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Old 12th May 2008, 23:39   #1
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Cool All about Shogun Modification

Guys,

I would like to start a thread l to discuss bike modifications for shogun/yamaha 135

To start let me discribe what I did to my shogun .

1. Wheels : Front CBZ's + disc breaks Rear: Yezdi's rim and Tyre which is a 18 inch for stability.
2. KRP Expansion Chamber for Shogun(there are 2 one for yamaha(silver) one for shogun(black))
3. KRP Power throttle.
4. Yamha's spoket in the rear for better pickup.
5. KRP Wide Handle Bar
6. KRP - HP Universal Power Filter

After putting all this together I was impressed by the power the bike produced.
So what do u say lets share our experiances .

Max
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Old 13th May 2008, 02:27   #2
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Hey Max,

Awesome thread to start with buddy and thanks for heeding to my suggestion

Here you go: Mods for my RX135 (sold a year back)

1. Wheels: Front MRF Zapper Moto cross; Rear: Yezdi rim and 18 inch motocross tyres for a short while and then back to the yezdi tyres.
2. Expansion chamber for Yamaha
3. Shogun handle bars
4. K&N filters.

With the above mods on the RX, I could touch insane speeds within a very short time. But my dream to own and mod a shogun was not fulfilled at all. Production was stopped by that time and i could not lay my hands on a well maintained second hand shogun. But the RX fulfilled my Need for Speed during my educational days.
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Old 13th May 2008, 09:54   #3
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Planning to pick up my old SHOGUN back. Btw where in Bangalore can I pick up KRP products ? I wouldn't change the exhaust though, because the stock one sounds SUPERB.

CHEERS,
G D
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Old 13th May 2008, 10:27   #4
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Yezdi has 16 inch tyres not 18 inch
A shogun has a 44 teeth rear sprocket
RX 100 has 39,135 4 speed has 34 and a 5 speed has 37
so how can it increase acceleration?

I have a 2000 model shogun which was restored recently with almost everything new from engine block to crank to clutch plates,and with a pulsar disc set up up front

Trust me KRP chamber is as good should i say as bad as a proton,if you need real power get a tuned chamber or if possible design one on your own with the help of softwares available over internet

And HP is one of the worst filter around get a UNI or at least a K&N
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Old 13th May 2008, 17:30   #5
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Quote:
Originally Posted by akshay4587 View Post

Trust me KRP chamber is as good should i say as bad as a proton,if you need real power get a tuned chamber or if possible design one on your own with the help of softwares available over internet

And HP is one of the worst filter around get a UNI or at least a K&N
My expansion chamber was tuned by a guy in VV Puram blore. But he shut shop or rather sold it to someone else and relocated to his home town (Hassan I guess) It had awesome power. And yes I did have a K&N in my yam135 when i owned it. Was not aware of HP filters then.. Was only aware of Uni & K&N.
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Old 13th May 2008, 23:21   #6
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Quote:
Originally Posted by P180V1 View Post
I wouldn't change the exhaust though, because the stock one sounds SUPERB.
Good decision. Shogun has the best exhaust note of all the 2 strokes sold in our country.. maybe only bettered by the RD.
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Old 14th May 2008, 00:02   #7
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Very true, RD is in a different league altogether.

CHEERS,
G D
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Old 14th May 2008, 03:42   #8
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Quote:
Originally Posted by maxj2005 View Post
Rear: Yezdi's rim and Tyre which is a 18 inch for stability.
Yezdi has 16 inch tyres, New 3.25 tyres arn't easy to find these days & only Ceat & Dunlop are available.
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Old 14th May 2008, 06:58   #9
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Ain't we missing our very own Addy here?
A shogun thread it is, afterall!
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Old 15th May 2008, 00:31   #10
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Quote:
Originally Posted by akshay4587 View Post
Yezdi has 16 inch tyres not 18 inch
A shogun has a 44 teeth rear sprocket
RX 100 has 39,135 4 speed has 34 and a 5 speed has 37
so how can it increase acceleration?

