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Thread: TVS Suzuki Max 100R - Good First Bike ?

  1. #21
    TVS Racing FTW ! TVSian's Avatar
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    Default Re: TVS Suzuki Max 100R - Good First Bike ?

    Few Important Works to be done in the near future.

    1) The Speedometer - Mechanics who ever saw it,Told me cable is dead and the meter,it's all jammed up and only specialists can work on it.Have contacted one garage who can work on it.Asked me to come tomorrow.Don't know what kind of work it is,told me it will cost 200 bucks.

    2) Left Air Filter Panel - There are knob-like things that pop into the holes on the frame for a proper fit.
    Previous Owner seemed to have 'played' with it and has broken one of the knobs and now it's not fitting properly.Mechanic told that it's better to change the whole panel,which only comes as a set and that too,a duplicate one.So he suggested me to do 'Moulding' - He isn't sure who exactly does it,but told we have to go to Pudupet for that.No idea how much it will cost either,I am guessing it will be under 100 bucks.Or else,I'd simply get a used panel from a salvaged bike,that's a safer bet.

    3) RVMs - Mirrors,well,I could not source Shogun Pair,But only left side.Others were cheap replicas that easily break off.So I decided to give up and find Max 100R Mirrors itself.A Pair costs 200 bucks roughly and looks good quality.

    4) Fuel Line Lock - The area I live,My neighbour says that there are thieves who steal petrol in the night,so I would like a simple lock.The switch for Main-Off-Reserve thing as a Keyhole that can be operated,only when its key is put in.I feel that it will be very effective.Hoping it would cost under 200 bucks.

    5) Carburettor Cleaning + Tuneup + New Spark Plug :
    One major work really.Due to the rusted tank,I feel that there are rust bits choking the filter and the carburettor which makes the bike cold-starting much harder and also stutter at times when accelerating.Also no history of Spark Plug,so will be changing that too.Should improve performance and efficiency.300 bucks for this one

    6) Used Fuel Tank - My current petrol tank is rusted inside out and rotten,Previous owner has done quite a shoddy work on fixing it and it looks quite horrible.Will be searching for a used Tank.My current tank also has that 'Do not mix oil with petrol' sticker and I am a little obsessed with it! Is there anyway to carefully peel it off from old tank and paste it back on replacement tank properly ? I am hoping to get a used tank under 1000 bucks

    7) Centre Stand - Major work I think.The bike kind of wobbles side to side with centre stand,but not front and back because both the wheels are on the ground even with the centre stand on.Mechanic tells me that it needs to be checked clearly to understand what's wrong.Can finish within 500 bucks,but if centre stand needs replacement,It will cost over that.

    8) Front Wobbling - Not exactly tank-slapper,but beyond 50Kmh/r,There is a slight wobble in the front steering.I am guessing there might be some kind of wheel bend/alignment issue or even tyre problem which needs to be seen.

    That's about it.Other works have been sided for a while.
    [My Motorcycle]

    2001 TVS-Suzuki Max 100R

  2. #22
    TVS Racing FTW ! TVSian's Avatar
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    Default Re: TVS Suzuki Max 100R - Good First Bike ?

    UPDATE

    Fixed a lot of things today! Thought I'd just fix the Speedometer,But here goes the story!

    1) Starting with the Speedometer,A shop named 'Amal Speedometer Service' at Saidapet.The guy was experienced and did a quick job.He was cheerful,spoke well,told me about his old Samurai and how it keeps running.Regarding the work,He basically took out the entire thing and rebuilt it by also changing a few small gears and some adjustments.He used a running Tablefan to connect,check and calibrate the speedometer.I believe he used good quality parts.Costed 200 bucks,But later found out that the Worm Gear in the Front Wheel Hub is jammed and Speedometer Cable is dead.

    So I went to a mechanic he suggested,Just two blocks away
    The place basically was a small shop with 2 Mechanics and 2 rather aged people running the shop.They have Motorcycle + Auto Spare Parts.I got 'Suprajit' Brand Speedometer Cable and 'V Plus' Brand Worm Gear Set.Not exactly SGP quality,But he suggested that they are of great quality.The Mechanics,Although young,Were very professional and polite.They worked on the bike very well.The speedometer started working like charm! I noticed that the Mechanics were also not very busy apart from an RX135 being worked on,changing front sprocket.So I thought I might be able to fix the other small things too.Got the Choke Cable replaced,'Suprajit' Brand.

    List of things that got fixed :

    Loose Steering Lock ✓
    Loose Leg-Guard ✓
    Loose Horn Connectors ✓
    Dead Choke Cable ✓
    Rusty Squeaky Switches ✓
    Clutch Cable Play ✓
    Bent Underengine Cowl ✓
    Loose Seat ✓
    Loose Brake Light Panel ✓
    Loose Kicker ✓

    Total cost of work including Labour,Spare parts - ₹500

    The bike feels great now! I also feel that some rattling noises that used to be present,has gone.Which is a nice thing!

    More Fixes coming up in the future,Which mechanic suggested to leave the bike to him for a day for a few tasks and other few tasks, take to Pudupet.

