[Visaster]

Hello mates,
I have been a passive reader for a long time now, spending an average of half an hour in my busy life in this forum. You bet its such a stress buster to read into what people do to their machines. I believe i am a true petrol head cause being in a workshop is such a stress reliever as long as the work is progressing in expected pace, and not in a spa.

I would like to give a quick history briefer on my journey with the beast.
It all started when i moved to Bangalore in the year 1998.
I was crazy about bikes since childhood be it my dad's Yezdi classic 250, my brothers cycle, my cycle ( Hercules MT B), my brothers Kinetic Honda (batch of the first launch in India), and my Bajaj M80.
It was time to upgrade into a man's machine so i was out checking all the rides. Had narrowed down on 3 bikes - RE 350, Suzuki shogun, Yamaha RX135. Well bullet was out considering its maneuverability in traffic, shogun considering its mileage and so it was YAMAHA RX135 finally. Though it was really difficult to let go of my other two options i settled into my final decision.

I got the approval from my dad after a 3 month long battle even though my close family were playing spoilsport filling in all ideas like. " Have you seen in traffic signals, as soon as the green light is on, the first bike to zoom out will be a Yamaha." Thanks Dad.
So finally the day came (first week of Jan 1999) when i go to the Pacer showroom in infantry road, Bangalore to book the bike. Guess what. Escort Yamaha is on strike and the dealer has no clue as to when the bike will be delivered. I was shocked depressed and all my dreams shattered. The dealer saw my face may be and gave us another option of paying the full amount on that day itself so that its guaranteed that in the first lot of bikes which come from the factory after the strike will have my black beast. It sounded so good but my uncle got skeptical of this suggestion, but i was not gonna give up after all the way i have come, so somehow i convinced him to pay the amount and there i was listed on the top. But then i just could not stop dreaming of me on my dream machine, it got intense with the days passing by. I used to call the dealer everyday and trouble him so much to get the inside details on the strike. And finally after a 3 week wait i got a call from the dealer that my bike has reached and i can come and pick the one i want.
The moment i put the phone down i changed and rushed to the showroom. There stood a lot of rx135s black and maroon through which i walked passed and my eyes focused into this bike which was right in the center guarded by all the other bikes. It was definitely love at first site.
I picked that bike and got the Delivery on the 14th of Feb 1999

Since the day i rode it out of the showroom, we both were inseparable, road trips, cross country, modification jobs, lost n found, what not :-)
Never comfortable with anyone else touching her till date.

So it was meant to be that i would take up this rejuvenation project for it has been with me through the best part of my life.

[(Alok)]

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[adityasiera]

wow..quite a story it is..
I am just done restoring my '96 shogun, and oh boy it feels great to see the admiring glances of curious bikers...feels even great to smoke them on traffic lights..
Now coming to your rx, what state it is in?
what do you plan to do with it(restore or mod)

[Visaster]

This was the pity stage my bike was in after a long train journey from Belgaum to Chennai. (Photos attached)
All parts rusting, Seat torn, Bike starts with quiet a trouble, Stops in between for no reason and makes you exhaust all your energy kicking it back to life, everything was falling apart, indicators broken, what not.

The beast was calling to me. I just could not find the time for it since i got the car for the last 4 years. But finally i could not see what was happening to the symbol of my past. So decided to go ahead and get it refurbished.

The next problem is what do i want to do? Either a rebuild or a modification?
Then looking back at all the modifications i had already done to the beast back in college ( CBZ headlight without the outer fiber, splendor speedometer, yezdi headlight, modified seat, Clear tail lamps, no back rest, Height increase, Shock spring modification, Exhaust alter, and so on ) i realized no matter what its best to go back to stock cause usually all modification starts falling apart hardly in a years time.

So it was going STOCK with my personal touch.

Where to find a decent mechanic who will do the right job, at the right time and to perfection. Having just moved to Chennai it was quiet an ordeal to find one.
Any suggestions of the best mechanic for RX in chennai (in and around Tnagar)

[aargee]

@Hey Visaster - We need to talk - ONLY IF, you're serious about the work. If this is not your primary motorcycle for commute, then, IMHO, DO NOT hand it over to any mechanic. Try to get the job done by yourself, its not that difficult.

How're you planning to get the job done? Change all the parts irrespective of the condition or change only the necessary parts that are worn out?

[Visaster]

Originally Posted by aargee

@Hey Visaster - We need to talk - ONLY IF, you're serious about the work. If this is not your primary motorcycle for commute, then, IMHO, DO NOT hand it over to any mechanic. Try to get the job done by yourself, its not that difficult.

How are you planning to get the job done? Change all the parts irrespective of the condition or change only the necessary parts that are worn out?

Well Aargee, Thanks for the input.
I am pretty serious about the do up.
This is definitely not my primary vehicle for commute
Do it yourself is something i would have thought about back in college but with the same amount of funds now :-)
Time is a big issue for me.
So i wonder how to get this done without the help of any mechanic.
But if you can give me tips on how i can get it done myself then i might consider.
Change all parts is the way to go i think.
Some parts are kinda new already
What about the paint job. Considering getting even the engine painted matt black.

