Team-BHP - Restoration: Renewing my Rajdoot 175 (1972 Model)

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- - Restoration: Renewing my Rajdoot 175 (1972 Model) (https://www.team-bhp.com/forum/post-war/164943-restoration-renewing-my-rajdoot-175-1972-model.html)

As the title suggests, my aim is not merely restoring my RD but to completely renew it(Obviously not the chassis ,tank and other external parts). I wish to renew it with all original parts and preferably manufactured before 1980(As later spares have not so good quality).

It all started in Dec 2013 when I had a discussion with my brother & he told me how dad used to drive us on the bike(I Obviously was very young to remember that) and that it had several other parts like choke lever and a different looking tail lamp (removed by a mechanic in Ranchi in 1993 while overhauling it).

I started searching for the tail lamps on net and stumbled upon a very different looking lamp that said "rare ranger tail lamps", asked about it to my brother and BINGO!!! However it was sold but now I had the pic at least.

I visited Karol Bagh & found that only aftermarket parts were available. Nobody could recognize the tail lamp there.

So, I started searching Internet and found a guy in Prabhani (Maharashtra) who had genuine old stock. I purchased tail lamp lens, gears,shafts,crank repair kit,piston pin, connect ing rod etc of before 80s.

Initially I didn't had intention share all these on internet but the toil I had to make for getting parts, part name and number etc pushed me to help those who are struggling to restore there bike.

I will try to share catalogue pics, part no, part pics, assembly chronology(how to etc). Apart from these I will share my experience on how to identify genuine Rajdoot spares as there are a lot to sellers who sell RD parts packed in genuine looking packing but they themselves don't know that they are just a good copy...a fake..completely.

I intend to post the entire restoration process as it happens and would highly appreciate members esteemed suggestion on how to do things in a better way.

However I am a busy person and may not update my post frequently but will surely try to move to the logical end of this restoration project.
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A BRIEF HISTORY OF RAJDOOT 175
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In 1962, Escorts Ltd. Faridabad bought the license to manufacture "SHL M11" in INDIA under the brand name "RAJDOOT" from Polish company KZWM in Kielce POLAND.

SHL M11 model was an improved version of SHL M06T. Earlier models produced by this motorcycle company were rugged but had weak engines.

SHL M11 was a significant improvements which was both rugged and had a powerful engine providing good cross country performance.

However, it had a low rpm engine, thereby limiting its performance to a certain extent.

This bike was so successful that it was exported to US also which had a thriving motorcycle industry at that time.

KZWM in Kielce POLAND manufactured 1,80,000 bikes between 1961-1968.

In India this bike was manufactured between 1962-2005 and was discontinued because of the limitations of a 2 stroke engine meeting tougher emission norms.

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(In pic) My dad on his Rajdoot 175, Spring 1984
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Parts That I Have Purchased So Far

(ALL SPARE PARTS ARE 100% GENUINE AND MAJORITY ARE OF 80s ERA OR BEFORE)

:Shockked:

