Yamaha RX100 Rebuild and Customize Update

somerset420 · Derestricted Danger Joined: 08 Apr 2009 Karma :

Hey all,

Inspired by RXS100_Chris' thread, I've recently begun to strip my 82 RX100.

I bought it from my friend's father about 4 years ago, and it sat behind my house rusting while I served a lengthy off the road sentence for driving waaaaaay too fast on my bigger 4 stroke.

Now, back on the road once again, I felt I needed to show off, instead of 'race off', and had never actually customized a bike before, always just gone for the bolt on exhaust and carb beginners mods. So i figured I'd get right down to it and strip it to the ground.

Unfortunately, at the time of stripping, I didn't have a great camera lying around to snap some shots with, so got a couple with my cell phone.

I do have some pics of the bike together before stripping, but can't find them, so for now Ill just give you the frame and engine shots. and a few of the preliminary spray job pics. Its totally sprayed right now, but the clear coat is taking a while to go up because of the sh*t weather we've been having here.

** PS The backstory to the bike is thus: first owner(s) of the bike were a group of local high school students, who apparently built(rebuilt im assuming) the bike for a class shop project. It then got sold to an older gent who used it as a daily driver, and also happened to stockpile boxes and boxes of parts for it, just for backups. Then got sold to my friends father, who threw out the parts RIGHT before i bought it from him. So I bought a bike, with no handlebar lock, shoddy electrics, drop racing handlebars, and a frayed clutch cable, not to mention the Spray can paint job. This was actually the first bike i learned to ride clutch on, so I had to buy it for nostalgia's sake. Plus its an RX. Who DOESN'T want one of these?? Twisted Evil

So.... First plan:

1. strip and prep the whole bike, plastics, fenders frame tank and all
2. Paint said pieces, hopefully with some awesome colors
3. change front drum brakes, to disc brakes, replace suspension
4. clean up dash instruments and tidy up gauge appearance (simplify)
5. possibly re-bore block a few sizes bigger (its already 2nd stage overbore)
6. tidy up all ports, intake manifold, and exhaust manifold
7. re-work electrics and re-wire for 12v (if i have the energy)
8. assemble bike
9. take it to the local bar and make everyone jealous
____________________
Prev: Honda NSR50 --> TGB Palio 50 --> Yamaha RC100 --> Peugot Speedfight 50 --> 05' Daelim Roadwin 150
Current: 83' Yamaha RX100, 94' Kawasaki AR50
\m/ Drive fast and take lots of chances

somerset420 · Derestricted Danger Joined: 08 Apr 2009 Karma :

So, after looking at the first 4 pics I just posted, and realizing they were crap.... I figured I needed something a little better....

The paint is Sikkens silver basecoat, with some House of Kolors Shimrin Kandy colors on top, and a final sikkens clear.

Im running into problems wiring the bike, as it looks like the last owner did some bush mechanics with the turn signals and grounds. Now i have to sort it out. Neutral

And I can't fully hook it up till the engine is on the bike.... sooo, the final build may be delayed a bit. But its starting to come together!

Got some serious rear shock absorbers for it. I hate the stock ones. And I've sourced a Gianelli exhaust, and also a YY Pang racing exhaust for it. The YY Pang is a high rev pipe, so I'm tempted to go with this, as when I last rode the bike, I seem to remember it being all top end, so that should give things a bit more power. Also, BDK Race engineering does a stainless steel version exhaust, but its bloody expensive. Although..... BDK makes the best aftermarket parts.

Also, got some moto-x handlebars for her. Found these a couple of years back, and thought they were cool, turns out I had the perfect use for them Cool

And, ive found that the stanchions on the disc brake forks I bought for the bike are crap! pitted and rusty as all hell..... soooo, I'll have to use them for now, then take it to my mechanic to swap them out when she finally is road legal. I was thinking of attempting this myself, but I've heard the springs can knock front teeth out if youre not careful.

Anyway, more later!
____________________
Prev: Honda NSR50 --> TGB Palio 50 --> Yamaha RC100 --> Peugot Speedfight 50 --> 05' Daelim Roadwin 150
Current: 83' Yamaha RX100, 94' Kawasaki AR50
\m/ Drive fast and take lots of chances

Andy C · Tree Seeking Missile Joined: 26 Apr 2005 Karma :

the paint looks professional, the colour is different! you get it done professionally/sprayer yourself?

Also, how much those exhaust set you back? Im thinking of getting a RXS100 at some point as when wont have a garage in a year or so will probably set my current bike and just have a little runaround.

How different (if at all) is the RX to the RXS? You got any before pics?

