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Thread: Restoration of 1985 model IND-SUZUKI AX100

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    Default Restoration of 1985 model IND-SUZUKI AX100

    Hi all, I am Sooraj from Kerala. I am just planning to restore my AX100 back to its full glory. Attaching the Pics of My AX100. Name:  WP_20130722_004.jpg
Views: 1734
Size:  107.6 KB I I need to do a lot of work to get it back to its original shape. Hope everything goes well . I had read a lot of threads here. And I don't know whether someone will be reading it. Meanwhile i had procured some parts for my bike as well. Will try to post the pics soon. I will try to do some jobs by my self rather than taking it to some workshops. If anybody is having the workshop manual or parts catalogue of this bike it would be of a great help to me as i am not having any of those. The bike is in the same condition as in the photo. Will try to start as fast as i can because the toughest time in this restoration will be the procurement of parts.

    And i will be thankfull to my dearest parents,My beloved brother Kiran, My grandfather, My uncle for their full support to me. I also need to thank my brother Roopak chettan for his full support and coordination. The list of people who help me never end so will be mentioning them also in the upcoming posts.

    And like every other bike this bike also has something to tell. This bike had rolled out of the factory outlet on 1st march 1985. That is the first batch of Ax-100 produced. So basically it is a CKD model. Back in that time there were no dealership for Suzuki in kerala. So this bike was bought by the first owner from Karnataka and he transported the bike to Kerala. The bike first had a karnataka registration. After some time the owner has to go to Saudi (at that time Persia) for his work. So the bike was kept unused as there was no one else to ride. Since his house was near the coastal area the bike had started to rust. His family members had told him that the bike is sitting unused and it had started to rust. So the owner asked his family members to sell the bike. At that time the bike reached its second owner by 1987. That time it has been registered to Trivandrum RTO. The bike was in his hands for almost 20 years. Then he had some health issues and was not able to ride the bike. He never used to cross 30kmph on this bike. And when the fitness check comes he used to give it to some local workshop people to do the works. It was the worst period for the bike as it lost all the essential elements. The tank has been changed to Max100 tank. There lost the signature tank and the OE IND-SUZUKI emblem. At another stage the Muffler has to be changed and they had put a Samurai Upgrade/Max100 muffler on to it. The front fork Assy. has been changed fully. Don't know what had exactly happened. Cannot met with an accident because it has the same factory IND-SUZUKI handle bars. And the owner never cross 30kmph. Again i dont know the exact reason it is just my guess. And now it has an Yamaha Rx series fork. The speedometer is a local one. And it does not have the metal side covers any more. And another fitness test was done when the owner had a serious health issue. He undoubtfully tells that the helmet lock was taken by the last mechanic. The owner had said that he kept that thing as a treasure. Then on one fine day i thought of adding one more addition to the garage. We used to grab spares for our other bikes from 2-3 local spare shop. And that time the owner of one shop said that his brother in law(the second owner as mentioned above) is having an IND-SUZUKI and the shop owner had said that he is planning to sell it as no one is about to take care of it. I asked him what would be the price. He told me the address and asked me to go and see the bike. On a Tuesday afternoon(i recollect it was a holiday) me and my brother went to that place and began to search for the house and i saw the bike. We stop beside the house and talked to the owner. We began to check the bike. Since there was limited space there we asked whether we could move it aside and ride it. He said due to the non-usage the front wheel was jammed and yes the front wheel was solid as a rock. Then i just fired her up. The first few kicks were to wake her up from the Hibernation. Then at last she roared. Then we said to the owner about the price. He quoted 10k and we said that we will inform him about then decision later. And on that saturday we went their again to inform him about the decision and to check with the paper works. That time his daughter was in the house and she refuses to sell the bike. She had said that because she had attachment towards this bike as she went to the school and college in this bike. But the owner was so stubborn that he said he will sell this bike at any cause. Me and my brother spoke to her and left the house. On one fine day i managed to find the money and we had reached his home to take away the bike. I just loosed the front brake cable and the wheel stated to roll. And my brother tried to ride the bike. But she refuses to fire up. And i some how managed to fire her up. Then on she don't had any issue in starting. May be like some dogs take a little time to mingle with its new master, i thought like that. I bought her to home and cleaned her up. And i forgot to mention one thing, eventhough the front fork was of Rx the mechanic had not changed the hub or the hubcover: it was still 110 dia. I tried a new brake shoe and it could not solve the problem. And i found the culpritit was that this fok assemble and the hub could not match. Till now i haven't repaired it and my brother and my friends are afraid of riding it as it doesn't have a break. But i am damn confident to take her through anywhere anytime. But as time rolled i had made up my mind to restore her back to her former glory. This is all i would like to say regarding the bike.If possible do enjoy the thread
    -Thanks
    Last edited by Shogunsamurai; 07-14-2019 at 11:06 PM.
    85 - IND-SUZUKI AX100
    97 - TVS SUZUKI SAMURAI
    99 - TVS SUZUKI SHOGUN
    06 - HERO HONDA PASSION PLUS