1. ENGINE COMPLETE ||111.51.00.00||

1.1 CRANK CASE ::111.56.00.00::
Crank case cover L.H, Crank case L.H, Crank case R.H, Base R. H Crank case, Oil Plug, Sealing housing, Bushing R.H Lay shaft,Bushing L.H Lay shaft , Bearing Crank Case (4X6204), Housing Catch spring, Catch spring, Ball, Clutch disengaging mechanism, Lever ass. clutch release (with screw adjusting and ball), Oil Seal complete, Stud, Gasket crank case, Screw complete set, Drain plug, Crankcase (shim, sleeve spacing, sleeve centring, circlips, washer thrust, Lock washer etc. ), Cable grommet L.T & H.T., Sleeve spacing.
1.2 CYLINDER BLOCK ::111.52.00.00::
Cylinder,Stud and de-carbonising kit, Cylinder Head, gasket carburettor link, Link carburettor, bracket link, gasket carburettor, Spark Plug.
1.3 CRANK SHAFT ::111.54.00.00::
Crank shaft assembly, crank plate, Bushing- connecting rod, Connecting rod, Bearing (small end & big end)-Connecting rod, key woodruff, Sprocket, Shaft L.H & R.H, Crank pin, Nut, Tab Washer.
1.4 PISTON ::111.53.00.00::
Piston, Piston Rings, Pin-Gudgeon, Circlip
1.5 CLUTCH ::111.57.00.00::
Drum assembly- Clutch, Gear- kick starter, Chain Primary, Clutch plates (Driven disk, disk inner friction, disc assembly- clutch driving), Spring- Gear kick starter, Cup washer, Lock, Bush, Push rods, ball, Nut- Castellated & Disc ass. thrust, Pressure plate, Nut- Mainshaft, Cup- Securing, Spring- Clutch, Housing Spring, Hub Clutch.
1.6 MAIN SHAFT ::111.58.00.00::
Main Shaft, Slide Gear (22T), Ring Spacing, Driving gear (22T), Bush- Driving gear (22T), Bush spacing, Driving Sprocket, Nut- Driving Sprocket, Seal- Dust.
1.7 KICK STARTER ::111.61.00.00::
Lever- Kick starter ass.(lever Kick starter, lever arm, sleeve rubber, Screw, Spring, Ball ), Plate- thrust, Spring- Kick Starter, Segment toothed- Kick Starter, Lever Shaft- Kick Starter.
1.8 LAY SHAFT ::111.59.00.00::
Spur Gear (35T), Gear (28T), Gear (19T), Lay Shaft
1.9 SPEED CHANGE MECHANISM ::111.60.00.00::
Foot Lever- speed Change, Pad- speed Change lever, Shaft- Speed Change, Dog Assembly- Speed Change lever, Spring- Speed Change lever, Housing- Spring, Slide- Piece, Spring, Lever- Speed Change, Lever bracket- Speed Change

2. DYNAMO MAGNETO ||111.62.00.00||

Stator Assembly, Coil assembly- Ignition (6v), Coil assembly- Lighting & charging, Condenser, Pad Assembly- Lubricating, Contact breaker point assembly, Plug wire (Cable high tension, cap spark plug terminal, spark plug terminal), Fly wheel Magneto

3. ELECTRICAL EQUIPMENT GENERAL ||111.30.00.00||

Wiring Harness, Fuse wire, Horn Dipper switch, Switch assembly break light, Junction block assembly

4. HEAD LIGHT ||112.28.00.00||

Head light ass. complete (Bezel, reflector complete, reflector clamp,bulb, holder, spring locking bulb holder), Master switch assembly, key ignition, grommet.

5. TAIL LIGHT ||112.29.00.00||

Lens gasket(OE), Tail light ass.(OE), Lens complete(OE), complete set(fake/after market)

6. Speedometer ||111.25.00.00||

Speedometer Assembly [Autometers, Ge and YankaY(OE)], speedometer cable

7. FRONT FORK WITH SWINGING FORK ||111.02.00.00||

Swinging fork front, Bush with cover, Bush pin, Race and bearing set, Nut- fork stem, Nut-upper shelf ass.

8. FRONT SHOCK ABSORBER ||111.03.00.00||

Front shock absorbers

9. WHEEL FRONT ||111.04.00.00||

Bearings, Cap ass.- wheel hub front, Hub ass. wheel- front, Cover wheel hub complete, Axle, Cam expander, Lever ass., Spring break shoe, Break shoe, Spoke and nipple, Bush ass. Spacing.

10. WHEEL REAR ||111.05.00.00|| & BREAK REAR WHEEL ||111.17.00.00||

Hub assembly- Rear wheel, Cover Hub with pin, Axle, Torque damper assembly and Casing torque damper, Hub, Hub nut and bolt, Stabilizer, Bush sprocket hub, Holder chain guard, Sprocket, Chain secondary, Cam expander, lever cam expander, Break shoe spring, Break shoe, Worm ass. (Driven gear, Driving gear, sleeve fixed , washer,Screw thrust, sleeve sliding, Pin slide, Spring slide pin, Ring dog), Spokes and Nipple set[36 PCs; 168-170~ mm without head; 173-175~ mm with head; Spoke thread 10 mm; Nipple 20~ mm (Nipple thread 10 mm)], Bush ass.- Spacing.