Nice project though Thumbs Up

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99 RS125 --> 02 SV650s --> 03 Speed Four --> 92 RXS100 --> 93 CB400sf --> 01 CB600f Hornet

Andy.B · Two Stroke Sniffer Joined: 03 Mar 2009 Karma :

Nice paint job! Always fancied a go with the candy colours... are they easy to spray or not?
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First bike: NSR 125 (Now being restored)

CBT 28/3/08

ms51ves3 · Super Spammer Joined: 07 Jun 2007 Karma :

Very nice

Keep us updated.

somerset420 · Derestricted Danger Joined: 08 Apr 2009 Karma :

I did all the prep work. Which wasn't perfect, I admit. The paint job was thanks to a friend of mine, who has been spraying for a while, but not professionally. He sprayed outdoors in about 25knots of wind and did a great job. The house of kolors candy didn't like the sikkens base coat, and marbled in a few areas, but only on the extreme edges of the tank and sharp curves that are hard to see. Its also slowing the hardening process of the sikkens clear considerably. But thats what I get for mixing paint brands I guess Rolling Eyes

Going shopping for parts this weekend, my local supplier is supposed to get a shipment in on friday so I should have more pics soon. When the engine goes on I'll post some vids of trial runs. I've had to mess around with the kick start because the gear had 1/3 of the teeth worn off it from aggressive starting. Got it sorted though....

Unfortunately, most local speed shops don't carry much for the RX or RXS anymore. The RX100, to my understanding, has a slightly different cylinder setup to the newer RXS. Not only was the RX100 a front drum brake model, the intake manifold is much smaller, while the exhaust port is bigger. The cylinder bolt pattern is different as well. The RXSpecial block has four bolts holding the cylinder to the bottom half, then four bolts securing the head to the block. While the RX100 has four long shafts that the cylinder block and the head slide down onto, and are secured by long sleeve bolts from the top. The RXS special, was a 135 or 115 block (available all over indonesia as the King RX) sleeved down to a 98cc. The RX100 was a 97 cc but only slightly sleeved so the room for re-boring was diminished signifigantly. There were a few other models in between, but they were all a mixup of the two models. There was an earlier RS100 but that was noticeably different.

The exhausts I've found have been $250 for the Gianelli (2nd hand but never used) and $400 for the YYpang used. I've ridden an Escort 115 with the YYpang on and 24flatslide and been scared for my life. But I couldn't stop riding Twisted Evil

I think the BDK exhaust was around 260pounds or so. My RX came with one of the last of the old school hand made All Speeds, before the company closed, then re-opened later, and started mass production. It needs a little weld job but I'll fix it up and do some trial runs with it.

I've just been offered a 175 engine from a newer RXS100 \m/ maaaan I'm so tempted. Bermuda only allows up to 100cc two strokes and 150cc four strokes, but hey....
____________________
Prev: Honda NSR50 --> TGB Palio 50 --> Yamaha RC100 --> Peugot Speedfight 50 --> 05' Daelim Roadwin 150
Current: 83' Yamaha RX100, 94' Kawasaki AR50
\m/ Drive fast and take lots of chances

somerset420 · Derestricted Danger Joined: 08 Apr 2009 Karma :

So, I've just picked up my inner tubes, after four days of searching for the one shop on the island that has an 18" tube bigger than 3.00

Along with a set of engine gaskets, which were equally hard to find.

Going to attempt to polish/sand/clean up the cooling fins on block and cylinder. also, may get it started! more pics in a few hrs
____________________
Prev: Honda NSR50 --> TGB Palio 50 --> Yamaha RC100 --> Peugot Speedfight 50 --> 05' Daelim Roadwin 150
Current: 83' Yamaha RX100, 94' Kawasaki AR50
\m/ Drive fast and take lots of chances

Gazdaman · I did a trackday!!! Joined: 12 Aug 2004 Karma :

Well impressed! When I first saw the thread, I thought this'll be shite.

But the paintjob looks cracking, love the rear shocks. Now just stick a 500cc 2t MX engine in it, and I may well hump it.

Gaz

somerset420 · Derestricted Danger Joined: 08 Apr 2009 Karma :

ok, so I worked on the bike a bit this afternoon, but didn't get far enough to start it.

First off, I've been digging through my archives trying to find pictures of the bike before stripping. Couldn't find much except these two.

https://img10.imageshack.us/img10/9797/n50026519113374846548.jpg

https://img524.imageshack.us/img524/345/n50026519113374856839.jpg

I know they're not very good. My buddy has a few more pics somewhere but I can't get in touch with him often, so as they come, I will post.

