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Thread: Rebuilding a Yamaha Rx135 4-Speed (1997) aka 'Rustique'

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    Default Rebuilding a Yamaha Rx135 4-Speed (1997) aka 'Rustique'

    After an agonizing wait, I've decided to take the plunge and rebuild my Yamaha Rx135 4Speed that stepped out of the factory gates in 1997.
    Today however, she's in quite a bit of bother. A far cry from how she must have been a decade and a half ago.

    Name:  Rustique - XBhp.jpg
Views: 18248
Size:  104.2 KB

    This above image is among the last set of pics i have of her. Rusted in multiple places, the plan is to rebuild her to riding spec.
    Looking forward to sharing this journey and learning from everyone about this fine machine.

    Cheers

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    Moderator antz.bin's Avatar
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    Advice is a form of nostalgia.
    Dispensing it is a way of fishing the past from the disposal, wiping it off, painting over the ugly parts and recycling it for more than it's worth.

    Antz Travelz!! | South India Exploration Ride | Leh Triplog (Work in progress)

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    Rusted dual disc 200's Avatar
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    Quote Originally Posted by firbie View Post
    After an agonizing wait, I've decided to take the plunge and rebuild my Yamaha Rx135 4Speed that stepped out of the factory gates in 1997.
    Today however, she's in quite a bit of bother. A far cry from how she must have been a decade and a half ago.

    Name:  Rustique - XBhp.jpg
Views: 18248
Size:  104.2 KB

    This above image is among the last set of pics i have of her. Rusted in multiple places, the plan is to rebuild her to riding spec.
    Looking forward to sharing this journey and learning from everyone about this fine machine.

    Cheers
    Welcome to the Two Stroke Forum, a bit more elaborate details of the bike & the owner which is obviously you, will help seniors here to pour in their suggestions, with mediocre details like what you've posted will not fetch you any suggestions or results.

    Hearty Congrats on your build though..
    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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    Hello Firbie - All the best for your restoration process. If you are not familiar on the road map to rebuild, take a look at restoration threads to get an idea and also might help to learn something.
    RX100 1996 | Karizma 2004 | Karizma-R 2011 | RXZ 1999 | RX 135 1998 | RX 100 1993 | CBF150 2005 - 2011

    2012 - Meghamalai | Kuttralam | 2011 Ooty | Munnar | 2010 Point Calimere | Horsley Hills | Yercaud

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    Post Brief History of My Yamaha Rx135 4Speed (1997) aka 'Rustique'

    Quote Originally Posted by antz.bin View Post
    Thread Approved
    Thanks for the speedy approval @antz.bin

    Quote Originally Posted by dual disc 200 View Post
    Welcome to the Two Stroke Forum, a bit more elaborate details of the bike & the owner which is obviously you, will help seniors here to pour in their suggestions, with mediocre details like what you've posted will not fetch you any suggestions or results.
    Hearty Congrats on your build though..
    Quote Originally Posted by SriramEfunds View Post
    Hello Firbie - All the best for your restoration process. If you are not familiar on the road map to rebuild, take a look at restoration threads to get an idea and also might help to learn something.
    Dualdisk & Sriram,
    thanks a ton for the warm welcome and the kind wishes. I have been more of a lurker on the forum this far. So it is glad to be posting again

    About the bike:


    Mine is a Yamaha Rx135, a 4Speeder who'll be 15 this year

    Her existing setup is as follows:

    • Block/Piston: 1st Oversize ART Piston in an un-sleeved block
    • Crank Replaced in 2005, running with crank rod of 'unknown' origins
    • Suspension: Rear Suspension replaced with OEM Escorts Shock-Absorbers. Front suspension running the same as 15 years ago, with bi-monthly oil & oil seal changes. Both, the Oil as well as the Oil Seals used are OEM Yamaha India parts
    • All Cables barring the Choke cable are OEM Yamaha
    • Speedometer is OEM Pricol
    • Light & Ignition pod are non-OEM make due to unavailability of OEM Parts
    • Wiring Loom - Replaced last month with MINDA OEM Wiring Kit
    • Fuel Tank - Replaced with Yamaha OEM last month
    • Running OEM Fuel Filter
    • Carburetor is the same that came with the bike 'Mikuni', runs standard 17.5/165 Jets & needle set at half-point (OEM Yamaha, replaced earlier this year)
    • Spark Plug is NGK Japan, OEM Yamaha
    • Oil Pump functions normally, oil being used is Yamalube. A small amount is also added to the fuel tank at every top up to prevent engine from running fully dry
    • Clutch & Pressure Plates are Yamaha OEM Replacements from the YBX (i think) 4 Stroke bikes
    • Engine was rebuilt last year for 1st Piston Oversize with all OEM Bearings & Oil Seals
    • Rims are Hero Honda & Tires were replaced earlier this year to Michelin Sirac 2.75*18 & 3.0*18, front & rear
    • Sprocketing is 16T up front, unsure whether it is (34/37 or 38T at the rear), both sprockets again being OEM Yamaha
    • Exhaust is the same 15 year old one, with an OEM Yamaha (36Lxxx) Core being added last year. The bend pipe sadly is non-OEM


    The Journey in a nutshell:

    In the past 7 years since she's been with me, there have been 2 cosmetic builds and countless 'mechanical' ones. Lack of knowledge, about this forum, sources of information on the parts & highly restricted finances had meant that i was to suffer endlessly. Having being butchered and pillaged by almost every mechanic i have been to, the journey has been nothing, if not a nerve wracking one.