11. CHAIN GUARD ASSEMBLY ||111.06.00.00||

Guard assembly top & bottom, Shield Top & bottom- Engine, Plug Chain guard.

12. BREAK REAR WHEEL ||111.17.00.00||

Pedal assembly brake, Lever brake,Spring- brake return, Rod brake ass.(Brake rod, sleeve, spring, barrel, nut- brake adjusting)

13. SWINGING FORK REAR ||111.22.00.00||

Bushing rubber, Bushing spacing, Chain tensioner L.H & R.H, Nut chain tensioner L.H & R.H,Axle- rear swinging fork, Outer- Bush, Bush

14. SHOCK ABSORBER REAR ||111.21.00.00||

Shock absorber assembly complete

15. FUEL TANK ||111.07.00.00||

Cap assembly- Fuel tank, Fuel cock- complete, Fuel filter

16. CARBURETOR MIKUNI / MIKCARB ||112.65.00.00||

Carburetor Mikcarb- Complete, Fuel Cup, spring, Float, Gasket

17. INLET SYSTEM ||111.14.00.00||

Connector rubber, Filtering element- Air cleaner

18. EXHAUST SYSTEM ||111.13.00.00||

Silencer assembly, Pipe- Exhaust, Gasket- Exhaust pipe, Clamp- Exhaust pipe fixing, Clamp complete- Exhaust-pipe.

19. SIDE SHIELD ASSMBLY ||111.10.00.00||

Knob screw assembly, Nut connecting rod, Nut-clamp, Rajdoot name plate

20. CENTRAL STAND ||111.20.00.00||

Central stand, Spring, Bolt- Foot rest, Hook- L.H & R.H[/left]

21. BRACKET ASSEMBLY REAR ||111.01.11.00||

Bracket- Assembly rear, Bush spacing, Bolt

22. Handle Bar ||111.19.00.03||

Air control (Lever, cover, washer, spring washer, body), Twist grip assembly, Clutch Lever assembly, Brake lever assembly, Screw adjusting, Yoke clutch lever, Yoke brake lever, Handlebar clamp L.H & R.H & insert.

23. SADDLE ASSEMBLY (non original)

Saddle assembly (Saddle plate, Bolster-Saddle, Upholstery-saddle, Strap Assembly)

24. Detailed Wiring Diagram & Master Switch Wiring Setup

:I Rule:

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::::PICTURES OF ABOVE PARTS WILL BE UPLOADED IN CHRONOLOGICAL ORDER::::
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::Camera resolution:: 13 mega pixel::

Old parts that will be reused:-
1. Chassis
2. Tank
3. Handlebar
4. Headlight dome
5. Side sheilds
6. Mud guard rear and front
7. Rear swing arm
6. Front forks
7. Rear number plate
8. Air filter box
9. Footrest
10. Front crash/leg guard
11. Rear saree guard

Modification:-

I am installing new MICKARB carburetor which has choke lever fixed on its manifold. I have old rajdoot175 so it had a choke lever.

The mechanic who in 1993 overhauled my bike removed the choke lever and PEGAZ carburetor.

I wanted to restore the old look so a radical idea came in my mind to design, fabricate and install a custom part that could enable handlebar choke installation.
Thereby retaining the original looks.

Although I feel its criminal to modify a Vintage but I did this modification due to two reasons:-

1. To make this bike look closer to how it was when my father brought it home for the first time.
2. I had an option of purchasing PEGAZ carburetor but decided against it as it had issues with cold starting and was not so environment friendly(low mileage)

:I Rule:

Speacial thanks to dealers who sold me parts, without them my bike would have become a Junk:-

Vishal kumar (Prabhani, no doubt, the most honest and helpful person I interacted with in 1.5 years of search for parts)

Dipak Solanki (passionate about Rajdoot)

Pryank Dubey (Honest, cool guy, has very rare spares, don't know from where he dig them out..and a great person by heart)

Shanu Singh (Had Patience for 1 year, extremely soft spoken)

Honey Saxena (Huge contact, go to man when you fail to find rare item)

Prem Verma- sold me many genuine spares.

Anand S - He sold me some original spares.