I have a 2000 model shogun which was restored recently with almost everything new from engine block to crank to clutch plates,and with a pulsar disc set up up front

Trust me KRP chamber is as good should i say as bad as a proton,if you need real power get a tuned chamber or if possible design one on your own with the help of softwares available over internet

And HP is one of the worst filter around get a UNI or at least a K&N
You are right akshay all I remember is that I had a yezdi tyre and in the rear was not sure if it was 18 or 16. Since I sold my bike in 2006 to a friend.
And for the rear spoket all I remember is the spoket size was bigger than it usually is and not the number of teeth.

I had peped up my bike in an around 2001 - 2004 so I believe that's what we had that time or rather could get my hands on these only.
I did all this with a guy in dehradun his name is Krishna .He used to work for the TVS suzuki (then) showroom there. Now he has his own garage .He still does all this stuff and is preety good at it.
I also remember that he did something to the engine block which he never told me(secret).
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Old 15th May 2008, 02:45   #11
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All the above mods are more suited for dirt/broken tarmac.

Here is what i did to get my shogun prepped up for the highways.
(won't mention the RX135, i spent much more time and energy and esp money on it but it never could be what the shogun could- but since i learnt everything about what to and what not to do on it, i give it the same respect).

-Bullet spokes on stock Adeep oem rims

-Stock rims with Michelin M45 2.75x18 at the front and 3.00x18 at the rear- awesome grip, great wet grip, much better lean angles even in wet and rear lock ups reduced to almost nil, even on concrete city streets.

-KB100/125 full length springs in front forks with 175ml fork oil per fork.

-The stock Gabriel rear shocks were a bit too soft for my taste and changed them for stiffer armstrong ones that complemented the faster rebounding front forks.

-Boyesen dual stage fiber reeds in the stock reed cage but polished intake for smoother intake

-Widened and polished induction port from the crank side- not touching the actual ports.

-Widened (tapered) and polished exhaust bore without touching the exhaust port, same for intakes and xfer ports

-mildly lapped head+bore

-Gypsy sealed beam in suitable dome of choice- P43T Philips/Osram 60/55W with Maruti oem wiring/holder, also almost eliminates rear bulb fusing at high rpms.

-Original KB100 rectangular solid stalk rvms- pretty steady at 100kmph.
Turn inwards for city use and one gets less than handlebar width to scrape thru traffic- turn outwards and wider to look behind one's arms/shoulders. :P

-Stiffer foam for seat with very thin layer of medium soft foam and contoured to prevent rash due to friction at the edge(not stepped- i shifted front and back depending upon terrain and riding style, plus a bit long legged)

-Last (i think) but not the least- TVS (ceramic coated) power-tuned exhaust for stock Shogun: instant 16bhp(claimed) with retuning for the stock shogun without any of the minor mods i did.
And it was maybe 10x the scream of stock bike at 8.5K rpm and beyond.

The black beauty screaming by and all chickens flying all over the van- still the stuff of my dreams.
Would have been replaced if only i had a Vmax, a 916 or a GXS1000R.

Note from the Team-BHP Support Staff : Post Edited. Smilie usage is restricted to two per post on Team-BHP. Please refrain from using excessive smilies.

Last edited by Aditya : 19th May 2008 at 18:12.
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Old 15th May 2008, 13:34   #12
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Cool Shogun Modifications

Great thread. I am a big Shogun fan. Was crazy about the bike. Bought a brand new Shogun in 1994. Since then I have owned 3 Shoguns over a period of 10 years.
The modifications mentioned by me here were similar on all the 3 bikes I had. I donít remember all the technical jargons but I will try my best to explain the mods I had done as clearly as possible.

