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Suzuki A100

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Roflhat
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Joined: 29 Jun 2015
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PostPosted: 21:32 - 29 Jun 2015    Post subject: Suzuki A100 Reply with quote

Hi,

new to forum and motorbikes. Just bought my first road bike, a 70's Suzuki A100. I think it's a 73 or 74. It's been off the road since '77 and is a bit rough in places. It has no papers or documents so I'm going to have to look into getting it back on the road. Plan just now is to get it running and registered.
From what I gather these bikes are relatively rare so hopefully I don't need too many parts. I'm used to working on cars and boats, I've recently finished restoring my '68 VW beetle, was a full body off resto which took 4 years.

If anyone has a manual in PDF or otherwise would be greatly appreciated!

Here's a couple photos of the bike as it sits just now:
https://i1013.photobucket.com/albums/af256/Roflhat/IMG_7399.png
https://i1013.photobucket.com/albums/af256/Roflhat/4c8e25fd-954d-43df-ba3a-d066742effc5.png
https://i1013.photobucket.com/albums/af256/Roflhat/00d5d386-c078-46a8-bb24-99a65a663688.png
https://i1013.photobucket.com/albums/af256/Roflhat/cf1cc7d3-e00e-4875-bc8b-dac8ae400d4b.png

I really like the street tracker look, but the bike is growing on me the way it is...
It's lightweight, 83kg dry. I like the idea of a super light bike, so bits might get chopped off.

Cheers,
Seumas
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Val
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PostPosted: 22:32 - 29 Jun 2015    Post subject: Reply with quote

check manuals section for links to many manuals sites:

https://www.bikechatforums.com/viewtopic.php?t=140295

You can at least see parts fishes here:

https://www.cmsnl.com/suzuki-a100-1976-1977-usa_model15914/partslist/
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Roflhat
Borekit Bruiser



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PostPosted: 09:08 - 30 Jun 2015    Post subject: Reply with quote

Val wrote:
check manuals section for links to many manuals sites:

https://www.bikechatforums.com/viewtopic.php?t=140295

You can at least see parts fishes here:

https://www.cmsnl.com/suzuki-a100-1976-1977-usa_model15914/partslist/


That's a brilliant thread, thanks very much!

Managed to find a cheap Haynes manual on ebay for it

cheers
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Matt B
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PostPosted: 11:26 - 30 Jun 2015    Post subject: Re: Suzuki A100 Reply with quote

Roflhat wrote:
I really like the street tracker look, but the bike is growing on me the way it is...


If they are getting rare then 'chopping bits off it' seems like the wrong way to go. Would be nice to see it just returned to standard glory Thumbs Up
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Roflhat
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PostPosted: 12:28 - 30 Jun 2015    Post subject: Re: Suzuki A100 Reply with quote

Matt B wrote:
Roflhat wrote:
I really like the street tracker look, but the bike is growing on me the way it is...


If they are getting rare then 'chopping bits off it' seems like the wrong way to go. Would be nice to see it just returned to standard glory Thumbs Up


Yeh I know what you mean, although some things are rare for the wrong reasons!

Having a look at the wiring today, it didn't come with a key so I'm wiring things to the battery for now to try and get it going. My budget is roughly £0 so hopefully it doesn't need too many parts.
Think I might just wire in a toggle switch as a battery isolator instead of the ignition switch.
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CBFcarl
Nearly there...



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PostPosted: 12:49 - 30 Jun 2015    Post subject: Re: Suzuki A100 Reply with quote

Roflhat wrote:
I've recently finished restoring my '68 VW beetle, was a full body off resto which took 4 years.


Are you gonna stick details of that on the workshop as well?
Sounds funky.
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A100man
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PostPosted: 14:06 - 30 Jun 2015    Post subject: Reply with quote

Nice original model. Whatever you do keep the paintwork/patina. Assuming the tank can still hold fuel.

I would get it running - you'll likley need to renew a few seals
(kickstart, gear-shaft, crank-etc..) and I bet it needs new points. They wear on the cam 'follower' which makes the timing very tricky - then use it.

Not that rare as they were still building them in Asia (Thailand ?) for years after Japan stopped, BUt that is a nice early one. - mine is 1980 and not so nice.

Good luck
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Roflhat
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PostPosted: 15:36 - 30 Jun 2015    Post subject: Re: Suzuki A100 Reply with quote

CBFcarl wrote:
Roflhat wrote:
I've recently finished restoring my '68 VW beetle, was a full body off resto which took 4 years.


Are you gonna stick details of that on the workshop as well?
Sounds funky.