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    Default Re: Restoration of 1985 model IND-SUZUKI AX100

    Thread approved.

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    Default Re: Restoration of 1985 model IND-SUZUKI AX100

    Quote Originally Posted by xBhp View Post
    Thread approved.
    Thanks for the thread approval. Sorry to say that this restoration will be of a slow pace and the present stage is only procurement of parts. I will try to post almost all the parts which i get.
    TVSian likes this.
    85 - IND-SUZUKI AX100
    97 - TVS SUZUKI SAMURAI
    99 - TVS SUZUKI SHOGUN
    06 - HERO HONDA PASSION PLUS

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    Default Re: Restoration of 1985 model IND-SUZUKI AX100

    Here are a list of parts which i have managed to procure during this much time. Thanks a lot to Harish chettan for the Supra's Reed and Manifold.
    Hoping to get more parts as quickly as possible. Attaching its pictures. Actually The Headlight is of BRYTAX. Has removed it from shogun during its restoration. The lens was broken due to bad storage.
    Attached Images Attached Images             
    85 - IND-SUZUKI AX100
    97 - TVS SUZUKI SAMURAI
    99 - TVS SUZUKI SHOGUN
    06 - HERO HONDA PASSION PLUS

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    Default Re: Restoration of 1985 model IND-SUZUKI AX100

    Quote Originally Posted by Shogunsamurai View Post
    Hi all, I am Sooraj from Kerala. I am just planning to restore my AX100 back to its full glory. Attaching the Pics of My AX100. Name:  WP_20130722_004.jpg
Views: 1734
Size:  107.6 KB I I need to do a lot of work to get it back to its original shape. Hope everything goes well . I had read a lot of threads here. And I don't know whether someone will be reading it. Meanwhile i had procured some parts for my bike as well. Will try to post the pics soon. I will try to do some jobs by my self rather than taking it to some workshops. If anybody is having the workshop manual or parts catalogue of this bike it would be of a great help to me as i am not having any of those. The bike is in the same condition as in the photo. Will try to start as fast as i can because the toughest time in this restoration will be the procurement of parts.

    And i will be thankfull to my dearest parents,My beloved brother Kiran, My grandfather, My uncle for their full support to me. I also need to thank my brother Roopak chettan for his full support and coordination. The list of people who help me never end so will be mentioning them also in the upcoming posts.

