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Old 28th November 2013, 22:24   #1
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Default Restoration - 1997 Yamaha RXG

Before going to the topic here is my ownership thread of Yamaha RX135.
1998 RX135 (14 year young Devil on Wheels - Preloved Yamaha RX135)

Couple of days back got another RX, but this time RXG. Before starting the ownership review of the new beast, I'm starting the restoration thread

Quick review of the bike condition:
Yamaha RXG
Model: 1997-Jul (RC expired more than a year ago)
No. of owners: 3
Insurance: No

- It is black with same sticker theme of my current bike (RX135 sticker & monogram)
- Missing parts: head lamps, tail lamps, indicators, speedometer & cable, rear number plate, front brake lever & cable, battery, 2T oil tank
- Rusted front and rear mud guards, seat bottom area
- After market handle bar
- Bald front tyre and good rear tyre
- Meshed up wiring harness
- No rust in engine head

TD Experience
- Tried starting and in 3rd kick the engine got life and started roaring
- Closed the tail pipe and throttled, to my surprise there is no abnormal noise from the engine
- Clutch is bit hard
- Gear engages smooth
- Went for a short TD, pick-up is not upto the mark (compared with my current RX) but not that worse
- Rear brake is 'OK'
- There is no wobbling / pull
- Exhaust note is a bit louder

Here is a couple of snaps taken today.

Restoration - 1997 Yamaha RXG-img_0269.jpg

Restoration - 1997 Yamaha RXG-img_0270.jpg

Mechanic already started stripping down (will post the detailed snaps tomorrow)

Restoration / Modification suggestions:
I wish to restore the old RX135 to complete stock condition. So this bike is going to be something out of stock looks (but no major modifications) Have some limitation with budget as I have to restore the RX135 too (in near future) I can spend a maximum of 15k.

Initially had a plan to mod this bike as RXZ or something similar to RD350 with twin exhaust, but now dropped those ideas. Wanted the vehicle to be 'Near Stock' condition with bright painting theme (I prefer a bright Blue painting with engine, hub, silencer, forks painted in daaaark grey / black)

Need your suggestions to decide the below
1) Which part to be replaced with brand new one, which current part to be used
2) If using the current/old parts, what has to be checked or what care/precaution to be taken
3) For chrome parts which is cheaper option Plating or replacing with brand new ones?
4) Planning for disc brake setup (used one) what should be the best buy price?

Any other suggestions are most welcome.

Thanks in advance. Will post more snaps tomorrow.

Last edited by Mr.Boss : 28th November 2013 at 22:26.
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Old 29th November 2013, 11:23   #2
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Default re: Restoration - 1997 Yamaha RXG

Strip down done last night. Here are the few snaps.
Attached Thumbnails
Restoration - 1997 Yamaha RXG-img_0279.jpg  

Restoration - 1997 Yamaha RXG-img_0281.jpg  

Restoration - 1997 Yamaha RXG-img_0283.jpg  

Restoration - 1997 Yamaha RXG-img_0280.jpg  

Restoration - 1997 Yamaha RXG-img_0287.jpg  

Restoration - 1997 Yamaha RXG-img_0289.jpg  

Restoration - 1997 Yamaha RXG-img_0285.jpg  

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Old 29th November 2013, 11:45   #3
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Default re: Restoration - 1997 Yamaha RXG

Quote:
Originally Posted by Mr.Boss View Post

1) Which part to be replaced with brand new one, which current part to be used
2) If using the current/old parts, what has to be checked or what care/precaution to be taken
3) For chrome parts which is cheaper option Plating or replacing with brand new ones?
4) Planning for disc brake setup (used one) what should be the best buy price?
Mate,
First of all congrats for your new toy and not every often do we get to see the Yamaha RXG being restored for all the bad name it got the company with its jerky ride because of the poor CDI Magnet. Which version do you have? Does the CDI Magnet come with the balancer plate to offset the jerky motion RXG's were famous for?

Regarding the replacement of parts am not quite confident with the budget you have outlayed (15K) you might get OEM Stuff.

If the mudguards are rusted, do not waste any effort in electroplating them, instead junk them and get the replacement stuff. They are not worth the effort.

For a disc Setup check if you can lay your hands on a Gladiator fork set up and that should be a good straight fit without the need to weld the adapter plate. If no go then search for the pricol disc break kit which you get with the adaptor plate. The CBZ Discs are more than a handful for the RXG.