Front Rim & Tyre: I have used both, 2.75X18 and 3.00X18 tyres on the stock rim. With the 3.00X18 Ceat tyre on the stock rim, the steering gets a bit heavy, and itís a bit difficult to fit the front stock mudguard (can be fitted though). The gap between the tyre and the mudguard would be so small that if a small stone gets stuck in the tyre, there is a chance of wheel lock. So, I had a sports mudguard fitted. The same as the ones on the motocross bikes.

Rear Rim & Tyre: Yezdi Roadking rim, 3.00X16 MRF/Dunlop tyre. The spokes were heavy duty spokes, which were thick and strong. This setup was really great on all type of terrains. Cornering was like a cake, the grip was solid, enhanced braking and the looks were great.

Front Forks: I have used all the 3, the Shogun stock forks, KB-100 forks and the Suzuki Fiero forks. In all the three I found the Suzuki Fiero forks to be the best in terms of ride comfort and handling. If you want relatively tall front posture, then KB-100 forks suit best.
The front fork boots were that of the Yamaha-YZ125.

Headlight (Lighting): Yezdi Roadking dome and rim with Autopal Fiat flat beam (right-hand side beam). 100/90W Philips halogen bulb with Lucas holder and wiring kit. Extra windings to the coil to provide adequate energy to the 100/90W bulb. The illumination and spread were terrific. With this lighting setup, I could not use the tail-lamp, as it would burn out.

Handle-Bar: Shogun stock handle welded with a rod running in the center from right to left and paint job done to give good looks.
Exhaust: Custom made exhaust chamber (painted dull black in colour) with mid range power tuning. Silent during low RPMs, it used to scream with clarity with the increase in RMP. It was like music to my ears. Power enhanced to a great extent. All depends on the tuning.

Chain Case: A custom made chain case, consisting only the upper cover.
Rear Shock Absorbers: I have used both Gabriel (for smooth suspension) and Armstrong (a little hard). Rear height increased by 1 inch by welding rings at the foot of the shock absorbers with precision.

Fiat/Ambassador mudflap fixed to the rear mudguard to avoid spray during rainy season. Also gave a rally look to the bike.

Regarding the alterations done to the engine components, I donít remember properly.
All I know is that the bore was ported; bigger piston and rings were fitted. The cranks sometimes were reset in Coimbatore (Lathe gurus!).

I used to participate in dirt-track and hill-climb events, so used to get the bike modified as per the requirement. When no events were happening or just for a change, I used to get the bike changed to complete stock condition. All these alterations used to be done by my mechanic Chotu (Mysore). We had a collection of bores, pistons, cranks etc., etc., and knobby tyres for dirt tracks.
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Old 15th May 2008, 14:14   #13
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Quote:
Originally Posted by Dolphin View Post
Rear Rim & Tyre: Yezdi Roadking rim, 3.00X16 MRF/Dunlop tyre.
The rear tyre size is 3.25X16, am sorry.
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Old 15th May 2008, 15:24   #14
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Hey Max thanks for starting the post... took me down a nostalgic path!
I used a shogun from '95 to '03 - totally stock - clocked 45K kms on it and was really sad to sell it.
I had bought it for 35K and sold it for 10K to a cook from rajasthan - When I asked why was he buying such an old shogun instead of a HH CD100 or something in that league - he promptly replied that he was buying it to participate in a race in his native district. Apparently parts of rural Rajasthan have these races at village and district levels. I wished him best of luck and was happy that the bike was still going to be used the way it was supposed to be!

I would stick out my neck to say "the best 2 stroke bike ever produced in India"
cheers!
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Old 16th May 2008, 07:27   #15
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The only modification I did to my Shogun was fitting a 100/90 x 18 rear tyre. The previous owner had fitted a 3.00x 18 race spec tyre on the front rim. The extra grip from these tyres greatly aided braking, which is pathetic. This tyre is now worn out and will be replaced. The stock headlight has been replaced by one a Bajaj Pulsar Type 1.
The sound, the vibration, the speed and the ease of riding make this bike a firm favourite of mine.
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