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Thread: RX-Special - Reincarnation

  1. #1
    Rusted SriramEfunds's Avatar
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    Default RX-Special - Reincarnation

    With so many new tech bikes offered in the market, I'm going to go back in times when there was a signature exhaust note and blue smoke.


    After fighting a great war in my mind and with conviction I thought of restoring one more RX and promised myself that this would be my last restoration. Yes, I keep saying this every time.




    This restoration will be my long awaited dream of 115cc mill plonked bike. Lot of efforts were put in my previous experiment (click this link) to convert 98cc to 115cc. But it short lived.Those days hardly any source to buy RX115 parts to build the bike. But now, I can utter in low decibel and there are many sources to get parts from any corner of the world.


    Topic - Search is on.


    I started to hunt for a bike to make my dream come true. Friends, local mechanic, social media and word of mouth were spread across. I knew it is not going to happen right away and consoled myself that wait for the good things to happen. And found one after nearly 5 months.


    It was bought in a condition that it could run but you will need earplugs so you don't want to hear the jingle bells and whistles from the engine.


    Manged to reach home without any stalling and took a closer inspection and noted down things that needs immediate action.


    The following were noted-
    1. Electricals gone.
    2. Brakes - Rear could slow down a bit.
    3. Seat was in worst condition with a cover on it.
    4. Kicker boss is gone. It could sway like a flag.
    5. Gearbox is one which engaged without any issues.
    6. Clutch slips
    7. Accelerator was in shape.
    8. Bike won't pull beyond 30 kmph
    9. side stand has lost most of metal and clinging on a piece that it would collapse anytime on long parking with side stand.
    10. Main stand welded bottom but bottoms all the way to the other side.
    11. Silencer dented.
    12. Both tires worn out.
    13. Switch gear buttons gone.
    14. Carburetor smudged
    15. Side oil tank decorated with muck.
    16. Side shields were all cracked at mount points
    17. No ignition key/locks.
    18. Rims are rusted and rear rim has a hole.
    19. Front mudguard done.
    20. Rear mudguard is replaced with plastic/ABS.




    Took time and fixed few things in the bike so that I can manage to run them. Gave some attention and changed the tires since they are worn out completely.


    Next step was to procure spares for restoration. I took a quick stock of things left over from my previous restorations, not bad, was able to help myself with wiring harness, indicator assembly, tail lamp etc.


    I took sometime and cleaned up the carburetor and changed the air filter and found that the bike never saw a new air filter atleast a decade.

    Filter element

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    The bike as it looks....



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    dismantling the bike

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    Paint jobs


    My favorite part of restoration as well the most frustrated to go through. Finding a painter is a headache and moreover getting his will to work is another milestone, off all, getting the parts painted in agreed time frame is the greatest of all. I have not touched upon the quality of work executed though but that's another thing.

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    I will be restoring the bike of 1995 model where the tank decal of last 12v edition. Thanks to my old friends for getting me the stickers that will go in to the tank.

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    Front end will boast the disc brake since they look bit sporty.

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    The following things I have been thinking to put on the bike.


    1. Add Tacho meter
    2. Add RXZ visor
    3. RXZ squarish headlight
    4. Black front RXZ mudguard
    5. RXZ indicators
    6. Stock coil plate for now. May be RDD lighting kit in future.


    The exhaust pipe will be the same chrome and pillion grab rail.

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    I started to procure the following parts over years for the restoration and kept adding now and then..


    115cc block
    115cc head assembly
    carburetor
    Clutch plates/friction plates
    bearings
    engine oil seals
    Cables(clutch/accelerator)
    Nut bolts
    Wheel axles
    Wheel spacers
    Carrier


    More to follow....
    Last edited by SriramEfunds; 05-26-2019 at 06:15 PM.
    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

  2. #2
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    Default Re: RX-Special - Reincarnation

    Thread approved.
    Please re-attach the pictures.

  3. #3
    TVS Racing FTW ! TVSian's Avatar
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    Default Re: RX-Special - Reincarnation

    Amazing sir,Super hyped on the project! I'm pinned to this thread! Eagerly waiting to see the outcome.All the very best
    [My Motorcycle]

    2001 TVS-Suzuki Max 100R

  4. #4
    Rusted SriramEfunds's Avatar
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    Default Re: RX-Special - Reincarnation

    There is a twist to the restoration. I have shelved the RXZ headlight squarish outlook for now. Going with classic round headlight however, the bike will sport the tachometer.
    It is always a learning for me while I undergo restoration. Fascinating part is, I maintain a excel sheet to track the parts and things to do and follow ups to be done etc. still i miss to add some parts to the list. This time, it was fork 'Dust seal' and the front end is incomplete.

    Further going to the engine side, I conveniently forgot to remove the oil pump bush while the parts given for painting. Everyone now can guess what it lead to. Miss!

    Oil pump was remove with shaft and gear wheel with pin. However, I missed to secure the circlip.

    The roller coaster is not yet over. I'm not able to find the washer plate and spring washer for the magnet that comes behind the nut. Isn't that beautiful.

    Best part is I had scheduled to complete the restoration before this weekend. How optimistic one can be?