    It was some time last year when i had my first cut of luck that things began to change for the better. I was to begin her rejuvenation process at the beginning of the year, but lack of funds for parts & the subsequent monsoons meant that it had to wait till now.


    A Mechanic's Tale:


    I finally have a mechanic who has agreed to let me work in his garage for a few hours every night and help me with the rebuild process. 'Mahesh' is a rare breed as far as mechanics come. Loyal to his Enfields, he has been my go-to guy for all things Royal Enfield. With the patience of a sage, he is a sight to see when working. Unassuming fella, he's at his workshop, coaxing the best out of Bullets 7 Days a Week. Yes, that's not a typo, this guy loves his bikes so much, he only takes a leave when there's a family celebration or when he's short of parts to finish off the job. Both scenarios are extremely rare and he's possibly got access to the entire range of RE OEM Spares.

    He usually is reluctant to take on bikes of other makes as "running around for parts saps him out of his energy". Thankfully, after much coaxing, he's agreed to assist and guide me in my Rebuild process.


    The 2012 Rebuild Begins:


    Been shoring up my war-chest of OEM Yamaha Parts for some time now. Brought the wrong ones, brought too many, brought too little, lost many a pretty penny, but its all added up. This rebuild process is all about bringing the bike to Factory specs with Yamaha OEM parts being used to the extent possible. The Engine has been mechanically rebuilt just a few months ago and is turning over decently. Hence, it is only going to see a good paint job. The internals shall be worked upon once a few critical parts are in hand, the funding for which, shall take a while.

    I managed to do a partial strip down of the bike last night. As of now, the Grab rail, exhaust assembly, fuel tank, carburetor, wiring loom, meter pod & headlight assembly have been dismantled. Fingers crossed on getting the garage space to finish the job tonight.

    I get in about 90 mins to 2 hours after office to work on the bike and the timeline for the rebuild is about a month.

    Shall keep updating with doubts, queries & my thoughts on the rebuild as time goes by

    To Be Continued....

    Thank You for a patient read
    Cheers
    dpak89 and Dinesh.P like this.

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    Wonderfully written the story so far. Well, though you have not shared as which part of this country you belong to, however, keep us posted on the cosmetic work. Also, I'm sure you are into right forum for the rebuild. Here there are many who have restored more than one bike and their knowledge gained over the experience will translate into productive approach. Keep us posted.
    RX100 1996 | Karizma 2004 | Karizma-R 2011 | RXZ 1999 | RX 135 1998 | RX 100 1993 | CBF150 2005 - 2011

    2012 - Meghamalai | Kuttralam | 2011 Ooty | Munnar | 2010 Point Calimere | Horsley Hills | Yercaud

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    NEatly penned history and specs! All the best for the build!
    Rx is a Phoenix!!! It always rise from ashes!!

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    Gud Luck for the build..
    Happy & Safe Riding to All

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    Wonderfully penned down, Congrats on the build. Keep us posted pls.
    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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    Default Yamaha Rx135 4-Speed Rebuild Update: Strip Down

    Quote Originally Posted by SriramEfunds View Post
    Wonderfully written the story so far. Well, though you have not shared as which part of this country you belong to, however, keep us posted on the cosmetic work. Also, I'm sure you are into right forum for the rebuild. Here there are many who have restored more than one bike and their knowledge gained over the experience will translate into productive approach. Keep us posted.
    Quote Originally Posted by dpak89 View Post
    NEatly penned history and specs! All the best for the build!
    Quote Originally Posted by vimalnair4u View Post
    Gud Luck for the build..
    Quote Originally Posted by dual disc 200 View Post
    Wonderfully penned down, Congrats on the build. Keep us posted pls.
    Thanks for all the wishes guys.
    @Sriram, I am from Mumbai (somehow missed out on that - silly me)

    Now for the Updates on the strip-down:

    Although, i'd have liked to go revv happy on the rebuild, i could only spare an hour post office hours to work on her. So, after 8.5 Hours of sweat, toil and loads of grime n grease, spread over a week, step 1 was finally complete. The bike is now in her individual pieces.

    It has been a slow crawl this far. She has bared all before me and it is not a pretty sight. All the butchering and cheating by the earlier 'mechs' that she'd suffered over the years came out in all its painful detail.

    I shall now begin a close inspection of all the parts and am sure that there are going to be tons of things to share, ask about and learn from everyone.

    Going to try clicking snaps but it gets kind of difficult when the grime takes over.

    Thanks for your time and hope to see you'll in the next round.

    Cheers and ride safe
    Last edited by firbie; 09-22-2012 at 08:26 AM. Reason: corrected typo

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