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Old 1st April 2011, 15:07   #1
NFS
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Default Bike - Suzuki Samurai (TVS/IND) Restoration Project

Motorcycle: 100cc
Manufacturer: TVS Suzuki Motors
Purchase date: Aug, 1995 New (single handed)
Brand: Samurai
Transmission: 4 gear Synchromesh
Registration: Palakkad, Kerala (expired in 2010 Aug - Yet to renew)
Vehicle currently in Chennai, TamilNadu
Completed: ~1L Kms
Accidents: None Major, one minor - rider fell down after hitting a garbage bin at night - somebody had placed it to the middle of the road - Repairs include bent foot rest - broken headlight - broken speedometer - broken clutch handle

Was my Primary vehicle starting from 1995 till 2005 (in 2005 I bought the Zen)

Long distance service: Drove it between Palakkad-Trichur, Palakkad-Coimbatore, Palakkad-Ernakulam many times.

Daily Commute: Daily office, late night/early morning returns (after a long day) from office, "Single kick" start. This was a work horse and served me all along my two wheeler days. Never it had let me down. Never stranded late nights or on long drives - Gave decent FE of 45 to 50Kmpl.

This is the candidate, today in a very poor state. Started to rust here and there a bit - Wanted to restore it - Cost involves - Re-building it (yet to show to a mechanic and get a quote) - Renew RC at Kerala (approx 5k) - Get NOC from Kerala - Have it Registered here at Chennai.

Question to the Experts of Team-BHP here are:
1. What is the best method of getting this restored?
2. Should I renew the RC at Kerala, as I need it registered here in Chennai. This will save 5,000Rs. Can I register the vehicle at Chennai without NOC?
3. How is the availability of Spares? Should I mod it to restore it? Add accessories of other bikes and make it look like some other bike?

What other suggestions do you have?

Last edited by NFS : 1st April 2011 at 15:45.
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Old 1st April 2011, 15:43   #2
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Default Re: Bike - Suzuki Samurai (TVS/IND) Restoration Project

Some pictures of the current state. Sorry about the low quality Cellphone camera pics.

Pic 1: Original Paint and Stickers
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Pic 2: Shockabs changed in 2005 as the old one was too stiff (Not much improvement felt)
Exhaust Silencer has a hole and will require replacement
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Pic 3: Original seats torn and need some upholstery work. Thinking of stitching covers over the original form. It is hard, but wanted to maintain the originals
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Pic 4: Rust on Fork chromes - will need some re-chroming
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Pic 5: Overall in stock as of now
Bike - Suzuki Samurai (TVS/IND) Restoration Project-pic5.jpg

Pic 6: Chassis needs to be repainted
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Pic 7: Not much Rust as of now - Fork leaking oil (I think)
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Last run: More than a year before!

Known Problems:
a. Engine goes off after a short run (not sure of the piston or bore)
b. Exhaust Silencer has a hole (too loud sound when started, with exhaust gas leaking near the center stand)
c. Minor electrical issues or maintenance may be required - one indicator lamp is missing
d. Tyres are really old (buttons are good) but rubber may be bad, will require a change.
e. Repainting and Re-Chroming to give a face lift (and re-registration requires the vehicle to be road worthy)

Last edited by NFS : 1st April 2011 at 15:55.
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Old 1st April 2011, 16:38   #3
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Default Re: Bike - Suzuki Samurai (TVS/IND) Restoration Project

Thanks to the assembly Feature of Team-BHP, I had an opportunity to test it today.

BHPians, I am inspired by the modifications carried out on this thread
http://www.team-bhp.com/forum/motorb...ai-1993-a.html (Suzuki Samurai 1993-)
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Old 4th April 2011, 18:59   #4
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Default Re: Bike - Suzuki Samurai (TVS/IND) Restoration Project

Sorry MODS, none of the experts noticed my thread I believe.

Experts, Please suggest!
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Old 4th April 2011, 19:44   #5
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Default Re: Bike - Suzuki Samurai (TVS/IND) Restoration Project

I am no expert, but here is another Samurai that was modified in the Modified bikes thread.

http://www.team-bhp.com/forum/motorb...ml#post2228145 (Modified Indian bikes - Post your pics here and ONLY here)

Should give you something to chew on till the experts fill in with their comments.

The best way to restore it IMO would be to start ground up. Get it evaluated with a trusted mech and take it from there.

Spares availability should not be a problem for us down south. The mech should be able to tell you if they can be sourced.

All the best and hope to see your bike back in good shape soon!

PS: Samurai was the very first bike which i inherited from my dad and learned riding geared bikes.
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Old 4th April 2011, 19:54   #6
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Default Re: Bike - Suzuki Samurai (TVS/IND) Restoration Project

well i'm no expert either but have a samurai 14 years young sparingly used now. As its Advt said this thing is a real no problem bike that never wants to see the mechanic. To your queries- its easy to restore & same is spares availability but those graphic stickers can be hard to locate. Most local mechs can do a good job of restoration, care to be taken just on paint job quality. No idea about registration process. Overhaul the engine & cleanup-weld the silencer pipe.