So I took the block and everything off to get a good look at the porting, apparently some work was done before, but upon inspection, not a whole lot had been touched, save for some basic smoothing of some casting flaws. I sharpened the dividers of the transfer ports so there is less turbulence.

https://img399.imageshack.us/img399/9022/moto0346.jpg

This pic is of a new style, RXS100 block (left), next to my old style RX100 block(right). note the thick cylinder liner on the newer block, and the nasty looking dividers between the transfer ports. The dividers on my block looked similar, so after about an hour with the dremel, and a few choice files, it was looking great. I also got rid of all the casting flaws in all the ports, with some metal grinding/polishing dremel bits, and just generally cleaned up all the portways. Also opened up the top of the exhaust port about a quarter to half a mm. Don't worry... I had my copy of A. Graham Bell's Two Stroke Tuning right beside me the whole time. Thumbs Up

https://img411.imageshack.us/img411/5557/moto0350.jpg

RXS100 Reed cage (left) vs my RX100 reed cage (right) Shocked

I know that my bike used to OWN RXS100's every time one of them decided to get boasty and challenge. Twisted Evil

It was always way more peppy and had lots more top end than my mates RXS and his ESCORT (same bike, bigger frame).

https://img13.imageshack.us/img13/2572/moto0353.jpg
The busted engine casing, right around the drain plug bolt. Confused

wtf. When I first discovered it, there was what looked like a single pin from the piston roller bearing wedged into the hole, pinned in by the drain plug, which would've made tightening it a right pain in the a$$. What I'd like to know, is how did the hole get started in the first place, and secondly, didn't the last owner realise that they were having a bit of trouble putting the drain plug in?? I checked my piston bearing and all is well, so it must've been floating around in the oil. Also, I pulled about a quarter ounce worth of metal bits out of the bottom of the engine, most of it non-identifiable, but there was one half C-clip, the other side chewed up I assume. ***where did it all come from?? the rest of the engine looks spotless!**

Now I know that was a crap photo, so before you complain, many apologies. My battery charger for my awesome digital cam has walked off, and I have to use my phone camera until I can afford the $100 for a new charger.

https://img12.imageshack.us/img12/5154/moto0359c.jpg

So at the end of the day, I've managed to clean up all my porting, which should mean a lot smoother running engine overall. Got the side casings on, and the engine mounted. The block is only dry fit right now, as I have to sort out how I'm going to polish the fins, it looks like it has been heat painted before, but it has all oxidised off and looks like crap. Anyone attempted to polish the cooling fins before?

I still have to get the tires on the rims. The tires I have are tubeless, and are stiff as hell, I started to try it myself with rim guards, but quickly said F**k that! when i was about to start chipping paint off left right and center. There is a company about half an hour away that'll use this high tech machine, and get em on without a scratch, guaranteed for $40. Im sold.

So now, that I've figured out how to link images straight into the post, I'll abuse it a little and throw in a few more pics. Enjoy

https://img11.imageshack.us/img11/9355/rxsstainless.jpg
BDK's stainless steel race pipe for 260pounds... looks gorgeous

https://img5.imageshack.us/img5/2924/moto0336.jpg
love the round gauges waaaaaaay better than the square boxes

https://img411.imageshack.us/img411/4565/moto0294.jpg
and one more paint job pic, cause I like it Razz

____________________
Prev: Honda NSR50 --> TGB Palio 50 --> Yamaha RC100 --> Peugot Speedfight 50 --> 05' Daelim Roadwin 150
Current: 83' Yamaha RX100, 94' Kawasaki AR50
\m/ Drive fast and take lots of chances

Andy C · Tree Seeking Missile Joined: 26 Apr 2005 Karma :

Nice project and nice linking the images, such a mission clicking and opening each image (maybe im lazy!)

That pipe is lovely but £260 seems a lot of money!!! Where you pick it up from?

Looking the progress, how much have you/do you expect to spend in this project?

It nice to see someone spending a fair amount as due to the low value of these bikes it doesnt seem to happen much anymore!
____________________
99 RS125 --> 02 SV650s --> 03 Speed Four --> 92 RXS100 --> 93 CB400sf --> 01 CB600f Hornet

somerset420 · Derestricted Danger Joined: 08 Apr 2009 Karma :

Thanks Andy. I haven't actually bought the pipe yet, I posted to see what reaction I'd get, cause yes, that is a lot of money, but over here (in Bermuda) most exhausts cost upwards of $400 because of the amounts people charge to fly/ship them in. Still, its not every day you come across a stainless steel exhaust for an RX.