    And like every other bike this bike also has something to tell. This bike had rolled out of the factory outlet on 1st march 1985. That is the first batch of Ax-100 produced. So basically it is a CKD model. Back in that time there were no dealership for Suzuki in kerala. So this bike was bought by the first owner from Karnataka and he transported the bike to Kerala. The bike first had a karnataka registration. After some time the owner has to go to Saudi (at that time Persia) for his work. So the bike was kept unused as there was no one else to ride. Since his house was near the coastal area the bike had started to rust. His family members had told him that the bike is sitting unused and it had started to rust. So the owner asked his family members to sell the bike. At that time the bike reached its second owner by 1987. That time it has been registered to Trivandrum RTO. The bike was in his hands for almost 20 years. Then he had some health issues and was not able to ride the bike. He never used to cross 30kmph on this bike. And when the fitness check comes he used to give it to some local workshop people to do the works. It was the worst period for the bike as it lost all the essential elements. The tank has been changed to Max100 tank. There lost the signature tank and the OE IND-SUZUKI emblem. At another stage the Muffler has to be changed and they had put a Samurai Upgrade/Max100 muffler on to it. The front fork Assy. has been changed fully. Don't know what had exactly happened. Cannot met with an accident because it has the same factory IND-SUZUKI handle bars. And the owner never cross 30kmph. Again i dont know the exact reason it is just my guess. And now it has an Yamaha Rx series fork. The speedometer is a local one. And it does not have the metal side covers any more. And another fitness test was done when the owner had a serious health issue. He undoubtfully tells that the helmet lock was taken by the last mechanic. The owner had said that he kept that thing as a treasure. Then on one fine day i thought of adding one more addition to the garage. We used to grab spares for our other bikes from 2-3 local spare shop. And that time the owner of one shop said that his brother in law(the second owner as mentioned above) is having an IND-SUZUKI and the shop owner had said that he is planning to sell it as no one is about to take care of it. I asked him what would be the price. He told me the address and asked me to go and see the bike. On a Tuesday afternoon(i recollect it was a holiday) me and my brother went to that place and began to search for the house and i saw the bike. We stop beside the house and talk to the owner. We began to check the bike. Since there was limited space there we asked whether we could move it aside and ride it. He said due to the non-usage the front wheel was jammed and yes the front wheel was solid as a rock. Then i just fired her up. The first few kicks were to wake her up from the Hibernation. Then at last she roared. Then we said to the owner about hte price. He quoted 10k and we said that we will inform him about then decision later. And on that saturday we went their again to inform him about the decision and to check with the paper works. That time his daughter was in the house and she refuses to sell the bike. She had said that because she had attachment towards this bike as she went to the school and college in this bike. But the owner was so stubborn that he said he will sell this bike at any cause. Me and my brother spoke to her and left the house. On one fine day i managed to find the money and we had reached his home to take away the bike. I just loosed the front brake cable and the wheel stated to roll. And my brother tried to ride the bike. But she refuses to fire up. And i some how managed to fire her up. Then on she don't had any issue in starting. May be like some dogs take a little time to mingle with its new master, i thought like that. I bought her to home and cleaned her up. And i forgot to mention one thing, eventhough the front fork was of Rx the mechanic had not changed the hub or the hubcover: it was still 110 dia. I tried a new brake shoe and it could not solve the problem. And i found the culpritit was that this fok assemble and the hub could not match. Till now i haven't repaired it and my brother and my friends are afraid of riding it as it doesn't have a break. But i am damn confident to take her through anywhere anytime. But as time rolled i had made up my mind to restore her back to her former glory. This is all i would like to say regarding the bike.If possible do enjoy the thread
    -Thanks

    good luck man, try powerhouse road behind tvm rly station for a used front fork........bargain hard
    Last edited by kb100; 01-18-2019 at 11:35 PM.
    TVSian and Shogunsamurai like this.
    Kawasaki KB100/enduro/125 substitute parts list http://www.xbhp.com/talkies/508615-post105.html

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    Default Re: Restoration of 1985 model IND-SUZUKI AX100

    Quote Originally Posted by Shogunsamurai View Post
    Here are a list of parts which i have managed to procure during this much time. Thanks a lot to Harish chettan for the Supra's Reed and Manifold.
    Hoping to get more parts as quickly as possible. Attaching its pictures. Actually The Headlight is of BRYTAX. Has removed it from shogun during its restoration. The lens was broken due to bad storage.
    Nice start up, three petal reeds are no longer available in oe, powerbox looks like eye treat, oe fuel filter is good but if your tank has rust inside then try to use jawa fuel filter of pacco make and it is worth it. Oe seat assy or seat plate is also hard to find here. All engine parts are available if you search religiously.

    Best of luck to your restoration from my side.
    Shogunsamurai likes this.