Kaarthik M Swamy (My friend - nothing more nothing less)

Mr. Yogesh Karlo- He sold me some very rare items. Has his own workshop in Bangaluru, an expert in old bikes. Humble and helpful person.

Shri Sushil Gajbhiye ji- He is a very humble, truthful and helping person, for me he had to travel miles to search parts and he never complained. He really helped me in getting some very rare items. He is really very close to me, he values relationship more than anything, thats the essence of a true bike lover. He is a czar when it comes to old bikes especially JAWA and YEZDI, he has successfully installed CDI kit on JAWA and YEDI. Really an awesome person.

Shri Aziz Dayawan Ji- He calls me chota bhai and his love reflects in his voice. We came to know each other via a facebook forum were I posted link of this page for helping someone, he picked it from there and then we started talking. He told me how his father also used to drive his SHL M11 with a cigrette just like my dad is doing in the introductory picture. He sent me some really rare parts and refused take money for that. Just like me he values relationship rather than money. Truly an honest, truthful and a person of high integrity.

Imran Fulta- Great person, sells all kinds of bike stuffs and before sellig clearly states wheather it is Original or aftermarket. Honest person and a good friend. Keeps asking me for my bike pictures, enquires on how the restoration is going. Great person.

1. Engine Complete ||111.51.00.00||

1.1 Crank Case ::111.56.00.00::

Crank case cover L.H, Crank case L.H, Crank case R.H, Base R. H Crank case, Oil Plug, Sealing housing, Bushing R.H Layshaft,Bushing L.H Layshaft , Bearing Crank Case (4X6204), Housing Catch spring, Catch spring, Ball, Clutch disengaging mechanism, Lever ass. clutch release (wirh screw adjusting and ball), Oil Seal complete, Stud, Gasket crank case, Screw complete set, Drain plug, Crankcase (shim, sleeve spacing, sleeve centring, circlips, washer thrust, Lock washer etc. ), Cable grommet L.T & H.T., Sleeve spacing.

1.2 CYLINDER BLOCK ::111.52.00.00::

Cylinder,Stud and de-carbonising kit, Cylinder Head, gasket carburettor link, Link carburettor, bracket link, gasket carburettor, Spark Plug.

1.3 CRANK SHAFT ::111.54.00.00::

Crank shaft assembly, crank plate, Bushing- connecting rod, Connecting rod, Bearing (small end & big end)-Connecting rod, key woodruff, Sprocket, Shaft L.H & R.H, Crank pin, Nut, Tab Washer.

1.4 PISTON ::111.53.00.00::

Piston, Piston Rings, Pin-Gudgeon, Circlip

1.5 CLUTCH ::111.57.00.00::

Drum assembly- Clutch, Gear- kick starter, Chain Primary, Clutch plates (Driven disk, disk inner friction, disc assembly- clutch driving), Spring- Gear kick starter, Cup washer, Lock, Bush, Push rods, ball, Nut- Castellated & Disc ass. thrust, Pressure plate, Nut- Mainshaft, Cup- Securing, Spring- Clutch, Housing Spring, Hub Clutch.

1.6 MAIN SHAFT ::11.58.00.00::

Main Shaft, Slide Gear (22T), Ring Spacing, Driving gear (28T), Bush- Driving gear (28T), Bush spacing, Driving Sprocket, Nut- Driving Sprocket, Seal- Dust.

1.7 KICK STARTER ::11.61.00.00::

Lever- Kick starter ass.(lever Kick starter, lever arm, sleeve rubber, Screw, Spring, Ball ), Plate- thrust, Spring- Kick Starter, Segment toothed- Kick Starter, Lever Shaft- Kick Starter.

1.8 LAY SHAFT ::11.59.00.00::

Spur Gear (35T), Gear (28T), Gear (19T), Lay Shaft

1.9 SPEED CHANGE MECHANISM ::111.60.00.00::

Foot Lever- speed Change, Pad- speed Change lever, Shaft- Speed Change, Dog Assembly- Speed Change lever, Spring- Speed Change lever, Housing- Spring, Slide- Piece, Spring, Lever- Speed Change, Lever bracket- Speed Change

2. DYNAMO MAGNETO ||11.62.00.00||