[aargee]

Originally Posted by Visaster

I am pretty serious about the do up.

I actually wanted to post this earlier, but couldn't find it for you.
Here's something that you may want to check out - http://www.team-bhp.com/forum/1930506-post.html and decide what you want to carry out. It has few pros & cons of the common approach.

Originally Posted by Visaster

Time is a big issue for me.

How about a year of time? Do not limit yourself with time; just keep working on every bolt & nut every weekend or everyday (but you'll be able to do this only when you are very passionate). Give a lot of time & DO NOT set an upper bound on time frame to complete. Keep extending as & when you need.

Originally Posted by Visaster

So i wonder how to get this done without the help of any mechanic.

Download Rx100 workshop manual, grab a owner's manual. Start stripping down the parts. If you do not have tools, start collecting them first. You'll mostly need wrenches of sizes 22, 17, 19, 10, 13, 12; star head & flat head screw drivers with long & short length; mechanic pliers & nose plier; plug spanner & having an adjustable wrench with long connector will be fun. Mostly 10, 12, 13 for most of the stuff, 22 for nut castle & front sprockets.

Originally Posted by Visaster

But if you can give me tips on how i can get it done myself then i might consider.

Always my friend

Originally Posted by Visaster

Change all parts is the way to go i think.

Check out my link above

Originally Posted by Visaster

What about the paint job. Considering getting even the engine painted matt black.

That's a huge thing & depend how you want to carry out; basically the older method is to get painted & do a lacquer of 2-3 coats which takes hell a lot of time & patience; newer method is to get painted & do a clear coat which most people do; adding a little gold color will help to beautify.

[Visaster]

Hey aarge,
Your post got me thinking. Why don't i do it myself.
Can you help me with some more queries?
Where do i source the new parts for the bike in Chennai without getting ripped off?
Where is the place i can get the best paint job done?

Dismounting the whole bike should not be a problem with the right tools at hand cause i have done the routine stuff myself back then.
Thanks for the list of tools required have got it written, will mostly get it by the weekend, again do you know where i can get all kind of tools in chennai.

I will like i am blinded in Chennai. Yet to know where is what.

Do you know of any site where i can get the complete list of parts which goes into one RX135?

[aargee]

Here you go - http://www.team-bhp.com/forum/motorb...ual-rx100.html

@Visaster - Most parts are the same between Rx100 & Rx135 except for the cylinder, cylinder head, piston, crankshaft assy. So this will give you a comprehensive list of parts as well as link to workshop manual.

I would always approach YMIS dealers for the parts; even though they sell at MRP, its with the bill & gives a peace of mind that I'm not taken for a ride. Get parts from Sri, Ambal or Paras Yamaha

Paint job, I'm not sure as I haven't got it done; may be some inside of Ambattur Industrial Estate should be of help; not sure though.

For tools, visit either G.P.Road or Parrys.

Edit - Just had an idea; can you get one of those spray cans & get the parts painted by yourself? The cans, IIRC, cost around Rs 400 or so & 2 such cans might paint your bike probably. Works out cheaper & gives immense pleasure & happiness is priceless

[Visaster]

Thanks aargee, i am planning to visit these places over the weekend to get certain tools especially the wrench.
Went through the Yamaha manual, it is an awesome thing to have by hand. Wish i had known such thing exsisted back then when i bought the bike.
I am so in debited to Team Bhp and fellow members for all the information provided in here.

I have worked out on a plan with keeping me and my capabilities in mind. ( suggestions on any changes are very much welcome)

STRIPPING THE BIKE
Find a proper place to do it. ( covered, spacious, well lit and secure )
Park on stable ground
Tools
Multiple medium sized cartons to hold the stripped parts
Waste cloths
All the tools
Anti rust spray
Lubrication can
Grease tin
Petrol can...
Order of removal (my personal choice)
Seat
Wiring under the seat
Back rest with number plate and indicators ( remove all into individual compo )
Back Mud guard
Side guards
Air filter
Battery
Oil can
Empty petrol
Remove carburetor
Petrol tank
Chain guard
Release break
Rear tyre ( break shoe separated )
Find a stool to support the back
Front tyre
Support to hold the front
Speedometer console
Front indicators and headlight

This is as far i am planning to go by this weekend.
I am not comfortable with the engine part so planning to get help of an local machine who has agreed to work on whatever i ask him to and not question me why i am doing what i am doing :-)

[aargee]

Originally Posted by Visaster

Order of removal (my personal choice)
Seat
Wiring under the seat
Back rest with number plate and indicators ( remove all into individual compo )
Back Mud guard
Side guards
Air filter
Battery
Oil can
Empty petrol
Remove carburetor
Petrol tank
Chain guard
Release break
Rear tyre ( break shoe separated )
Find a stool to support the back
Front tyre
Support to hold the front
Speedometer console
Front indicators and headlight

Remember to drain the engine oil before you start any work. Try to keep the wiring part in the end. If you still insist, be careful enough to disconnect the wiring part only for the rear as you've CDI, nothing wrong, but I would be careful not to short circuit anything & blow up the CDI; best thing is to get the entire wiring done after replacing all the parts. Hope you're aware to obtain an OE Minda wiring kit with sockets matching the generator.

