1998 Yamaha RX135 Restoration completed : Now, 5 speed converted!

Mr.Boss · 5th April 2015, 16:22

Latest update:
- Covered 3.6k km
- Disc brake set up is painted but not fixed yet
- Few chrome parts started rusting

(Thanks to Quality Metal Works)

Mr.Boss · 22nd April 2015, 09:23

I got some free time to work on my RX again.

Oil pump was leaking and I couldn't get the oil seal for a while. A couple of weeks back when we went around hunting parts for RX100 restoration, fortunately we got a couple of oil seals. Last evening I opened the Oil pump and found oil is leaking at both the oil seals and packing.

Pump taken out

1998 Yamaha RX135 Restoration completed : Now, 5 speed converted!-img_1354.jpg

Dismantled it completely and cleaned them with petrol.

1998 Yamaha RX135 Restoration completed : Now, 5 speed converted!-img_1360.jpg

Oil seals

1998 Yamaha RX135 Restoration completed : Now, 5 speed converted!-img_1363.jpg

1998 Yamaha RX135 Restoration completed : Now, 5 speed converted!-img_1364.jpg

New oil seal and packing

1998 Yamaha RX135 Restoration completed : Now, 5 speed converted!-img_1362.jpg

Assembled them back, fitted to the vehicle and confirmed it is working well

Let me monitor for few hundred kms and keep this thread updated.

pramodkumar · 22nd April 2015, 11:13

Quote:

Originally Posted by Mr.Boss

I got some free time to work on my RX again.

Is there a way to get the spring? I would need one.

Pramod

Mr.Boss · 22nd April 2015, 11:18

Quote:

Originally Posted by pramodkumar

Is there a way to get the spring? I would need one.

To my knowledge the answer is "NO"

But if you are OK with a used one, I can get during my next visit to Pudupet.

pramodkumar · 22nd April 2015, 11:20

Quote:

Originally Posted by Mr.Boss

To my knowledge the answer is "NO"

But if you are OK with a used one, I can get during my next visit to Pudupet.

New/Used anything would work. Please look for the spring alone, this is a spare pump which is lying around. Also a set of oil seals for me

Pramod

The Great · 22nd April 2015, 12:46

It is really good to see that you are getting oil pump related spares, maybe the Rx 100 ones are still available. But to my bad-luck Rx 135 5 speed oil pumps have vanished from everywhere. I am hunting for a 5 speed oil pump since almost 2 years now. Even my oil pump has a leak but the lack of micro spares makes it difficult to repair the original one. AFAIK 5 speed oil pumps are smaller than 135 4 speed ones (not sure about this though).

Mr.Boss · 22nd April 2015, 15:15

Quote:

Originally Posted by The Great

It is really good to see that you are getting oil pump related spares, maybe the Rx 100 ones are still available. But to my bad-luck Rx 135 5 speed oil pumps have vanished from everywhere. I am hunting for a 5 speed oil pump since almost 2 years now. Even my oil pump has a leak but the lack of micro spares makes it difficult to repair the original one. AFAIK 5 speed oil pumps are smaller than 135 4 speed ones (not sure about this though).

I doubt the oil seal will remain same for all 3 oil pumps (100 / 135 4s / 135 5s) and the packing may be different. Let me check if I could get the oil seal & packing kit for 5 speed.

The Great · 22nd April 2015, 15:19

Quote:

Originally Posted by Mr.Boss

I doubt the oil seal will remain same for all 3 oil pumps (100 / 135 4s / 135 5s) and the packing may be different. Let me check if I could get the oil seal & packing kit for 5 speed.

It sure is different in all models. 100, 135 4 speed old, 5 speed and 4 speed catcon model, all have slightly different oil pumps.

Mr.Boss · 2nd July 2015, 09:15

After covering 4k km

1998 Yamaha RX135 Restoration completed : Now, 5 speed converted!-img_3258.jpg

Mr.Boss · 5th August 2015, 10:07

Water entered the carburetor after I drove the bike under heavy down pour last evening. Bike struggled to accelerate and lost breath when the throttle is opened. Carburetor cleaning done this morning.

1998 Yamaha RX135 Restoration completed : Now, 5 speed converted!-img_4257.jpg

Mr.Boss · 3rd October 2015, 17:47

Getting ready for Version 2.0

1998 Yamaha RX135 Restoration completed : Now, 5 speed converted!-img_20151003_171456.jpg

Viju · 5th October 2015, 08:04

Quote:

Originally Posted by Mr.Boss

Getting ready for Version 2.0

Wow, looks nice. I cannot seem to identify that disc rotor.
What combination of parts are you using for the front disc set-up?

Mr.Boss · 5th October 2015, 08:46

Quote:

Originally Posted by Viju

Wow, looks nice. I cannot seem to identify that disc rotor.
What combination of parts are you using for the front disc set-up?

