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Old 13th April 2015, 17:27   #1
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Default 1990 Yamaha RX100 Restoration

This bike belong to my Friend and I'm working & posting on behalf of him

'History' about this bike & the owner:
He is a good friend of my mechanic and we became friends at my mechanic's garage only. He is another RX fan, never owned one but rode RX100 for a long term at his work place. He was looking to buy one and ended up buying a 1990 RX100, claimed to be "fully restored" paying a hefty amount sometimes back without taking the opinion from mechanic. Bike was glittering with custom painting and stickers.

Once we (self & mechanic) saw the bike, we weren't satisfied with both performance as well as appearance. But it's already too late. The only good thing is all papers were in form and fit to be on road. Bike was little sluggish and clearly audible noise from engine at all rpm. Months passed, the bike was used in the same condition. Couple of days back the noise started increasing and acceleration deteriorated along with evident clutch slippage. We decided not to trouble here any further.

Having a cup of tea in hand the owner asked "Why don't we restore it?" and with no surprise or hesitation we said "YES". Then we realized my 3rd RX restoration was already put on hold for Pulsar Classic project and now if we start working on this bike, it will be further delayed. But we don't have another option as this bike is his primary (and only) mode of transportation and we don't want him to suffer. Pulsar Engine was already removed for renovation and it may reach us by next week after the mechanical and painting job. So we started striping the engine & transmission to understand the current condition.

1990 Yamaha RX100 Restoration-wp_20150410_20_27_34_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_53_47_pro.jpg

Initial Observation:
- Running on 3rd Oversize Piston
- Not sleeved yet
- Excessive scoring marks in piston as well as Cylinder
- Connecting rod free play at Crank end
- 1 Clutch spring broken
- Clutch plates lost their life long ago
- Clutch bell free play
- Worn out clutch collar
- Sprockets were nearing their end of life
- Messed up electrical harness
- Bent rear axle bolt (we had a tough time removing it)
- Excessive play in gear shift pedal

What to do?
Since the bike doesn't require much aesthetic upgrade, we are leaving this portion untouched as of now.
Phase 1:
- Engine rebuild
- Replace all bearings
- Replace complete clutch assembly
- New screw kit
- Replace chain & sprockets, sprocket hub, rear axle assembly
- New wiring harness
- New lock set (current one has individual keys for ignition, gas tank, side lock)
- OE Handle bar
- All cables
- Gear shift pedal
- Change Transmission oil & Air Filter

Phase 2:
- Better shoes
- Front Disc Brake

Phase 3: (Optional & long term)
- Painting (OE theme)

Current Status:
- Almost all necessary parts procured
- Looking for a used bore (STD or 1 OS) We got some pointers from a couple of known mechanics. Let me update the status once we could see them in person.

1990 Yamaha RX100 Restoration-wp_20150412_10_16_12_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_34_55_pro.jpg

I need some pointers to procure the below parts,
- Oil Pump
- Oil tank
- Used Cyliner (a.k.a Bore) STD / 1 OS
- Seat Assembly

PS:
Here are my other RX restoration threads
http://www.team-bhp.com/forum/motorb...amaha-rxg.html (Restoration - 1997 Yamaha RXG)
http://www.team-bhp.com/forum/motorb...storation.html
http://www.team-bhp.com/forum/motorb...-rx135-4s.html

Last edited by Mr.Boss : 13th April 2015 at 17:29.
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Old 14th April 2015, 08:30   #2
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Default Re: 1990 Yamaha RX100 Restoration

Quote:
Originally Posted by Mr.Boss View Post
I need some pointers to procure the below parts,
- Oil Pump
- Oil tank
- Used Cyliner (a.k.a Bore) STD / 1 OS
- Seat Assembly
Oil Pump is available for ~500 pricol make, the OE is around 1900 and there are many fakes, You can contact gee bee auto spares Bangalore, they will ship it to your door step so you can save the petrol cost roaming around for a new pump. Even though you have a working oil pump always use small quantities of premix, most oil pumps(weather OE or not give away very easily)
Oil Tank is available for less than 100 RS let me know if you have any difficulty finding one at any local spares shop, there are facebook groups where they are available with 2T oil gauge, but they surely are asking for an Arm and a leg.
Going for used cylinders, you must be very carefull, 1. there are a lot of Chinese cylinders in the market and 2. check the ports very carefully, local mech use hand file for porting. You can go bit more higher than the present .75 over size on the present cylinder block, there are bigger than .75 mm pistons available.

Seat assembly is available in most Yamaha shops if not let me know I can help, I got my base plate (metal) for 325, beading for 125, foam for 400 and seat cover for 300. You can get new seats for less than 2k

Let me know if you need anything, I can connect you to couple of shops in Trivandrum who can ship things to you.