I got it when I was 16, near Glasgow. Towed it back home, it was a lot worse than it looked. Ended up doing a complete body off restoration on it. Every single panel has been welded and repaired. New floorpans, bonnet, boot, bottom 10 inches all round have been repaired.
Here it is when I got it:
https://i1013.photobucket.com/albums/af256/Roflhat/rusty2.jpg

New floorpans in:
https://i1013.photobucket.com/albums/af256/Roflhat/floorpan.jpg

Filler was several inches thick in places:
https://i1013.photobucket.com/albums/af256/Roflhat/rusty1.jpg

All new mounts, seals, bolts, everything:
https://i1013.photobucket.com/albums/af256/Roflhat/gearbox.jpg

Here's some photos of how it looks now:
https://i1013.photobucket.com/albums/af256/Roflhat/1391685_653710524673135_1729313720_n.jpg
https://i1013.photobucket.com/albums/af256/Roflhat/IMG_2787.jpg


Lowered 2.5" all round, wider wheels (5.5") with 195 fronts and 205 rears. Front disc brake conversion, eccentric camber nuts, 19mm front anti roll bar, KYB gas shocks all round, the list goes on!
Recently put a 2.0 VW type 4 engine in it, twin 40 kadron carbs, 009 distributor, full stainless exhaust. Drives really well.
It cost all the money I ever earned so this bike has to stay el cheapo!
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Roflhat
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PostPosted: 15:41 - 30 Jun 2015    Post subject: Reply with quote

A100man wrote:
Nice original model. Whatever you do keep the paintwork/patina. Assuming the tank can still hold fuel.

I would get it running - you'll likley need to renew a few seals
(kickstart, gear-shaft, crank-etc..) and I bet it needs new points. They wear on the cam 'follower' which makes the timing very tricky - then use it.

Not that rare as they were still building them in Asia (Thailand ?) for years after Japan stopped, BUt that is a nice early one. - mine is 1980 and not so nice.

Good luck


Cheers. Yeh I'm a fan of the patina of it, as long as it's solid enough. I might sand the tank down a wee bit and clearcoat it to stop further corrosion.
Do you get electronic ignition conversions for these?

That's good news about them not being too rare, hopefully parts will be cheap. I'm going to get it running before spending any money on it.
I was thinking about a K & N air filter, what do you think? I know on beetles folk recommend sticking with the stock one for longetivety.
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A100man
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PostPosted: 16:13 - 30 Jun 2015    Post subject: Reply with quote

Roflhat wrote:


Cheers. Yeh I'm a fan of the patina of it, as long as it's solid enough. I might sand the tank down a wee bit and clearcoat it to stop further corrosion.
Do you get electronic ignition conversions for these?

That's good news about them not being too rare, hopefully parts will be cheap. I'm going to get it running before spending any money on it.
I was thinking about a K & N air filter, what do you think? I know on beetles folk recommend sticking with the stock one for longetivety.


No electronic ignition that I know of - some wizzo might have made one but I wouldn't bother. I also tried a pod filter clamped directly to the flange on the carb/clutch cover and it made it worse so I wouldn't bother with that either. Got a bit more power by modifying the exhaust port (wider/higher) and trimming the disc valve and jetting up so now good for an indicated 70... if you're patient.

If you really want to get it screaming then get Mick Abbey to take a look at it and make an expansion. I bet he could get 15 hp out of one..(stock is about 9 I think).
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Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600
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Roflhat
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PostPosted: 17:21 - 30 Jun 2015    Post subject: Reply with quote

Alright cool. Glad to hear advice from someone who's been there and done it, saves me money and time!

Modifying it can wait until it's up and running anyhow. Been having some trouble with the wiring. I've removed the ignition switch but I don't know which wires I should attach where. Right now I've put all the wires that were on the ignition (apart from the green one) straight to the positive on the battery and just put and earth from the battery to the frame.
The speedo lights are working, indicators, brake light, headlight all work but when all the wires are attached they're very dim.

When I attach the green wire to the +ve terminal nothing works.

anyone able to point me in the right direction?
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Roflhat
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PostPosted: 21:00 - 30 Jun 2015    Post subject: Reply with quote

NKVD fan wrote:
I used to get bullied when I owned one, had the side panels molested with tippex at college to read gAy100.

Pro tip, the lights and ignition don't run off the battery.

Awful design, the ingest oil through the disc cover and the intake trunk leaks into the gearbox.


Haha unlucky! I might just take the stickers off so that doesn't happen

ah right ok, I was wondering if I could ditch the battery altogether and run the electrics directly off the magneto?
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A100man
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PostPosted: 00:00 - 01 Jul 2015    Post subject: Reply with quote

Don't know if this is correct for your year model. But my wiring diag says for ON postion Red (Battery +6v)connects to orange (neutral light) and green with white (l?) connects to yellow with white (from magneto/generator). OFF position connects black with white to black with yellow..