    Parts to buy/Work to do

    Full Water Wash and Cleanup
    Missing Handle Holding Nut
    Need New Mirrors
    Loose Rear Taillamp Switch
    Loose Left Panel (Mould)
    Rusted Tank (Replace)
    Need Fuel line Lock
    Main Stand Wielding Work
    Right Front Footpeg Bent
    Carburettor Clean+Retune
    Indicator Buzzer Replacement
    Battery Recharge
    New Spark Plug
    Need New Air Filter
    New Motul 2T Oil
    New Gearbox Oil (10w40)

    The bike should start much easier and feel a lot better after the remaining works are done.But I do not have a specific date when this would be done,But I know these would be done in the near-future!

    Stay Tuned guys! Thanks for the support!


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    [My Motorcycle]

    2001 TVS-Suzuki Max 100R

  3. #23
    TVS Racing FTW ! TVSian's Avatar
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    Default Re: TVS Suzuki Max 100R - Good First Bike ?

    UPDATE

    The Oil Lamp on the Console has started to come up,so I am going to get Motul Motomix 2T for Engine and Motul 3000 20W40 900ml for Transmission.The steering lock has come loose once again,so I will be fixing that one too.
    [My Motorcycle]

    2001 TVS-Suzuki Max 100R

  4. #24
    TVS Racing FTW ! TVSian's Avatar
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    Default Re: TVS Suzuki Max 100R - Good First Bike ?

    UPDATE

    Got the mirrors and fixed them today! Original FIEM ones.Costed about ₹185.Also the Flute Screw was loose and the threads were not there so I had to change that too,Resulted in a much nicer exhaust note without the flute jumping around.Removed the Under-Engine cowl with was rusted and was rattling at speeds above 40KM/hr.Now the bike is ready,waiting for Oils to arrive! Name:  IMG_20181112_123053.jpg
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    [My Motorcycle]

    2001 TVS-Suzuki Max 100R

  5. #25
    TVS Racing FTW ! TVSian's Avatar
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    Default Re: TVS Suzuki Max 100R - Good First Bike ?

    UPDATE

    Got the Oils replaced yesterday! I will explain the steps I have done.Always open for correction!

    Safety first,So wear good protection safety glasses,gloves and mask.Carry proper tools : Spanner Set,Screwdriver.etc.

    1) Warm Engine and turn off,Remove
    any cowls/guards under the
    engine.
    2) Place Pan under Crankcase.
    3) Remove Oil Drain Screw.Try to not
    get your hands with oil even if you
    are wearing gloves.
    4) Let it fall and drip completely,Need
    to wait for a few minutes.
    5) In the Meantime,Remove Right
    Panel,There you will find Engine
    Oil Tank.Remove it from its
    position.Do NOT disconnect
    anything.
    6) Clean the Oily Mess around the
    tank and in its location.I used a
    hard toothbrush and a metalwire
    dish-scrubber.
    7) Remove Cap,Filter from Tank Neck
    and Drain Old Oil completely (Use
    seperate bottle to catch old oil).
    8) DO NOT FIT IT BACK just yet ! or
    you will have clearance issues
    with the Funnel as the seat would
    not allow Funnel to sit properly.
    9) Now get to Gearbox side,Put back
    Oil Drain Screw and properly
    tighten.
    10) Open Gearbox Oil Cap,and pour
    Motul 3000 20W40 900ml
    Oil,then close the Oil Cap.Use a
    Plier to tighten it.
    11) Open 2x Motul Motomix 500ml
    Oil and keep them ready beside
    you.
    12) Now open Engine Oil Tank
    Cap,Put back the Filter in its
    neck,Put the funnel and hold
    funnel firmly.Make sure you have
    a good grip on the tank and the
    funnel,with one hand.
    13) With the other hand,Pour the
    Motomix Oils one by one.
    14) After finishing,Close the cap and
    tighten
    15) Now install the Oil Tank back to
    it's place.Make sure you don't
    overtighten or you might break
    the plastic mounts on the
    tank.Previous owner has already
    broken one.
    16) With Ignition OFF,Give it 4-6 times
    soft kicks.
    17) Now turn on Ignition and fire
    her up!
    18) Let her idle for a few minutes and
    then go for a short spin.Don't
    revv high.Shift early,use all 4
    gears.
    19) Clean your safety
    equipments,Tools and keep them
    back wherever you took it from!

    What I did,Mix up both the old oils and stored them so I can use for lubricating hinges,locks.etc.Before mixing,I also applied the Old Engine oil on rusted parts behind the oil tank when I removed it.I hope it works on atleast preventing further rusting.You might also notice that I got 3xMotomix Oils.We only need two to get a full tank of oil.I bought the third so that I can top up every 500KMS as suggested by the manual.

    Viola! You're done! Now let the pictures do the talking!Name:  IMG_20181112_175756.jpg
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    [My Motorcycle]

    2001 TVS-Suzuki Max 100R

  6. #26
    TVS Racing FTW ! TVSian's Avatar
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    Default Re: TVS Suzuki Max 100R - Good First Bike ?