Another option is to use indiaspares, I just bought some 1000 worth goodies from them, they also have COD. I have not heard good reviews about their cylinder kits.

Best of luck with you new build, all the parts are available and there is no scarcity(the 2T gauge is illusive though). You can restore this in a week max if you wish to. The RX I did took me 3 weeks after being extremely lazy and using all the excuses available in the book

Pramod
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Old 14th April 2015, 09:23   #3
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Default Re: 1990 Yamaha RX100 Restoration

Some updates as of last (late) night
- Got the crank fixed with Maco connecting rod
- Center case assembled with all new bearings
- New clutch assembly
- Exchanged the current cylinder for a 0.25 used one
- Got 2T oil tank
- Front forks removed to check for bend

1990 Yamaha RX100 Restoration-img_0915.jpg

1990 Yamaha RX100 Restoration-img_0999.jpg

Quote:
Originally Posted by pramodkumar View Post
Oil Pump is available for ~500 pricol make. You can contact gee bee auto spares Bangalore

Oil Tank is available for less than 100 RS let me know if you have any difficulty finding one at any local spares shop, there are facebook groups where they are available with 2T oil gauge, but they surely are asking for an Arm and a leg.
I never knew Pricol pumps were so cheap. How is their reliability? We managed to get the 2T oil tank here, but without the level gauge.

Quote:
Originally Posted by pramodkumar View Post
Going for used cylinders, you must be very carefull, 1. there are a lot of Chinese cylinders in the market and 2. check the ports very carefully, local mech use hand file for porting. You can go bit more higher than the present .75 over size on the present cylinder block, there are bigger than .75 mm pistons available.
Current cylinder is little damaged near the intake port. We managed to exchange the same with 0.25 used cylinder in a very decent condition (Ports were untouched)

Quote:
Originally Posted by pramodkumar View Post
Another option is to use indiaspares, I just bought some 1000 worth goodies from them, they also have COD.
I'm looking to stock some spares for future. How is the quality of spares from them?

Quote:
Originally Posted by pramodkumar View Post
Let me know if you need anything, I can connect you to couple of shops in Trivandrum who can ship things to you.
Thank you so much Pramod. I will be in touch whenever I need some support.
Thanks again for the kind words.
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Old 14th April 2015, 09:56   #4
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Default Re: 1990 Yamaha RX100 Restoration

Quote:
Originally Posted by Mr.Boss View Post
I never knew Pricol pumps were so cheap. How is their reliability? .
Pricol used to be OE Yamaha suppliers, the pumps are not bad, but they are cheaper because of the demand in the market. Looks like the non compete deals are over hence we are seeing pricol branded stuff in the market. Even though there is a working pump, I would still use premix, it not only ensures the tank is rust free, also reduces the chances of a ceasure, all my bikes run both.

Quote:
Originally Posted by Mr.Boss View Post
I'm looking to stock some spares for future. How is the quality of spares from them?
I ordered an oil pump for my 100, 2-3 fuse holders and a couple of battery straps, all still doing duty on my bike.


Quote:
Originally Posted by Mr.Boss View Post
Thank you so much Pramod. I will be in touch whenever I need some support.
Thanks again for the kind words.
The great thing about the biker community is, there is always someone to help you, for instance, after reading your post I immediately need your help, PM sent

Pramod
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Old 14th April 2015, 14:04   #5
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Default Re: 1990 Yamaha RX100 Restoration


Looks like the RX bug has hit you extremely hard Mr. Boss sir

Its really great to see someone so passionate. Also the help you are offering to a friend is great. (which I can truly relate to and understand the rush and joy of restoring/ a bike gives)

The detailing in bringing back the bike to life is awesome. I know small small things matter a lot in the overall outcome of the bike and shows the pure love that one has for the vehicle.

Eagerly awaiting more finished product pics.

Cheers

Last edited by The Great : 14th April 2015 at 14:05. Reason: Spelling and repeated word deletion
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Old 14th April 2015, 14:44   #6
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Default Re: 1990 Yamaha RX100 Restoration

Parts purchased (may be useful for fellow members / visitors to understand the current pricing)

1990 Yamaha RX100 Restoration-wp_20150412_10_35_11_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_35_22_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_35_36_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_35_43_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_35_58_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_36_09_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_36_23_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_36_35_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_36_47_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_36_55_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_37_04_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_37_26_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_37_42_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_38_11_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_38_36_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_39_03_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_39_14_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_39_40_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_40_59_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_41_17_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_41_24_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_41_36_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_41_54_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_42_12_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_43_28_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_46_59_pro.jpg

1990 Yamaha RX100 Restoration-wp_20150412_10_50_13_pro.jpg

Quote:
Originally Posted by The Great View Post
Looks like the RX bug has hit you extremely hard Mr. Boss sir

Its really great to see someone so passionate. Also the help you are offering to a friend is great. (which I can truly relate to and understand the rush and joy of restoring/ a bike gives)
Thanks for the kind words buddy. RX bug is hitting every now and then.
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Old 14th April 2015, 14:49   #7
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Default Re: 1990 Yamaha RX100 Restoration

Quote:
Originally Posted by Mr.Boss View Post
Parts purchased
Is this a 6v RX 100 or converted to 12 V?