I think in total so far, with a few small things missing, cause I started buying parts about 3 years ago, and haven't really kept a log... I've spent roughly WOW 2600bucks. I just added it up and surprised myself, lol

I will probably end up spending at least another $500 on the bike as OEM parts prices are through the roof down here, and the difference in cost to ordering from foreign is minimal.

Still need to get new brake pads etc. Electrical components, tires put on rims, and then license and insurance Confused

so I wont be surprised if this thing puts me around the four/four and a half grand mark.

But these days, lots of guys around here are bringing out RXS100's and selling them, as they are not available in the numbers they are elsewhere. And they are all pretty much crap paint jobs and a Nikon/Micron exhaust. Possibly a cylinder kit here or there. Not much else, and the general price tag is $3000 for a new painted/setup rxs.

At least mine will be like no other on the road Twisted Evil

and fast as heck
____________________
Prev: Honda NSR50 --> TGB Palio 50 --> Yamaha RC100 --> Peugot Speedfight 50 --> 05' Daelim Roadwin 150
Current: 83' Yamaha RX100, 94' Kawasaki AR50
\m/ Drive fast and take lots of chances

somerset420 · Derestricted Danger Joined: 08 Apr 2009 Karma :

A little bit further on Smile

https://img11.imageshack.us/img11/2427/moto0363.jpg
my piston! cleaned this up a bit just bacause, but I have a brand new one somewhere for it, so...

https://img10.imageshack.us/img10/1860/moto0364.jpg
Dug out my Allspeed pipe (Bottom, chrome) just to remind myself how thrashed it looks, and put it next to the YYPang race pipe Twisted Evil

....which unfortunately needs a LOT of work before it goes on.

https://img518.imageshack.us/img518/8426/moto0367.jpg

https://img411.imageshack.us/img411/9074/moto0372.jpg
Put a matched pair of these on, just this evening Thumbs Up

And Can finally take it off the box, and put it on the kickstand!(which i just bolted on too. woohoo! got that gangsta lean lol

https://img513.imageshack.us/img513/4061/moto0370.jpg

https://img21.imageshack.us/img21/9848/moto0375.jpg

https://img2.imageshack.us/img2/1008/moto0374.jpg

Just a dry fit, and nothings tightened, just wanted to see looks before I deal with bearings and seals and brake pads.

Having issues getting the rims to seat properly, but got tired, so I will sleep on it and tackle them tomorrow. Thumbs Up

____________________
Prev: Honda NSR50 --> TGB Palio 50 --> Yamaha RC100 --> Peugot Speedfight 50 --> 05' Daelim Roadwin 150
Current: 83' Yamaha RX100, 94' Kawasaki AR50
\m/ Drive fast and take lots of chances

somerset420 · Derestricted Danger Joined: 08 Apr 2009 Karma :

so i've been assembling. and got everything out and hooked up today to try and start her!

https://img6.imageshack.us/img6/8366/bike17.jpg

https://img17.imageshack.us/img17/1024/bike13.jpg

https://img26.imageshack.us/img26/5569/bike7.jpg
Put the Gianelli exhaust on for a bit, just to see how it runs..... when I get it started.

https://img24.imageshack.us/img24/125/bike8j.jpg

https://img150.imageshack.us/img150/3157/bike5h.jpg
everything sittin straight Thumbs Up

https://img10.imageshack.us/img10/222/bike16.jpg

https://img11.imageshack.us/img11/877/bike15.jpg
no brakes..... yet

https://img9.imageshack.us/img9/8859/carb1.jpg
DellOrto24 Thumbs Up

https://img6.imageshack.us/img6/1107/bike1ldp.jpg
thats where it last sat. Im having trouble getting the clutch to engage. as no amount of adjusting this little adjustment screw (controls the push on the clutch pin) will get it to open up.
https://img21.imageshack.us/img21/4125/bike11.jpg
But its probably because the bike sat for like 4 years, tomorrow I'll go hold the cable in, try to pry the plates apart with a screwdriver and get them to move, then oil them up real well.

But silly me, I already filled the bottom half with oil. Sooooo.... now i have to drain it, and do it all over again. yay. Rolling Eyes

____________________
Prev: Honda NSR50 --> TGB Palio 50 --> Yamaha RC100 --> Peugot Speedfight 50 --> 05' Daelim Roadwin 150
Current: 83' Yamaha RX100, 94' Kawasaki AR50
\m/ Drive fast and take lots of chances

Gazdaman · I did a trackday!!! Joined: 12 Aug 2004 Karma :

Yeah if it's sat for a while you need to do exactly what you've said. Whip the plates out, and separate them with a screwdriver. They just gum together after a while.

