[pramodkumar]

Originally Posted by ashwinprakas

Now 60k and 6 months invested in the motorcycle she is still missing the fiber bits.

Getting the ZMA fiber parts is almost impossible, I have tried picking up one in the past. I seriously hope he can find all this in time.

Pramod

[pramodkumar]

So I reach the Gati Godown and for 10 minutes they cannot find the bike

After frantic searching we saw it lying under a pile of stuff , It was beat up Pretty bad, the side stand and the center stand were bent, The front brake leaver broken, the foot rest is bent. I knew it would have been impossible to take it home without a flatbed auto. But still I wanted to check if it will start.

So we pour 200 rs worth of petrol and 2T oil and finally start kicking, it didn't start, even after kicking the thing for 15 minutes non stop, it didn't budge. I was very excited and i forgot to carry even basic tools such as a plug spanner, I parked the bike and started looking for a workshop so that I can borrow some tools. I couldn't find the workshop but I found a Flatbed auto. Finally bike was loaded and it reached my home.

Finally my unicorn was at my home.

Pramod

it was all covered in dust, I wanted to give it a quick wash. but the urge to ride was super strong. So i took the plug out and it was little dirty, changed the plug and couple of kicks and it comes to life. Took her for a small spin and it was definitely not in ridable condition. it was the most sketchiest bike I had ever ridden.

After riding about 100 mts I took a u turn and came back home, this was not the kind of riding experience I wanted in my head to last. Came home and quickly took some pics to document damages during shipping.



The tank was dented



Front brake leaver broken



Side stand bent



Main stand broken

It was rough, I couldn't park the bike in my garage due to the stand. i just decided to call it a day and check for more later.

Pramod

[ku69rd]

Hi Pramod,
Never knew you would really change the title. Thank you... Goes well with what you went through.

Again this is an interesting thread and I will be all glued to it. If you think I can do two cents for it... Let me know.

[pramodkumar]

Originally Posted by ku69rd

Hi Pramod,
Never knew you would really change the title. Thank you... Goes well with what you went through.

Again this is an interesting thread and I will be all glued to it. If you think I can do two cents for it... Let me know.

You are responsible for this title

Your blessings are enough as of now sir. I will disturb you if anything is needed.

Pramod

[pramodkumar]

The tank was absolutely crap, It was welded, the shape was all out of whack.

The worst thing about Kashmir is their workmanship, there is absolutely none. I know a lot of people will disagree, they will quote the handicraft sector, the artisans etc.. But this is about simple mechanical tasks, welding, denting, mechanical is not their strong point.

Simple things like you have to remove plastic bits while welding, is an alien concept for those Kashmiri grease monkeys who call them mechanics. Nothing pisses me more off than botched jobs, if there is an award for botched jobs, Kashmiri grease monkeys will win all the awards hands down.

Let me give you an example. This is how the panel gap should be in an RXZ



This is how the grease monkey at Kashmir decided to fix the leak.



If you still don't see it I have encircled it.



I know finding a good condition RXZ tank is impossible. so I reach out to my friend in Kashmir and a week later he sends me this pic



Now that I procured the Tank I was keen on planning the build, So next phase of the build starts.

To be continued.

Pramod

[CrAzY dRiVeR]

Originally Posted by ashwinprakas

Now 60k and 6 months invested in the motorcycle she is still missing the fiber bits.

Is it that hard to procure in Trivandrum?

A BHPian had restored his bike recently in Bangalore and wasn't so hard. He bought a second-hand bike for office errands, and during service, just suddenly decided to get all the panels replaced and made it looking new! No waiting, no drama for procurement - IIRC.

If you want, can get the details where he got it done.

[pramodkumar]

Now my previous post did come out as a rant, well it’s not a rant.

Kashmir is a place where people have very limited means, people can’t freely buy things, to put things in perspective, my friend is trying to get a 12mm bolt, it’s been 2 weeks since he started searching still no luck.

Now availability of spares is not the only issue, people can’t afford proper fixes, they can’t afford expensive upkeep so these bikes change hands, they change hands so that every time that happens it goes to a person poorer than the previous one, until it reaches a scrap guy who ultimately sells it for scrap metal.

So the bikes are real survivors, these have stood the test of time, these have served their multiple owners well. These have seen newer bikes go to the junkyard. These have been flogged to death, but still managed to survive.

These bikes deserve a second chance, these are no longer an until bike, these are forever bikes.