Also remember, you may find it extremely difficult to remove the rear fenner without removing the rear wheels; and once you remove both the wheels, it becomes extremely difficult to balance the motorcycle.

My suggestion would be the below, but its upto you discreetion.
- Carb & entire intake manifold (including airfilter box)
- Chain guard, seat, fuel tank (no need to empty the fuel); replace front sprockets, chain
- Rear wheel, change the fenners, swing arm(if required), axles, collars, bushes, suspension, rear handle grips etc & then fix the rear wheel
- Front wheel, change the coneset, fenner, suspension, speedo, pilot lamps, turn lights, head lights, switches, handle bar etc & then fix the front wheel

But my question will be why do you want to remove now? Have you got all the new parts to replace? Simply stripping down will only demotivate you. Just my opinion though.

Originally Posted by Visaster

so planning to get help of an local machine who has agreed to work on whatever i ask him to and not question me why i am doing what i am doing :-)

You're blessed then; be cautious enough to talk to him about the cost before you allow his hands on your vehicle.

[Visaster]

Thanks a lot on that thought, Well i have made a rough list of things i need. I wont be buying it one shot then i will like i am doing a major job and would want to put more time into it and that will just ruin things for me.
So i am gonna take it slow.
Ho i don't think i will get De-motivated.
The main part now is to find a good paint shop. I don't wish to ravel all the way till Avadi or where ever.
But i saw a painter near by my house. Terrible, they are painting open air and then storing the tank in a steel Almira.
All the dust and everything settles on it, and that guy has no remorse on the dirty job he is doing.

Yet to finalize on the paint and sticker.

Want to give the bike my own touch, so its custom painting and stickers.


paint work is the one which is gonna take a toll on my project i think.
I am planning get the whole thing sorted out by December and its gonna make a Pondy run by Christmas.

[Visaster]

Here i go again.
It was a very eventful week.
Got some Tools and borrowed a couple from the neighborhood mechanic.

Started the stripping at about 10:30 in the morning after a superficial wash.
The parts started coming off the bike one after the other.

By lunch i was done with the stuff i could do and the machine came over for the final dismount of the engine from the frame and stuff.

The complete job was done by 5 in the evening.

Took a lot of energy out of me, got me dirty and smelling of petrol and grease, few cuts and bruises...

The bike is no more. All i am left with is multiple parts. Now i have to sit and sort out which parts can be salvaged and what i need to throw away.

Waiting to get the bike back to shape, feels like i have destroyed it.
But for the good, its going to back to prim in few more weeks to go.

[aargee]

Missed your post @Visaster; better late than never

Originally Posted by Visaster

All the dust and everything settles on it, and that guy has no remorse on the dirty job he is doing.

Get it done by yourself or ask your friendly mechanic as where he's getting it done & hand over the job to them.

Originally Posted by Visaster

Want to give the bike my own touch, so its custom painting and stickers.

Way to go!!!

Originally Posted by Visaster

paint work is the one which is gonna take a toll on my project i think.

Well, check for the parts; IMO, waiting for parts are disaster than painting.

Originally Posted by Visaster

I am planning get the whole thing sorted out by December and its gonna make a Pondy run by Christmas.

Good Luck

Originally Posted by Visaster

Got some Tools and borrowed a couple from the neighborhood mechanic.

Man!!! you've gotta good mechanic; who's that guy? May be I should befriend with him

Originally Posted by Visaster

The bike is no more. All i am left with is multiple parts. Now i have to sit and sort out which parts can be salvaged and what i need to throw away.

How about the engine's conditions? Aren't you changing the engine bearings, oil seals, gaskets? I hope it doesn't leak underneath the crank casing

How about the condition on...
1. Front fork & suspension?
2. Wheel bearings?
3. Front & rear fenners?
4. Connecting rod? Did you check the play? If you aren't planning to open up the engine, then don't check this.
5. Swing arm & the bush?
6. Friction & clutch plates?
7. Sprockets & chain?

PS - The engine.bmp is not showing up

[Visaster]

I need to work out all the stuff i need to change, buy, throw by next weekend, so that i can start the shopping and blowing some money.
It seems like a big list already.
I still imagining all the parts i would need externally and writing it down.
I am not sure of all the engine related parts which i need to buy.
Lemme go to the yamaha service centre and torture couple of guys who know about parts required for the rebuild.
Yeah gasket is my main concern.
I just cannot tolerate and leaking or cracks or scratches.

All the way NEW.
Lets see hoe it works out