Rotor is taken from a old Bajaj Caliber Croma, I also have another decent condition rotor from Pulsar UG2

Yet to decide on the part combination, I have few sets purchased a while ago
Hub : Pulsar Classic (Used one)
Spokes : Pulsar Classic
Rim : Sandar (New, had a Hero Rim purchased an year ago but it started rusting)
Forks : Pulsar Classic (Used legs + New fork tube & Springs)
Rotor : Caliber Croma / Pulsar UG2 (both used)
Caliper : Endurance / Bybre (Endurance is new one & Bybre is taken from a running bike)
Master Cylider : Endurance / KBX (Endurance is new one, KBX taken from a running bike)

Mr.Boss · 6th October 2015, 09:12

I could stop with better confidence now

1998 Yamaha RX135 Restoration completed : Now, 5 speed converted!-dscn9236.jpg

Part mix:
Hub : Pulsar Classic (Used)
Spokes : Pulsar Classic
Rim : Sandar (New)
Forks : Pulsar Classic (Used legs + New fork tube & Springs)
Rotor : Caliber Croma (Used)
Caliper : Endurance (New)
Master Cylinder : Endurance (New)

sree_chandru · 18th December 2015, 14:51

Hi,
Saw your restoration work. Very neat and good.
Due to recent floods, One of my colleagues Yamaha RX135 was drowned.
The Vehicle should have been inside water for 3 days.
Do you thin we can restore it? Is the restoration worth it?

How much do you think that it would take to totally bring it up from scratch?

5th April 2015, 16:22	#31
Mr.Boss Distinguished - BHPian Join Date: Mar 2011 Location: GPS signal lost Posts: 2,811 Thanked: 7,464 Times View My Garage	Re: 1998 Yamaha RX135 Restoration Latest update: - Covered 3.6k km - Disc brake set up is painted but not fixed yet - Few chrome parts started rusting (Thanks to Quality Metal Works)
	() Thanks

22nd April 2015, 09:23	#32
Mr.Boss Distinguished - BHPian Join Date: Mar 2011 Location: GPS signal lost Posts: 2,811 Thanked: 7,464 Times View My Garage	Re: 1998 Yamaha RX135 Restoration I got some free time to work on my RX again. Oil pump was leaking and I couldn't get the oil seal for a while. A couple of weeks back when we went around hunting parts for RX100 restoration, fortunately we got a couple of oil seals. Last evening I opened the Oil pump and found oil is leaking at both the oil seals and packing. Pump taken out Dismantled it completely and cleaned them with petrol. Oil seals New oil seal and packing Assembled them back, fitted to the vehicle and confirmed it is working well Let me monitor for few hundred kms and keep this thread updated.
	(1) Thanks

22nd April 2015, 12:46	#36
The Great BHPian Join Date: Feb 2007 Location: Mumbai Posts: 740 Thanked: 943 Times View My Garage	Re: 1998 Yamaha RX135 Restoration It is really good to see that you are getting oil pump related spares, maybe the Rx 100 ones are still available. But to my bad-luck Rx 135 5 speed oil pumps have vanished from everywhere. I am hunting for a 5 speed oil pump since almost 2 years now. Even my oil pump has a leak but the lack of micro spares makes it difficult to repair the original one. AFAIK 5 speed oil pumps are smaller than 135 4 speed ones (not sure about this though).
	() Thanks

2nd July 2015, 09:15	#39
Mr.Boss Distinguished - BHPian Join Date: Mar 2011 Location: GPS signal lost Posts: 2,811 Thanked: 7,464 Times View My Garage	Re: 1998 Yamaha RX135 Restoration After covering 4k km
	(1) Thanks

5th August 2015, 10:07	#40
Mr.Boss Distinguished - BHPian Join Date: Mar 2011 Location: GPS signal lost Posts: 2,811 Thanked: 7,464 Times View My Garage	Re: 1998 Yamaha RX135 Restoration Water entered the carburetor after I drove the bike under heavy down pour last evening. Bike struggled to accelerate and lost breath when the throttle is opened. Carburetor cleaning done this morning.
	() Thanks

3rd October 2015, 17:47	#41
Mr.Boss Distinguished - BHPian Join Date: Mar 2011 Location: GPS signal lost Posts: 2,811 Thanked: 7,464 Times View My Garage	Re: 1998 Yamaha RX135 Restoration Getting ready for Version 2.0
	(1) Thanks

6th October 2015, 09:12	#44
Mr.Boss Distinguished - BHPian Join Date: Mar 2011 Location: GPS signal lost Posts: 2,811 Thanked: 7,464 Times View My Garage	Re: 1998 Yamaha RX135 Restoration I could stop with better confidence now Part mix: Hub : Pulsar Classic (Used) Spokes : Pulsar Classic Rim : Sandar (New) Forks : Pulsar Classic (Used legs + New fork tube & Springs) Rotor : Caliber Croma (Used) Caliper : Endurance (New) Master Cylinder : Endurance (New)
	(1) Thanks

18th December 2015, 14:51	#45
sree_chandru Newbie Join Date: Nov 2007 Location: Chennai Posts: 8 Thanked: 0 Times	Re: 1998 Yamaha RX135 Restoration Hi, Saw your restoration work. Very neat and good. Due to recent floods, One of my colleagues Yamaha RX135 was drowned. The Vehicle should have been inside water for 3 days. Do you thin we can restore it? Is the restoration worth it? How much do you think that it would take to totally bring it up from scratch?
	() Thanks