To put things to perspective, I am attaching a small video of how much abuse the factory paint on the most abused part(foot rest) can take. See for yourself, this is perhaps the reason why we love these.

https://youtu.be/xT4fTAYQInk

Bikes are not build this way anymore, when I see a modern bike in tatters, my respect for these little giant killers increases multi folds

Pramod

[ku69rd]

So would this mean that you will now try your hand to paint the RXZ ?
After burning the paint, the cleaning will take time. Good luck and keep us posted as and when you make progress.

[pramodkumar]

Originally Posted by ku69rd

So would this mean that you will now try your hand to paint the RXZ ?
After burning the paint, the cleaning will take time. Good luck and keep us posted as and when you make progress.

Actually I was too impressed with the company powder coating that I decided to do touch ups. It was an absolute fail

https://youtu.be/cdNYy7be7O4

Funny my Rx 100 is still on factory powder coating, it was touched up with paint every time there was a chipping of powder coating.

More than doubting the factory paint I am worried about my OCD which will kill me because I hand a chance to powder coat but I didn’t

So to keep everyone happy I am powder coating, but I will strip the paint before I give for powder coating

Pramod

[pramodkumar]

So finally last Sunday, I decided to take the apart the RXZ.

https://www.youtube.com/watch?v=Sbh3iT780sM

The Most of the superficial parts were already taken apart, It was easy, took me about 30 minutes.

Once the bike was taken apart, I can make a complete list of parts needed.

Pramod

[pramodkumar]

Below is the list of spares

1. New headlight dome(Already procured)
2. New wiring kit(Repairing the old one)
3. new cables(tacho cable already procured)
4. New rxz handle
5. New Grips
6. New Yokes
7. New switch gear(both sides)
8. New clutch leaver
9. Front brake master cylinder(gladiator)
10. Front rotor(gladiator new)
11. Front Caliper(gladiator new)
12. Front Brake hose(gladiator)
13. Brake fluid Dot 3
14. Speedo Worm(gladiator)
15. Speedo cable(Gladiator)
16. Hub Spacer
17. Axel
18. New visor
19. Visor Glass
20. New indicators 2 Nos(Already procured)
21. Body panels
22. New Battery
23. New seat
24. Tail light assembly
25. Rear Brake shoes
26. Front tyre(Michilin Sirac Street270X18)
27. Rear Tyre(Michilin Sirac Street 300X18)
28. Rear Mudflap
29. Front mudflap
30. Sticker Kit
31. Rubber kit
32. Side stand(already procured, pulsar)
33. Center stand(already procured)
34. Misc Bulbs
35. Engine screw kit
36. Air filter screw kit
37. Air filter element
38. Carb rebuild kit
39. Reed valve
40. New rims(Hero Honda)
41. Crash Guard(Bar/Butterfly)
42. Packing kits
43. Piston Rings(if needed)
44. 12mm 1 inch Bolts(36NOS) + Washer nuts(36)
45. 10MM 1/2 Inch bolts (36)+ Washer nuts(36)
46. chain adjusters
47. New axels
48. New engine mounting bolts
49. rear view mirrors
50. Visor Mounts
51. Headlight stay
52. front monogram bracket
53. pilot lamp(already procured)
54. meters(already procured)
55. Rider Foot rest bar
56. Rider foot rest rubber(already procured)
57. Pillion footrests
58. Lock Kit(Already procured)

Pramod

[pramodkumar]

Finally a small sneak peek into what is to come.



In the mean time engine was taken apart

https://youtu.be/Qc9X8La2zUc

Next stop, rebuilding the engine.

Pramod

[lazy]

I too have fond memories of the RXZ.
Belonged to a dear friend, while I had the KB100 RTZ.
We both loved our bikes endlessly and believes our rides is the faster of the two

Anyway, I still have mine, restored it to showroom condition in 2014, did all the work myself except the paint.

cheers

[pramodkumar]

Originally Posted by lazy

I still have mine, restored it to showroom condition in 2014, did all the work myself except the paint.

cheers

Would love to see some pics.

In other news, the rxz engine is almost complete. Here is a quick video of the rebuild.

https://youtu.be/cFDzaRcwDFU

Pramod

[Shubhendra]

Originally Posted by pramodkumar

By then I had acquired all the spares I needed, I had a mint condition chassis, new body panels and other knickknacks needed for the bike.

Hi Pramod,
Restoring an unusual Yamaha is a pain. I am trying to find out Headlight fairing and visor from few months for Purple Yamaha RXZ 135 (5 Speed with disc brakes) and same for Suzuki Shogun (silver color) but i am yet to get lucky.
If you can guide me to the correct person for the same would be great.


Regards,
Shubhendra