    The whole idea of recording the restoration in Xbhp form (as always) is to document the blunders and things that are important for the restoration project. This not only would help 2 stroke community to refer and learn the story but also gives me a chance to refer rather scratching my head to recollect what happened and when.

    For those who still want to restore their bikes, noted some points here.

    1. Always have someone(friend, brother, another 2 stroker) to review your plan, list and intended job work that needs to be carried out.
    2. Keep an index of parts/things for the restoration and possibly try to organize in a designated cartons. This saves whole lotta time from digging the box to ensure it is there.
    3. Always, keep extra bolts nuts and even cotter pin extra with you. Not all the time we have fasteners which sits tight.
    4. Try breakdown the areas of restoration and keep parts aligned together.
    5. Get a bottle of thinner/alcohol and petrol while working.
    6. Avoid working during weekends. Worst nightmares of searching for parts in the last minute will not occur.
    7. Wear gloves while handling painted parts especially tank and avoid fingerprints and scratches on painted tanks.
    8. Use the right tools so that fasteners aren't damaged. Do not over tight the nut/bolt/screws.
    Last edited by SriramEfunds; 05-26-2019 at 06:27 PM.
    Divya Sharan, Mr.Boss and TVSian like this.
    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

  5. #5
    Rusted SriramEfunds's Avatar
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    Default Re: RX-Special - Reincarnation

    Update:-

    There is a miss to dust seal on fork leg. Searched around, not available around. That's when good friends come pitch in. Well, the dust seal is of Gladiator and it is directly compatible with RXZ fork legs.

    Right now, the bike is almost ready but have to wait for dust seal. Test ride is due.

    Next in schedule:-

    1. Check the set up.
    2. Run the engine.
    3. clutch engage
    4. Gear box check
    5. Tune the carb
    Attached Images Attached Images  
    Last edited by SriramEfunds; 05-27-2019 at 01:02 AM.
    Divya Sharan, Mr.Boss and TVSian like this.
    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

  6. #6
    yam
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    Default Re: RX-Special - Reincarnation

    congrats buddy, Never say never again

    I have been saying that for a very long time, I added 2 more RXZs and a shogun after that to my stable.

    From the previous builds of yours I can guarantee that this one is going to be an eye candy.

    I also see you have got the much sorted after 6 hole silencer

    One question though, why have you gone for painting the chassis instead of powder coating?

    Pramod
    TVSian likes this.
    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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    Rusted SriramEfunds's Avatar
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    Default Re: RX-Special - Reincarnation

    Quote Originally Posted by yam View Post
    congrats buddy, Never say never again

    I have been saying that for a very long time, I added 2 more RXZs and a shogun after that to my stable.

    From the previous builds of yours I can guarantee that this one is going to be an eye candy.

    I also see you have got the much sorted after 6 hole silencer

    One question though, why have you gone for painting the chassis instead of powder coating?

    Pramod
    Thanks Pramod. Nice to hear that you added bikes to the stable.

    Well, I went for paint job only after seeing the workmanship and the outcome. I don't have much idea on powdercoating jobs undertaken in Chennai. I'm sure that there are some but I was in opposite direction.

    Since the outcome of paint job was good so have no regrets.

    Tomorrow there are some things needs to checked just to make sure I have everything I wanted.

    Update:-

    Got the fork dust seal. Let's see how tomorrow shines for me.
    TVSian likes this.
    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

  8. #8
    Rusted SriramEfunds's Avatar
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    Default Re: RX-Special - Reincarnation

    Update:-

    Dust seal plonked.

    Front end is put up, meters, lock, forks locked with triple T.

    Coming next:-
    Headlight
    Blinkers
    Brake hose.

    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

  9. #9
    yam
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    Default Re: RX-Special - Reincarnation

    Quote Originally Posted by SriramEfunds View Post
    Thanks Pramod. Nice to hear that you added bikes to the stable.

    Well, I went for paint job only after seeing the workmanship and the outcome. I don't have much idea on powdercoating jobs undertaken in Chennai. I'm sure that there are some but I was in opposite direction.

    Since the outcome of paint job was good so have no regrets.

    Tomorrow there are some things needs to checked just to make sure I have everything I wanted.

    Update:-

    Got the fork dust seal. Let's see how tomorrow shines for me.
    The only issue with painting is it chips and peals off easily and will be a total disaster for a frame off restoration.

    Could you PM me the cost for that front end? I am looking to get it for one of my RXZs.

    Thanks,
    Pramod
    TVSian likes this.
    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

  10. #10
    Rusted SriramEfunds's Avatar
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    Default Re: RX-Special - Reincarnation

    Quote Originally Posted by yam View Post
    The only issue with painting is it chips and peals off easily and will be a total disaster for a frame off restoration.

    Could you PM me the cost for that front end? I am looking to get it for one of my RXZs.

    Thanks,
    Pramod
    Well it depends on how good the painting was done. I have to say that paint job came out well. I'm loving it.

    Update:-

    Nothing done today. Most probably tomorrow or only on weekend.
    TVSian and ShahDgr8 like this.
    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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