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    Default Re: Restoration of 1985 model IND-SUZUKI AX100

    Quote Originally Posted by kb100 View Post
    good luck man, try powerhouse road behind tvm rly station for a used front fork........bargain hard
    Thanks for the info brother. I am actually planning for some conversion. My plan is to get a samurai's fork and also change the drum dia to 130mm so that it matches my other vehicle as well. I might get 2 fork tubes fork tubes at some reasonable rates and i am having the T stem. Please give some valuable information like this when the restoration continues. Thanks

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

    Quote Originally Posted by avhad sitaram View Post
    Nice start up, three petal reeds are no longer available in oe, powerbox looks like eye treat, oe fuel filter is good but if your tank has rust inside then try to use jawa fuel filter of pacco make and it is worth it. Oe seat assy or seat plate is also hard to find here. All engine parts are available if you search religiously. Best of luck to your restoration from my side.
    Thanks for the info brother. Yeah actually the tank is little bit rusty and i am planning to get another tank. And about the seat plate. The one in the bike looks like brand new and i don't think it will be OE. Yeah need to source the engine parts as well. Thanks for the support @kb100 and @avhad sitaram
    TVSian likes this.
    85 - IND-SUZUKI AX100
    97 - TVS SUZUKI SAMURAI
    99 - TVS SUZUKI SHOGUN
    06 - HERO HONDA PASSION PLUS

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    Default Re: Restoration of 1985 model IND-SUZUKI AX100

    Found some more original parts. Attaching its pictures below. The list includes a Hose No:02 for oil pump, blank metal key, choke lever ,seat base,Stud bolt cylinder, front footrest clamp and a footrest rubber.Name:  IMG_20190208_164547.jpg
Views: 512
Size:  101.4 KBName:  IMG_20190208_164717.jpg
Views: 517
Size:  101.4 KBName:  IMG_20190208_164734.jpg
Views: 497
Size:  94.4 KBName:  IMG_20190208_164952.jpg
Views: 514
Size:  99.9 KB
    prasath_xbhp and TVSian like this.
    85 - IND-SUZUKI AX100
    97 - TVS SUZUKI SAMURAI
    99 - TVS SUZUKI SHOGUN
    06 - HERO HONDA PASSION PLUS

  9. #9
    TVS Racing FTW ! TVSian's Avatar
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    Default Re: Restoration of 1985 model IND-SUZUKI AX100

    Quote Originally Posted by Shogunsamurai View Post
    Thanks for the info brother. I am actually planning for some conversion. My plan is to get a samurai's fork and also change the drum dia to 130mm so that it matches my other vehicle as well. I might get 2 fork tubes fork tubes at some reasonable rates and i am having the T stem. Please give some valuable information like this when the restoration continues. Thanks

    ----consecutive posts auto-merged-----
    @kb100 and @avhad sitaram
    Actually sir,My humble suggestion is to go for a front disc Pulsar/Gladiator setup.It should cost about 3K I think.The difference is instantly noticeable.
    [My Motorcycle]

    2001 TVS-Suzuki Max 100R

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    Default Re: Restoration of 1985 model IND-SUZUKI AX100

    Quote Originally Posted by TVSian View Post
    Actually sir,My humble suggestion is to go for a front disc Pulsar/Gladiator setup.It should cost about 3K I think.The difference is instantly noticeable.
    @TVSian i have already told you that don't call me sir you can just call my name buddy. And about the fork assy. I have told that i am going for the samurai's fork because two of my other bikes have the same fork Assy. So while storing some parts for future use it would be easy for me as all have the same. When i go for a IND-Suzuki fork or a Disc setup i need to store parts for it to. It would be somewhat difficult for me. And moreover i am planning to stick back to vintage look. I do value your suggestion and i will think about it as well.

    Actually for my Shogun i have procured a new hub Assy. as well .What i need is to get a rim and fix all of them to the shogun and swap the Hub assy. of shogun to my Ax (because the hub assy on the shogun is in a good condition).
    Last edited by Shogunsamurai; 05-05-2019 at 09:50 PM.
    TVSian likes this.
    85 - IND-SUZUKI AX100
    97 - TVS SUZUKI SAMURAI
    99 - TVS SUZUKI SHOGUN
    06 - HERO HONDA PASSION PLUS

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