Phase-1 build:
This was started in 2nd half of 2016 when I was clearing my excess stock of RX spares (mostly used ones) and I felt I had sufficient spares to build a complete bike and why don't I build the RX100 rather than letting the spares to someone else?
Engine was opened and with no surprise it needed a complete rebuild. We decided to get the bottom end done properly and leave the rebore job for time being (G1 bore was running with 2OS piston and looked to be in decent condition without any seizure)
- Replaced all bearings
- Crank calibrated
- Clutch bell rubber kit replaced
- Gearbox was little abused, luckily I had a spare gearbox in good condition.
I wish I should have tinkered and painted the frame, which we skipped for so many reasons and failed proposals. Only modification done was welded a bracket to fix fork center lock. Started assembling the bike with left out spared from the previous restoration. Earlier for one of the restoration we used the engine side cases from this bike (the one on the original bike had a minor crack on the clutch side and leaking oil) and now I'm living with a not so good engine covers.
Part mix-match: Actuals, belonging to this bike:
- Engine, frame, T-Stem and swing arm
From
here
- Gas Tank (the spare black one)
- Front mud guard
- Rear wheel assembly (including tire, removed after I switched to 16" wheel assembly))
- Wiring harness
- Brake pedal
- Handle bar and switch
From
here
- Lever and yoke
- Kicker
- Foot rest and stand
- RX100 sprockets
From
here
- Meter assembly
- All lamps
- Center lock
- Crash bar
- Clutch and magnet cases
- Chain guard
From many other donor bikes and spares collected
- Mikuni carb
- Old RX100 silencer (excellent beat) and oil pump
- Galdiator front forks and disk brake
- Discover SNS rear shocks
- All cables
- RX135 Coil plate (to match the wiring harness)
- Pillion holder and seat
- Plastic rear mudguard
- Side shields
those 'few' donor bikes along with my trust worthy mechanic. All these were happening at my residence on weekends
![Yamaha RX100 restoration - From bits & pieces-00.jpg](https://www.team-bhp.com/forum/attachments/motorbikes/1622355d1689725049t-yamaha-rx100-restoration-bits-pieces-00.jpg)
About the bikes in above snap,
- RXZ 1997 model, 4 speed, fully restored belong to my friend. He has another 2000 model RX135 4 speed in pristine condition.
- RX135 5s is mine
- Other 2 RX135 in snap were donor bikes. Few spares were used on the subject bike, rest were removed and stored for future use. Made 1 bike out of 2 (along with other spares that we had) and sold it.
- SS125 was purchased for alloy wheels and disk brake (used
here) and carb & few engine spares were used on my friend's 2007 Gladiator, rest is lying.
Tried so many combinations
Gladiator disk brake along with forks
Started assembling the available parts
Engine bottom end is ready with new (used) gearbox, new bearings and calibrated crank assembly
Other bits and pieces
G1 series bore.
Notice the RX135 manifold, it was plugged with some rubber at the bottom, then M-Seal and a plastic cap over it.
Clutch basket with new rubber kit
And this was the final outcome
With this condition I managed to get the documents in order (through agent) and using it in same condition for past 6 months.