Pramod
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Old 14th April 2015, 14:56   #8
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Default Re: 1990 Yamaha RX100 Restoration

Quote:
Originally Posted by pramodkumar View Post
Is this a 6v RX 100 or converted to 12 V?

Just noticed the wiring harness. Thanks for pointing out Pramod, we got a wrong harness.
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Old 14th April 2015, 15:33   #9
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Default Re: 1990 Yamaha RX100 Restoration

Quote:
Originally Posted by Mr.Boss View Post

Just noticed the wiring harness. Thanks for pointing out Pramod, we got a wrong harness.
I have bought my share of wrong parts and kept them at home, the latest is a 130 main jet for the 100. Just read what's written on the package, didn't read the inscribing. When you usually ask for a 100 wiring harness they give you the 6V variant, you have to specify otherwise.

Pramod
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Old 15th April 2015, 09:28   #10
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Default Re: 1990 Yamaha RX100 Restoration

Quote:
Originally Posted by pramodkumar View Post
Is this a 6v RX 100 or converted to 12 V?
Quote:
Originally Posted by Mr.Boss View Post
we got a wrong harness.
What is the difference between RX100 6V & RX135 wiring harness? This bike was converted to 12V without changing the wiring harness. Last night I compared the new & existing harness and confirmed they are exactly same.

PS: I doubt the 6V & 12V magneto end connectors were different (I may be wrong) but in this case the coil plate was not changed, coils were wound with existing connector.
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Old 15th April 2015, 09:36   #11
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Quote:
Originally Posted by Mr.Boss View Post

What is the difference between RX100 6V & RX135 wiring harness? This bike was converted to 12V without changing the wiring harness. Last night I compared the new & existing harness and confirmed they are exactly same.

PS: I doubt the 6V & 12V magneto end connectors were different (I may be wrong) but in this case the coil plate was not changed, coils were wound with existing connector.
The only difference between a 6V and 12V RX100 is in the RR unit, bulbs, battery and flasher relay. Rest are all the same.
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Old 15th April 2015, 11:14   #12
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Default Re: 1990 Yamaha RX100 Restoration

Few updates from last night
- Block re-bored (2 OS Goetze piston) and fixed
- Front end replaced with Pulsar fork & disk assembly
- Rear axle, sprocket, sprocket hub & dampers fixed
- Front & Rear tires replaced (the one I took out from Pulsar project)

1990 Yamaha RX100 Restoration-img_1097.jpg

1990 Yamaha RX100 Restoration-img_1099.jpg

1990 Yamaha RX100 Restoration-img_1102.jpg

Forks had some serious scoring marks. Also one was already leaking. I had a Pulsar disk assembly (Forks, hub, rim, spokes, axle, worm gear, caliper, master cylinder, hose, etc) initially purchased for my RX135, but didn't find time to fix them. Those parts were used for this bike.

1990 Yamaha RX100 Restoration-img_1103.jpg

This was the time when I reached home.
1990 Yamaha RX100 Restoration-img_1104.jpg

Quote:
Originally Posted by SunnyBoi View Post
The only difference between a 6V and 12V RX100 is in the RR unit, bulbs, battery and flasher relay. Rest are all the same.
Thanks buddy, I was referring to the harness.
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Old 15th April 2015, 11:53   #13
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Default Re: 1990 Yamaha RX100 Restoration

Quote:
Originally Posted by SunnyBoi View Post
The only difference between a 6V and 12V RX100 is in the RR unit, bulbs, battery and flasher relay. Rest are all the same.
Quote:
Originally Posted by Mr.Boss View Post
Thanks buddy, I was referring to the harness.
When I meant rest all are the same I implied that the wiring harness was same too Apologies if it wasn't clear!
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Old 15th April 2015, 15:29   #14
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Default Re: 1990 Yamaha RX100 Restoration

Nice to see one more RX getting ready to hit the streets the way it should! What was the overall spend on spares? My clutch assembly suffers occasional slippage at higher RPM. I am not able to figure out whats the problem, but feel the pressure plate may be giving up. Also looking for someone who can do a good wheel truing job in Bangalore.
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Old 15th April 2015, 23:59   #15
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Default Re: 1990 Yamaha RX100 Restoration

Successfully completed the job Bike started today (in 6th kick to be precise) and engine runs like a gem without any abnormal noise.

Only few minor tasks pending and that will be completed by tomorrow. Let me post the snaps of final outcome tomorrow morning.
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