Do keep us posted with your experiences.
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Old 29th November 2013, 12:24   #4
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Default re: Restoration - 1997 Yamaha RXG

Quote:
Originally Posted by Mr.Boss View Post
Before going to the topic here is my ownership thread of Yamaha RX135.
1998 RX135 (14 year young Devil on Wheels - Preloved Yamaha RX135)

Any other suggestions are most welcome.

Thanks in advance. Will post more snaps tomorrow.
The plans should be concentrate on the mechanicals. Once done you can focus on aesthetic. I would strongly recommend to OEM parts. you can get the parts list from the net. If you donít get let me know.

Change all the rubber, and cables, oil seals. Check the front suspension spring tension, rear shocks. You can very well place the order with ASS.
First collect all the parts for mechanical first then you can collect the aesthetic parts latter , if you want to do this in 2 phases.

Remember , there are fake parts are sold online and offline with original OEM packaging.

Sri
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Old 29th November 2013, 14:27   #5
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Default re: Restoration - 1997 Yamaha RXG

Quote:
Originally Posted by ku69rd View Post
Which version do you have?

If the mudguards are rusted, do not waste any effort in electroplating them, instead junk them and get the replacement stuff.

For a disc Setup check if you can lay your hands on a Gladiator fork set up
Thanks dude. This one is the last batch of RXG produced (end of 1997), hope this should be equipped with parts after counter measure.

Mud guards will be replaced with new ones (Plastic in front as I wish to paint them matching the body color and rear will be regular steel one)

Regarding the disc set up, will be in Phase 2.

Quote:
Originally Posted by svpatra View Post
The plans should be concentrate on the mechanicals. Once done you can focus on aesthetic. I would strongly recommend to OEM parts. you can get the parts list from the net. If you donít get let me know.
Thanks for the suggestions Sri. If you have the part list, please mail me. I will PM you the mail ID.
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Old 29th November 2013, 23:04   #6
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Default Re: Restoration - 1997 Yamaha RXG

what should be the nominal cost for
1) Painting (Frame, Tank, Shield, Front bud guard, Engine + Crank case)
2) Plating (Silencer, pillion grab rail, rim, fasteners)
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Old 30th November 2013, 10:53   #7
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Default

Quote:
Originally Posted by Mr.Boss View Post
what should be the nominal cost for 1) Painting (Frame, Tank, Shield, Front bud guard, Engine + Crank case) 2) Plating (Silencer, pillion grab rail, rim, fasteners)
It depends where you are located and what kind of paint work you are looking at, can range from 5 - 15k
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Old 1st December 2013, 10:05   #8
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Default Re: Restoration - 1997 Yamaha RXG

Update:
- Frame sent for sand blasting yesterday, will be collecting them on Monday
- Got most of the parts yesterday (attached the invoice copy)
- Items procured other than in the list
- Seat assembly
- Rear shock absorbers (from Pulsar, gas loaded)
- Side shields + monograms (already available)
- 2T oil tank (already available)
- Chain cover
- Few more nuts, bolts, washers

To be purchased (no stock / unavailable yesterday)
- Rim (from Hero Honda)
- Lock set (with steel keys)
- Reg plates
- Mud flaps
- Brake cable
- Handle bar (yet to finalize the type)
- Cross bar / bumper (Single bar type)
- Horn (from Apache)
- Head lamp (should prepare myself with DCM Toyota / Swaraj Mazda reflector - same as my other bike setup)
- Battery (will get it once start assembling the bike)
Attached Thumbnails
Restoration - 1997 Yamaha RXG-dscn5709.jpg  

Restoration - 1997 Yamaha RXG-dscn5710.jpg  

Restoration - 1997 Yamaha RXG-dscn5711.jpg  

Restoration - 1997 Yamaha RXG-dscn5712.jpg  

Restoration - 1997 Yamaha RXG-dscn5713.jpg  

Restoration - 1997 Yamaha RXG-dscn5714.jpg  

Restoration - 1997 Yamaha RXG-dscn5715.jpg  

Restoration - 1997 Yamaha RXG-dscn5716.jpg  

Restoration - 1997 Yamaha RXG-dscn5717.jpg  

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Old 1st December 2013, 11:54   #9
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Default Re: Restoration - 1997 Yamaha RXG

