyderabad, Good Job Buddy,

I had a step by step thread here that we lost in the in-famous xbhp server crash sometime back

Mhale pistons are of better quality than Goetze.

And if you are not using the oil-pump, ensure that you temporarily seal the oil-inlet on the carburetor, else the mixture will be very lean. This is also probably the reason why she won't idle happily or pull strongly.

Im hereby declaring my kb rebuild a failure , the crank case is leaking oil ,the paint is blisetring and the chrome is rusting,not to mention a long list of other chronic problems....
guess the mechs, painters, chrome platers greed for more bucks was greater than my determination to keep her running

Thanks to all the xbhpians (especially argee,harish ,jd666...)for your support

I feel a great sadness and enormous anger at all those who cheated and took you for a ride.I have a 1987 Feb reg KB100 which I still run.When I did the rebuild in 2002 the spares were available,but had to sit with the mech.,all the time and ensure no goof up happened.I got my painting of both chasis and body baked in oven for 4 hrs,and even to-day after 7 yrs still shines...which cannot be said about the plating.I too got cheated ,but on a small scale....Recently again I had to open the engine and do up the crankshft,new piston,big end and small end bearings, oil seals,packing etc.,My mech was able to source it but made a terrible mix up in assembling it.I had taken the vehicle back and am in the process of opening the engine and refitting everything by myself.Hope to finish by this week end.......So i know what your feelings are..but never give up.Unfortunately I saw your posts only now as otherwise I could have helped. I have the full service manual for the KB100 and not for the RTZ.The only dif is the resonator pipes and fitting on the crank case.If u want it I can send a Xerox copy of it to your address.
You will PAY ME BUY NOT GIVING UP ON YOUR RESTORATION AND RUNNING THE KB LIKE A NEW VEHICLE.
KB is a great Bike ..don't give up on it.
Mine is 23 yrs old and still going strong

!!!!!!

Oh!!! I am really sad for you bro! Sry was busy with col these many days. As psr says pls don't give up hope. I was too frustrated with problems in the beginning but now she's doin really great. Try to get the job done with some other reliable mechanic na?? I was really impressed by the pics initially, but i guess the mech has screwed up a lot of things. So what are you upto now??

long time no see harish......hows college ,

im back to square one the circle has started again presently in the hunt for parts again , getting a new reliable mech is difficult to impossible , as for now im going to wait and watch

manual

heres the manual for kb100 Picasa Web Albums - P.S. Raghavan - KB100

Thanks a lot psr sir

manual

Here's the high resolution scan of the manual Picasa Web Albums - P.S. Raghavan - KB100

thanks a ton again psr sir

It was no problem.. hope all KB 100 people use it as a reference for re-building....Pass it on to all who need it.
I have done all the corrections and the bike is running with more pep now..tempted to twist the throttle ...but I know the consequences.Done 200 Kms..will wait for it to cross 800 before I go above 4 K RPM.

Where are you located? Depending on the city, I may be able to help you with a mechanic.