    UPDATE

    Finally,after weeks of searching,I was able to find a half-decent original Fuel Tank for my bike! The old tank had huge amounts of M-Seal in it.So I was lucky as it didn't leak all these days.The mechanic hit it with a spanner with normal force and to my horror,It just broke open a huge hole....Good god! I immediately changed it to the new tank.Thanks for him to work even when it was raining.Had about 2 Litres of fuel.Got them transferred to the new tank,but small amount spilled out during the transfer.Also changed the horrible buzzer with it,Got the Carburettor Retuned.Mechanic told it was fine and doesn't need a clean up for now.Best part,is that I finally fixed the Air Filter cover,All it took was reverse-drilling a screw,stick it there and it now acts as the knob like the others and sits right in the slot.Neat fit,rattle has also gone! Extremely happy with the outcome.

    Now have to relocate the Horns right below the tank behind the headlamp,and throw away that altered crashbar.

    Let the pictures do the talking! Name:  IMG_20181122_103511.jpg
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    [My Motorcycle]

    2001 TVS-Suzuki Max 100R

  7. #27
    Rusted Bibhu's Avatar
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    Default Re: TVS Suzuki Max 100R - Good First Bike ?

    Congratulations. Lemme know if you need any help with parts and such.
    TVSian likes this.
    HYPERTHRUST CLEARED AND COUNTING
    5.....4.....3....2.....1

    [SIGPIC][/SIGPIC]

  8. #28
    TVS Racing FTW ! TVSian's Avatar
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    Default Re: TVS Suzuki Max 100R - Good First Bike ?

    Quote Originally Posted by Bibhu View Post
    Congratulations. Lemme know if you need any help with parts and such.
    Thank you sir There are some parts I am still searching for
    Here is the list of parts I'm searching for :

    1) Oil Tank - Current one's 2 mounts are broken and only one of them is holding it,other two barely holding.I used a giant washer to hold them

    2) Left and Right Crankcase Screws set - Looks like the crankcase was opened in this bike,once.But screws were missed,so different screws were installed and honestly,I don't think it's good.Some screws don't even have the threads anymore.So need to change them.


    3) Spark Plug - I feel morning starts and cold starting generally would become far easier.Do you recommend Iridium ?


    4) Battery Holder Clamp - Currently it has some twisted metal holding the battery and it is held by a metal wire tied.Not very confident about it.Would it be available ?

    5) Speedometer Casing and Clamp - Speedo is working fine,But it kind of moves around a bit too easily.Mechanic told me it's normal and nothing could be done about it.Is it true ? Would changing the old casing and clamp fix the rattle ?

    6) Shogun Handlebar
    7) Shogun Indicators (Both are optional)

    Please comment your valuable suggestions sir
    [My Motorcycle]

    2001 TVS-Suzuki Max 100R

  9. #29
    Rusted Bibhu's Avatar
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    Default Re: TVS Suzuki Max 100R - Good First Bike ?

    Quote Originally Posted by TVSian View Post
    Thank you sir There are some parts I am still searching for
    Here is the list of parts I'm searching for :

    1) Oil Tank - Current one's 2 mounts are broken and only one of them is holding it,other two barely holding.I used a giant washer to hold them

    2) Left and Right Crankcase Screws set - Looks like the crankcase was opened in this bike,once.But screws were missed,so different screws were installed and honestly,I don't think it's good.Some screws don't even have the threads anymore.So need to change them.


    3) Spark Plug - I feel morning starts and cold starting generally would become far easier.Do you recommend Iridium ?


    4) Battery Holder Clamp - Currently it has some twisted metal holding the battery and it is held by a metal wire tied.Not very confident about it.Would it be available ?

    5) Speedometer Casing and Clamp - Speedo is working fine,But it kind of moves around a bit too easily.Mechanic told me it's normal and nothing could be done about it.Is it true ? Would changing the old casing and clamp fix the rattle ?

    6) Shogun Handlebar
    7) Shogun Indicators (Both are optional)

    Please comment your valuable suggestions sir
    I can get you everything on the list apart from the shogun stuff. Please pm me.
    HYPERTHRUST CLEARED AND COUNTING
    5.....4.....3....2.....1

    [SIGPIC][/SIGPIC]

  10. #30
    TVS Racing FTW ! TVSian's Avatar
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    Default Re: TVS Suzuki Max 100R - Good First Bike ?

    UPDATE

    Fuel efficiency checked today!

    Reserve-to-Reserve Method :
    Previously Bike came to Reserve at ODO Reading at 188KM.
    Filled exactly 2.5 Litres
    Lost about 500ml due to Tank change : Fuel contamination with Rust & Accidental spillage during Fuel Transfer
    Now Bike came to Reserve at 260.6KM :

    260.6KM - 188.0KM = 72.6KM
    72.6KM ÷ 2.0 Litres = 36KMPL

    This is before the carburettor tuning and also mixed with both high revving usage and slow-running.Hoping to see better results,as now the carburettor has been tuned.

    Filled 2.83 Litres of Fuel for ₹225 (₹25 for Oil - Lesson learnt,so that Fuel tank would remain rust-free).Would be checking again as the bike gets to reserve.
    [My Motorcycle]

    2001 TVS-Suzuki Max 100R

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