Congrats on the buy.
Enjoy the rebuild.
I feel the budget is too low. Realistic budget will be 30K+.
Not bad you managed to get a lot of things in one shopping visit.
Any idea whether the same shop has RX135 tank and Stock bore kit.
Where are you getting your painting done.
Looking forward to the build.
I just finished my rebuild of a 1998 Rx135, ending with some gross mistakes. So troubleshoot is on cards.
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Old 1st December 2013, 12:57   #10
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Default Re: Restoration - 1997 Yamaha RXG

Quote:
Originally Posted by Visaster View Post
Congrats on the buy.
Enjoy the rebuild.
I feel the budget is too low. Realistic budget will be 30K+.
Not bad you managed to get a lot of things in one shopping visit.
Any idea whether the same shop has RX135 tank and Stock bore kit.
Where are you getting your painting done.
Looking forward to the build.
I just finished my rebuild of a 1998 Rx135, ending with some gross mistakes. So troubleshoot is on cards.
Thanks dude.
Regarding the budget, initially started the job with 15k budget (using most of the old parts either painted or plated) but now decided to go with all new parts (except frame, tank, engine/GB, silencer, etc) Budget will be 30k+ now.

RX tank & stock bore kit is not available right now, but the dealer said he can get it in a weeks time if required.

Getting it painted somewhere in Tambaram Sanatorium/Chrompet (yet to visit the place)

Please share the details of your rebuild, is there any thread available? Also please share the 'Lessons Learned' from your rebuild. Where did you got the bike painted and how much did it cost.

Edit: Just now saw your thread. Will go through it.

Last edited by Mr.Boss : 1st December 2013 at 12:59.
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Old 1st December 2013, 20:32   #11
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Lightbulb Suggestion required - Yamaha RX Purchase / rebuild

Guys,

I have 2 RX at home (1998 RX135, 1997 RXG)

RXG restoration is under progress and expecting to complete the job in another couple of weeks (restoring with brand new parts as much as possible) RX135 will also be restored in near future (again with brand new parts)

After restoration of both the bikes I will be left with more than a complete set of parts (except the frame, crankcase & engine parts, forks, Silencer)

Now comes the confusion.

- Should I preserve those parts to use (if required) in future

(or)

- Get another RX in scrap condition (just a frame, crankcase and few tits and bits here and there) but with proper documents and fit these parts (+ add essential new parts) and start enjoying another RX pleasure (even if I chose this option, I can't afford third restoration in near future. So parts will be stored and hunt for a cheaper bike will start as of now)

Need your valuable suggestions here.
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Old 1st December 2013, 21:48   #12
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Default Re: Suggestion required - Yamaha RX Purchase / rebuild

Depends on how much you're going to click on ODO. If you're going to use it like 10 Km a day during weekdays, that pretty much sums to 250 odd Km a month which is 3000 Km a year. And any genuine Rx bore, if used sane to slightly aggressive riding, can last for 80000 Km. This means, you've got another 25 more years before your cylinder kit needs replacement.

Consumables like clutch, sprocket, throttle wires, gaskets, 2T & engine oils, nuts & bolts, spokes, tires, meter cable, rubber bushes are available in plenty everywhere. Even if you stock them for the 3000 Km a year running, you'll need to replace them like once in some 20K km. So if you stock some 4-5 set, they're more than sufficient.

Note - The 3K km was given as ballpark figure, depending on that, pls re-estimate on your daily running needs.
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Old 2nd December 2013, 08:52   #13
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Default Re: Restoration - 1997 Yamaha RXG

Friends, there are few dents in the silencer. Is there any way to get them corrected?
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Old 2nd December 2013, 12:00   #14
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Default Re: Restoration - 1997 Yamaha RXG

Quote:
Originally Posted by Mr.Boss View Post

Thanks for the suggestions Sri. If you have the part list, please mail me. I will PM you the mail ID.
i have sent the parts list.

Sri
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Old 2nd December 2013, 12:43   #15
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Default Re: Suggestion required - Yamaha RX Purchase / rebuild

Quote:
Originally Posted by aargee View Post
Depends on how much you're going to click on ODO.
Thanks aargee.
My running will be 50km/day (weekdays/weekends) and will be covered by 3 vehicles (1 Car + 2 bikes) So in an average 1 bike will cover 500~600km/month.

Appreciate your suggestion on Option 2 in my initial post.
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