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Thread: Suzuki Samurai restoration

  1. #1
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    Default Suzuki Samurai restoration

    Hey guys,
    I have a Suzuki Samurai that has been lying around since a year and a half in the parking lot. It has caught a lot of rust and dust in the time being. I finally had the time to have a look at it this morning, and I saw that it still has petrol in it. I tried giving it a go but it won't start. I wasn't expecting any miracle start after such a long time but gave it a try nevertheless.
    I'm looking to restore this motorcycle as a project.
    Can any experts here give me some guidance as to where to begin. It had starting issues even back then when it was in working condition (kind of lol). I'll be uploading the pics in a couple of hours or so. If people could help in here, it would be great. Thanks!

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    Moderator The Monk's Avatar
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    Default Re: Suzuki Samurai restoration

    Biking is not about what you have between your legs, its all about how well you use it!!!!!!!

    Give your details here if you want to help your fellow xBhpian stranded in your city

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    Default Re: Suzuki Samurai restoration

    Quote Originally Posted by The Monk View Post
    I've read both the threads. I guess the difference is that in both the above threads the bike seemed to be in working condition. Mine seems to be in working condition but just wont start. And also I'd like to know any places in Mumbai where I can source parts from. Anybody from Mumbai who knows such places kindly help out!
    Another thought me and my friends had was to install an RX100 japanese block in it. I wanted to know whether or not it's doable. If yes then where can I get the part in Mumbai?

  4. #4
    yam
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    Default Re: Suzuki Samurai restoration

    Quote Originally Posted by Divyesh Panchal View Post
    I've read both the threads. I guess the difference is that in both the above threads the bike seemed to be in working condition. Mine seems to be in working condition but just wont start.
    For any 2 stroke to start, you need 3 things, air Fuel and 3rd and most important; spark. If you are planning to do it yourself then I suggest you take out the spark plug and connect the plug cap to the plug while its out and kick couple of times to see if its sparking, few things to note while doing it is you should not be holding the plug in the hand as the shock you get from the plug are quite powerful, second thing is equally important, the plug should be resting against some metallic part of the bike to provide the plug a suitable ground. if its sparking move to the next bit if not then you have a faulty ignition system.

    Troubleshooting the ignition system

    Step1. Take the plug out and remove the plug cap(by turning it anti clockwise) now hold this HT lead a few MMs away from the metallic parts of the bike and start kicking to see if that produces a strong spark, if yes you have a faulty spark plug or little less likely a faulty plug cap, if this solves the spark issue install a new plug/cap and try starting the bike, it should come to life, if not then move to step 2

    Step 2. Checking the ignition lock, you don't have much options here but if you have a working neutral light you can isolate the lock issue easily. if the lock is faulty the neutral light wont come on when you try kick starting, if it does then move on, else spray generous amount of WD40 and see if that make a difference

    For the next set of steps you need to swap parts to check if there is an issue with the components, these components are the coil and the CDI.

    If there is no ignition problem or one of the previous troubleshooting solves the issue then you can move on to the next component, which is checking if the system is receiving fuel.


    Troubleshooting fuel issues

    Old fuel disintegrates over a period of time and gums up the jets, so even if the bike starts its advisable to get the carburettor thoroughly cleaned and rebuilt.

    Step 1, disconnect the fuel inlet tube and see if there is a fuel flow, be careful while doing it and avoid spilling fuel on the bike or yourself. Keep the fuel tap closed when you disconnect the tube, if there is fuel flow then move to next step if there is none, your filter/fuel tap is clogged, replacing it might solve the problem.

    Step 2, disconnect the rubber hose that connects the carburettor to the air filter and place your palm on the opening behind the carburettor where the hose was connected, kick couple of times and your palm should be wet with fuel, if not, your carb needs a rebuild, if its wet then try kicking for a couple of minutes and the bike should start, if not then safely drain old fuel and get fresh fuel and try to start again.


    If all this fails you need to get it to the mech. Note, please take pics of each part you are taking apart so that you know what goes where, Suzuki bikes are highly fiddly so expect bruised knuckles and fingers
    Quote Originally Posted by Divyesh Panchal View Post
    places in Mumbai where I can source parts from. Anybody from Mumbai who knows such places kindly help out!
    There are a lot of shops in Mumbai where you can source parts, body parts should be easily available, engine parts are also farily easy as most of the parts were shared by shogun, samurai, shaolin, AX 100, max 100 and ind suzukis. Make a list of things you need and then go looking for it.
    Quote Originally Posted by Divyesh Panchal View Post
    Another thought me and my friends had was to install an RX100 japanese block in it. I wanted to know whether or not it's doable. If yes then where can I get the part in Mumbai?
    Its a extremely stupid idea to fit a rx 100 engine, one the suzukis have a single cradle chassis and yamahas have a double cradle chassis, so its not going to be easy, second the bike would no longer be road legal since the engine number and the make of the engine would be different, plus this would also ruin the bike in terms of valuation and character.
    Cigarettes are like squirrels... perfectly harmless until you put one in your mouth and light it on fire.

    Wanna learn more about 2 Stroke DIY maintenance? Subscribe to https://www.youtube.com/yamakaze

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    Default Re: Suzuki Samurai restoration

    very nice instructions by yam. . I have a 2002 Suzuki MAX100R and am also looking to do a complete restoration myself. please post pics of your samurai soon. eager to see in its condition. . do you plan to do just a restoration or some modifications after?

    ----consecutive posts auto-merged-----

    Quote Originally Posted by Divyesh Panchal View Post
    Another thought me and my friends had was to install an RX100 japanese block in it. I wanted to know whether or not it's doable. If yes then where can I get the part in Mumbai?
    yam has answered correctly to this question. I thought of buying the piston-cylinder kit for my MAX100R. Since samurai and MAX100R share the same kit, I'm posting this pic for your reference.

    Name:  20160119_211815.jpg
Views: 1698
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    Last edited by prasath_xbhp; 06-08-2016 at 06:29 PM.
    My Motorcycles :-

    IND Suzuki AX100 ( 1984 )
    TVS Suzuki Fiero ( 2000 )
    TVS Suzuki MAX100R ( 2002 )

    Hero Splendor Plus i3S ( 2018 )

    Be Passionate about your BIKE and Ride Safe...



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    Default Re: Suzuki Samurai restoration

    Quote Originally Posted by prasath_xbhp View Post
    very nice instructions by yam. . I have a 2002 Suzuki MAX100R and am also looking to do a complete restoration myself. please post pics of your samurai soon. eager to see in its condition. . do you plan to do just a restoration or some modifications after?

    Here are a few pics!
    Attached Images Attached Images    

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    Default Re: Suzuki Samurai restoration

    Clean that carb throughly. I suspect its a carb issue.

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  8. #8
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    Default Re: Suzuki Samurai restoration

    have you restored the bike yet?. plz update the status of the restoration work....
    My Motorcycles :-

    IND Suzuki AX100 ( 1984 )
    TVS Suzuki Fiero ( 2000 )
    TVS Suzuki MAX100R ( 2002 )

    Hero Splendor Plus i3S ( 2018 )

    Be Passionate about your BIKE and Ride Safe...



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    Default Re: Suzuki Samurai restoration

    Suzuki Samurai 1998 Model fully restored with all OE Spare partsName:  SUZUKI%20SAMURAI%201998.jpg
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    TVSian, cyborgk and Aryan14-3 like this.

  10. #10
    TVS Racing FTW ! TVSian's Avatar
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    Default Re: Suzuki Samurai restoration

    Looking amazing.Hats off! Great work on the bike!
    [My Motorcycle]

    2001 TVS-Suzuki Max 100R

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