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Thread: Our Humble 1999 TVS Scooty ES Rebuild

  1. #1
    Rusted karthikdattag's Avatar
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    Default Our Humble 1999 TVS Scooty ES Rebuild

    For those of you who dint know, TVS scooty is also a part of my 2-stroke family. Actually belongs to my wife & has come to me as a dahej (Dowry). LOL that was the only thing i got & that too in pretty bad shape.

    This scooty was bought in 1999 first hand & has been abused like crazy since then. Typical ladies driving estyle!!!!!!!

    When i rode this for the first time, i was like how do ladies ride such a crap!!! Anyways have been regularly servicing this & have made some replacements like Clutch, drive belt, jet kit. It hardly does 50Kmph & pulling with 1+1 is a pain.

    Hence started the complain from wife, "Why dont you get me a brand new scooter, like activa or deo?? You keep filling our garage with 20yr old junk (referring to my Red RD350, please guys we all know ladies have minimal idea about what twin cylinder is or heck how 2-strokes work etc etc) & can't get me a new one?

    Some funny converstion:

    Me: What is the problem with this scooty?

    She: Its old.

    Me: WTF (not literally or else i would have be clobbered) !!!!!

    She: I don't know, get me a new one.

    Me: What if i made this a brand new piece, right from engine to body?

    She: Hmmmmmm....... Nice......... Can you do that?

    Me: You asking me lady? Ofcourse i can do it. Give me a month's time & will give you a brand new scooty rebuilt.

    She:

    Me: Thank god, saved Rs.50,000/- (Price of deo or activa).

    But anyways guys, my original intent was to save this 2-stroke & not sell it for some 1000 bucks.

    Spoke to my friend (Tuner) & he was like, WTF, scooty???? I was like yes, please please please....... Actually my guy is not into < 100cc category, but anyways he agreed to help.

    Now here is a brief list of things we intend to do:

    1. Brand New CrankShaft Assembly
    2. Brand New Piston-Cylinder Kit or 1st O/S on existing one.
    3. Street Port Setup for easy 1+1 commute. Looking for better torque & hence going for porting.
    4. Rejetting due to above.
    5. Exhuast clean up (Sand Blasting)
    6. Brand New Speedometer assemby
    7. Brand New Switches (Start, Horn, Light ON/OFF, High/Low Beam, Turn Signal)
    8. 35W/35W Halogen Bulb for Head Light
    9. Complete Black Scheme for colours (Existing one was silver)
    10. Brand New Tyres
    11. Brand New Brake light & Indicator Assembly
    12. Brand New Rims
    13. Brand New LH & RH RVMs
    14. Brand New Gear Box
    15. Any other minor or major issue which may come up during rebuild.
    Here are some pics of the scooty & the spares procured till date. My expectation is factory quality finish & i am sure i will accomplish it.

    Thanks for looking.
    Last edited by karthikdattag; 10-17-2011 at 10:28 AM.
    Akkiben likes this.

  2. #2
    Super Moderator Noor's Avatar
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    Thread approved
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    Rusted karthikdattag's Avatar
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    Thanks a lot for speedy approval.

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    A 2T is a 2T, always a beauty whether Scooty or RD. Rode this one quite a bit during my PUC days. In thick city traffic its fun. All the best. a ported Scooty, I am sure thats a rarity


    Quote Originally Posted by karthikdattag View Post
    Hence started the complain from wife, "Why dont you get me a brand new scooter, like activa or deo?? You keep filling our garage with 20yr old junk (referring to my Red RD350, please guys we all know ladies have minimal idea about what twin cylinder is or heck how 2-strokes work etc etc) & can't get me a new one?
    LoL! This morning a neighbour told me the same thing
    A lone amateur built the ark. A large group of professionals built the Titanic...

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    Rusted yamdoot's Avatar
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    Quote Originally Posted by karthikdattag View Post


    But anyways guys, my original intent was to save this 2-stroke & not sell it for some 1000 bucks.

    Spoke to my friend (Tuner) & he was like, WTF, scooty???? I was like yes, please please please....... Actually my guy is not into < 100cc category, but anyways he agreed to help.

    My expectation is factory quality finish & i am sure i will accomplish it.

    Thanks for looking.

    Should be fun restoring it. I did the same to my Ki-Ho instead of scrapping it for 1000/- and now its more enjoyable than an Activa.

    Use original spec body screws and rubbers and it will be a solid build.
    1985 Yamaha RD350 HT
    1989 Ki-Honda 110
    1994 Suzuki Shogun
    1997 Yamaha RX135
    2008 Yamaha FZ
    Suzuki Supra Powerup
    Hero IMPULSE
    TVS NTORQ


    No Cams, No Valves, No Headaches.

  6. #6
    Rusted karthikdattag's Avatar
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    Quote Originally Posted by NitinGirish View Post
    A 2T is a 2T, always a beauty whether Scooty or RD. Rode this one quite a bit during my PUC days. In thick city traffic its fun. All the best. a ported Scooty, I am sure thats a rarity

    LoL! This morning a neighbour told me the same thing
    True. Yes it will be ported, not for top-speed runs, but for better torque delivery.

    Thanks.

    Quote Originally Posted by yamdoot View Post
    Should be fun restoring it. I did the same to my Ki-Ho instead of scrapping it for 1000/- and now its more enjoyable than an Activa.

    Use original spec body screws and rubbers and it will be a solid build.
    Sure doc, point noted.

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    I have hardly seen anyone rebuilding any moped or scooterette that too a 2-stroke. This is truely awesome.

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    TVS Scooty na!!!!!! Maga, this is by far the best thread for me. My sis had one back in college, so i am emotionally attached to this one. Great going kano.
    1988 Yamaha RX100
    2002 Yamaha RX-Z 5-Speed
    2011 Yamaha R15

  9. #9
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    I have a 1997 first ES model of scooty... still going strong.. rode 170 kms on NH 7 from Jalgaon to Akola and reached

    She is my first love.. learned riding on it... ohh sorry.. learned on a Luna TFR...


    Crossed 50... a big fall... the only time caught for riding without license........ full shining in school.... ohh a hell load of memories of my scooty....

    I must say it has one of the best build in terms of engine and of fiber parts... like the HH CD 100 first model which proudly sported "Made in Japan" engine... yes i have that too....

    Will soon restore her.... glued to your thread for free DIY.....

    Cheers
    sid
    WARNING!! Objects seen in Mirror are Disappearing Rapidly!!!!!!

    Never be Afraid to Slow Down!!!!

  10. #10
    Rusted dual disc 200's Avatar
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    Woww...! Another fun rebuild..! Good going Karthik...! Keep us updated...! Hope there won't be any porting or any race spec standards in this one atleast... lol

    P.S. Damn...never knew you were married too...! Almost all the guys except a few are married & still in this smokey little world less than 300cc's.
    Whenever there is a Rainbow in the sky, I know it's u mastering the art of Cornering. U will always be remembered brother, R.I.P Arun.

    The 5 Speed Restoration
    The Z Restoration


    /2001 Yamaha Rx 135 5 Speed/ 1999 Yamaha RXZ 135/ 2012 Honda Dio/ ?

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