Gaz

jp14 · Nova Slayer Joined: 06 Feb 2009 Karma :

This is looking awsome!! I'm looking forward to seeing it finished!

What clocks have you put on there? They deffinately are a hell of alot better than the square clunky standard ones.

DM · Scooby Slapper Joined: 16 Oct 2004 Karma :

I can offer some slightly newer pics from the OP. The clutch is apparently still causing him grief despite a new cable and upgrading the springs. He says that sticky plates aren't the issue. The friction plates only had maybe 1000km on them as I replaced them shortly before the bike was sold to him, but I can't recall the condition of the metal plates.

In any case, I've been DYING to get some videos from him of the bike in action but that'll have to wait until the clutch is sorted. I've heard it revving and it definitely sounds, er, aggressive Smile

.

somerset420 · Derestricted Danger Joined: 08 Apr 2009 Karma :

sorry its been so long guys! things have gotten rather busy around here with work and stuff, the summer season is kicked in, I barely have a moment to sit down let alone post pictures.

Hopefully this will make up for some lost time. Short vid of the rebuilt bike, together and running, just down the road from the garage.

I got a flat yesterday. Going to replace the inner tube today, so as soon as its rolling again, I will have much better pics of the completed bike.

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

enjoy.

ps. the camera mic doesn't do that pipe justice. the gianelli has an awesome tinny aluminum two stroke can sound that brings a tear to my eye. more vids shortly
____________________
Prev: Honda NSR50 --> TGB Palio 50 --> Yamaha RC100 --> Peugot Speedfight 50 --> 05' Daelim Roadwin 150
Current: 83' Yamaha RX100, 94' Kawasaki AR50
\m/ Drive fast and take lots of chances

somerset420 · Derestricted Danger Joined: 08 Apr 2009 Karma :

btw i never got the hang of the quote thing

jp14: Those are the stock gauges for this particular model; '82 Yamaha RS100. some models had different square gauges depending on where they were made, or shipped. i've only seen one other RX100 with these round gauges, and its here in Bermuda.

I like them way better than the huge square ones. I was going to replace them with small generic chrome gauges when I first started the rebuild, but looking back now, I should've done more prep on them before I sprayed them, I can still see the scuff marks from the sandpaper if I look hard enough. Rolling Eyes

[/quote]
____________________
Prev: Honda NSR50 --> TGB Palio 50 --> Yamaha RC100 --> Peugot Speedfight 50 --> 05' Daelim Roadwin 150
Current: 83' Yamaha RX100, 94' Kawasaki AR50
\m/ Drive fast and take lots of chances

jp14 · Nova Slayer Joined: 06 Feb 2009 Karma :

Ah right.

I don't see why they would use the square monstrosities instead of the much better looking round ones on later models, I have an '87 RXS100 and that has the square ones on, do you think the round ones would work on an Rxs?

somerset420 · Derestricted Danger Joined: 08 Apr 2009 Karma :

they should do. they are both mechanical driven, although the threaded cable ends for the speedo and tach cables might be slightly different, you should be able to mcguyver them into working.

I switched the forks and front hub on mine, for a newer RXS 100 (probably 96' or so) and I had to change the end of the speedo cable that attached to the hub drive unit.
____________________
Prev: Honda NSR50 --> TGB Palio 50 --> Yamaha RC100 --> Peugot Speedfight 50 --> 05' Daelim Roadwin 150
Current: 83' Yamaha RX100, 94' Kawasaki AR50
\m/ Drive fast and take lots of chances

jp14 · Nova Slayer Joined: 06 Feb 2009 Karma :

Hmm, I might have to try that! Do they have the rev counter as well or do they only have speedos?

CHR15 · Turbo nutter bastard Joined: 14 Jun 2008 Karma :

do you have mot's or anything like that in bermuda? also what about road tax?
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

warped one · Banned Joined: 25 Dec 2007 Karma :

Wow, I remember learning to ride one of these. They are awsome machines, and beutiful to ride around the country side.

Can I make a suggestion, CAFE RACER.
You know you want to.

Cheers

Warped
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amnesia - Never in the history of usernames has one been more accurate. Warped indeed. You sir are a fecking oddball.

somerset420 · Derestricted Danger Joined: 08 Apr 2009 Karma :

ms51ves3 · Super Spammer Joined: 07 Jun 2007 Karma :

That's a Kawasaki AR50 with some knobblies and a different exhaust and mudguard.

Yamaha RX100 Rebuild and Customize *Update*

Yamaha RX100 Rebuild and Customize Update