Black with yellow is direct from the ignition source coil (via contact points ) to coil primary. turning to off position shorts coil primary to gnd in other words. Dont connect B/Y to red !
Leave it open and see if you get a spark at the plug.

I think early models have three gen coils one for ignition source (see above), one for battery charge and one for night running (lights) or something like that. Later models have only two coils one ignition source and one dual purpose with two tappings.

J

PS So no you don't need a battery for it to run.
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Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600
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Roflhat
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PostPosted: 09:22 - 01 Jul 2015    Post subject: Reply with quote

Cheers, I'm going to have a look and see if that makes sense!
I'll take a photo of the wiring
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Roflhat
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PostPosted: 10:29 - 01 Jul 2015    Post subject: Reply with quote

Had another look at it but couldn't match up the wires. Here's the wires from the ignition switch (now removed):
https://i1013.photobucket.com/albums/af256/Roflhat/IMG_7418.jpg

These wires all match up to wires from the harness. Two black wires connect to the solid black wire on the ignition. The black and white wire on the ignition was connected to the -ve battery terminal.

So far I think the orange wire is for the indicators and neutral light and the grey wire is for the headlight and brake light.
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A100man
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PostPosted: 13:38 - 01 Jul 2015    Post subject: Reply with quote

Ok looks like model year differences - that diag I looked at was in the users manual fo 1980 model year. I also have a Haynes somewhere which has older stuff in it..

Suffice to say that I think the ignition circuit should function withou the
ignition switch connected - a bit odd I know.. Did you try for a spark yet ?

J
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Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600
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Roflhat
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PostPosted: 21:27 - 01 Jul 2015    Post subject: Reply with quote

A100man wrote:
Ok looks like model year differences - that diag I looked at was in the users manual fo 1980 model year. I also have a Haynes somewhere which has older stuff in it..

Suffice to say that I think the ignition circuit should function withou the
ignition switch connected - a bit odd I know.. Did you try for a spark yet ?

J


I've ordered a Haynes manual for it, should be here soon hopefully.
Yeh I think it should too, I just need to figure out where to connect the wires. I've tried for a spark with a few combinations of wires with no success. I've also tried a different spark plug, not the right kind but it should still spark if it's wired right.
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Roflhat
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PostPosted: 16:24 - 22 Jul 2015    Post subject: Reply with quote

anyone got a spare ingition barrel kicking about?
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A100man
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PostPosted: 22:56 - 22 Jul 2015    Post subject: Reply with quote

[quote="Roflhat"]anyone got a spare ingition barrel kicking about?[/quote

Sorry no pare ignition barrel but..Did you get it started yet ? A spark ?
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Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600
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Roflhat
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PostPosted: 09:10 - 23 Jul 2015    Post subject: Reply with quote

not yet m'afraid, haven't had a chance to work on it recently. Still need to have a look at the Haynes manual and figure out how to wire it. I think once I've got it started I may splash out on an ignition barrel, just don't want to put money into it until I know it works
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A100man
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PostPosted: 23:00 - 23 Jul 2015    Post subject: Wiring Reply with quote

OK so I found my Haynes and I think wiring diagram to match your ignition.

As suspected you should be able to start it without the ignition barrel in place.

Pos OFF links Black and Black with White (Batt neg/gnd) together - this shorts
ignition source coil to ground. No ignition switch => no short to gnd of the ignition primary..

Pos ON DAY link batt neg to gnd. Black is free to power coil primary. Green (generator coil output - low level) connects to White with red that charges battery via diode rectifier.

Pos ON Night as day but now Yellow (generator coil output - high level) connects
to both White with Red (battery charge) AND Grey (lights).

That's it.

If it's not sparking without the ignition fitted double check points/timing.
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Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600
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Roflhat
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PostPosted: 12:23 - 10 Sep 2015    Post subject: Reply with quote

Sorry havent been on for a while,
thanks for the reply thats really useful, I'll have a go at it this afternoon
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Roflhat
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PostPosted: 18:18 - 10 Sep 2015    Post subject: Reply with quote

That reply was perfect Very Happy
Got a spark after about 15 minutes of fiddling with the wiring.
Cleaned out the tank then poured fuel in it only to find out there was about 100 pin size holes in it... More like a sieve than a fuel tank.
So i got an old lawnmower tank from my Grandpa and strapped that on. Had a go at starting it but no luck. Think I'll take the carb off and clean it.
https://i1013.photobucket.com/albums/af256/Roflhat/IMG_8295%201.jpg
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Papa Lazarou
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PostPosted: 21:01 - 10 Sep 2015    Post subject: Reply with quote

Nice bike.

You'll find various tank sealants around. Some are not so good with modern petrol...
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