Not many go for engine mods as results are not worth the effort-cost & that frisky frame is no good even if one tunes up a good engine. I think cylinder transplants from Shogun/ Rx100 can be a worthy mod. Not sure about Rx part and so its for the experts here to opine on. There are some add-on options for both engine & frame which does have a positive impact, most are done on bike in the thread you mentioned & have a look at this thread mods (TVS-Suzuki Samurai mods)

Its a silly machine may be the reason why there's no much response.

Last edited by Rennjit : 4th April 2011 at 20:07. Reason: link
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Old 5th April 2011, 13:28   #7
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Default Re: Bike - Suzuki Samurai (TVS/IND) Restoration Project

Quote:
Originally Posted by NFS View Post
Motorcycle: 100cc
Manufacturer: TVS Suzuki Motors

Question to the Experts of Team-BHP here are:
1. What is the best method of getting this restored?
2. Should I renew the RC at Kerala, as I need it registered here in Chennai. This will save 5,000Rs. Can I register the vehicle at Chennai without NOC?
3. How is the availability of Spares? Should I mod it to restore it? Add accessories of other bikes and make it look like some other bike?

What other suggestions do you have?

1. What is the best method of getting this restored?

Ths depends on what level of restoration you want. If you want a complete original brand new look start collecting spares. Get the complete engine oil seal kit, bearings, piston rings, crankshaft if possible, carb manifold, etc. I came across an original sticker kit for the samurai recently.
Search for a good industrial chrome guy and chrome only those parts which really need a chrome job. IMO early TVS bikes rarely need any chroming.
Get the chassis sandblasted before painting and try for a good stove enamel painting on the chassis and body.

2. If the bike is registered in you name already, you can use it anywhere.
Btw, change of registration should not cost you more than 4k. It also has to be re-registered anyways as its more than 15 years old.

3. I strongly advice you doing any cosmetic mods to the bike. The samurai looks much better in its original form. Mods like adding a powerbox manifold , polishing ports and front disc will do.
Sadly TVS no longer supports spare back up for the bikes that made it what it is today. Its a shame really.

You can mail me on yamdootrd350@gmail.com for any info.

Hope the above info proves valuable to you.

Regards,
Nitesh
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Old 12th June 2012, 12:34   #8
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Default Re: Bike - Suzuki Samurai (TVS/IND) Restoration Project

Hi Yamdoot, thanks for the insight. I too have a 1998 model Suzuki Samurai, still runs like a King. Thought I'll get it painted and done up. Can you let me know from where I can get the original sticker kit for black suzuki samurai.

Many thanks in advance, Reuben (reubensm@gmail.com)

Quote:
Originally Posted by yamdoot View Post
1. What is the best method of getting this restored?

Ths depends on what level of restoration you want. If you want a complete original brand new look start collecting spares. Get the complete engine oil seal kit, bearings, piston rings, crankshaft if possible, carb manifold, etc. I came across an original sticker kit for the samurai recently.
Search for a good industrial chrome guy and chrome only those parts which really need a chrome job. IMO early TVS bikes rarely need any chroming.
Get the chassis sandblasted before painting and try for a good stove enamel painting on the chassis and body.

2. If the bike is registered in you name already, you can use it anywhere.
Btw, change of registration should not cost you more than 4k. It also has to be re-registered anyways as its more than 15 years old.

3. I strongly advice you doing any cosmetic mods to the bike. The samurai looks much better in its original form. Mods like adding a powerbox manifold , polishing ports and front disc will do.
Sadly TVS no longer supports spare back up for the bikes that made it what it is today. Its a shame really.

You can mail me on yamdootrd350@gmail.com for any info.

Hope the above info proves valuable to you.

Regards,
Nitesh
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Old 13th June 2012, 11:15   #9
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Default Re: Bike - Suzuki Samurai (TVS/IND) Restoration Project

all depends on how intimate the vehicle is to you and how long you planning to keep, based on this make your move, keep in mind the money & effort you put in restoring cannot be recovered completely.

Sourcing parts for samurai is not a big deal you will get it from lots of shops in GP road Chennai
with the current condition do a complete rebuild of engine (rebore,crank,oil seals)
OE stickers also should be available
if u need to transfer the papers to Chennai, you need to get an NOC and to get an NOC you need have the papers in current
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Old 13th June 2012, 14:03   #10
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Default Re: Bike - Suzuki Samurai (TVS/IND) Restoration Project

Not a Samurai but this link shows the fruits of a stock restoration. Just for illustrative purpose for you to get an idea sir.

Suzuki Shaolin Restoration


There are a lot of common parts that Suzuki's share viz - Samurai - Shogun - Ind Suzuki - Shaolin. Hence sourcing parts shouldn't be that difficult.

Last edited by The Great : 13th June 2012 at 14:05.
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Old 13th June 2012, 18:20   #11
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Default Re: Bike - Suzuki Samurai (TVS/IND) Restoration Project

I think the bike is in pretty good shape and can be restored easily for very little ....one thing that was horrible on the TVS of the era was the switch gear. I think these were made to rust like iron...........hell !!
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