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A beginner's guide to motorcyle restoration

7th May 2021, 15:56 by Chirag Moro

I myself did a couple of Pulsar restorations for close friends who didn't want to part with the bike for some sentimental values.

BHPian Mr.Boss recently shared this with other enthusiasts.

Starting this thread based on a couple of request from members outside this forum and for the benefit of our fellow members and readers.

Disclaimer:

I'm not an expert in restoration, sharing this content based on my learnings from the past and inputs from fellow members (inside & outside this forum)
Further inputs, suggestions, improvements, corrections, critics from anyone is always welcome
Most important disclaimer: I don't hold any responsibility if you end up spoiling your machine by following these steps If at all anything fails, let's celebrate the failure together

I enjoyed the way another thread on a similar subject was put.

Decision
Preparation
Execution
Finishing

Decision

Follow the simple 5W2H analysis

What?
Why?
When?
Where?
Who?
How?
How much?

Starting with What?

The obvious answer is Restoration but the indirect question is whether to restore or not?

2 cases here:

Classic / vintage: Answer is 'YES' straight away if one has time, money and patience
Regular commuter still in production: YES, only if there is any sentimental attachments. Otherwise buying a new one makes sense

I myself did a couple of Pulsar restorations for close friends who didn't want to part with the bike for some sentimental values. And both the bikes are immaculately maintained and used until now. Details here.

Next comes Why?

It depends on the need. Very few go for a mechanical restoration to keep the machine on duty and most of the restorations I come across (including my own bikes) are not daily driven machine, restored just for the passion, love and lust towards the machine and kept as garage queens (my first RX covered 12,000 km post-restoration in 7 years).

Let's touch the How? portion before going for the other 2 W's

The most easiest as well the toughest part is here, making the right decision

Complete restoration or partial?
One go or in steps?

This question is mostly answered as an outcome of previous question. Also depends on the condition of the machine and ability to spend (sometimes based on the part and labor availability).

My first bike (Blue RX135 ) was done in steps:

Got the bike, used for a year
Understood the issues, areas to be addressed
Started with the tires, brakes and repaired the engine (re-bored to next oversize)
Cosmetic upgrade, full strip down restoration
Brakes upgrade (Front disc brake)
Transmission upgrade (5-speed gearbox)
Further cosmetic / functional changes (16" rear wheel, rear shocks)

Details here.

This being my 2nd RX (1st one stayed with me for a very short duration), I learnt from my mistakes and were taken care from the 2nd bike onwards.

2nd RX was not in a running condition when I purchased it, so I was left with no other option except to strip down immediately and do a full restoration. Details here.

My suggestion for how to proceed is:

Get used to the bike before stripping down, understand the issues and areas which need a change / repair / improvement and then proceed for restoration
Prioritize: Give importance to the mechanicals than the cosmetic upgrade

Next comes the other portion of How?

100% left to the mechanic
Partial supervision & direction
Jointly with mechanic
100% DIY

It depends mostly on an individual's knowledge, ability to spend time and energy. I started with the 3rd option (FYI, my first RX restoration was the very first RX my mechanic worked on and stripped down. Our gentlemen agreement was, he has to do whatever I say and I take full responsibility if anything goes wrong) and once I got enough trust in the mechanic's outcome, I moved to 2nd option (after 7+ years, one of my RX is getting restored without my presence).

How much?

How much can we spend? This is the most influential and deciding factor for any repair / restoration work. It doesn't mean the quality can be compromised for a lower budget. For any budget constraints, split the restoration in steps and prioritize the mechanical job over the cosmetic upgrade.

Where?

Find the right resource (then the expert one) who could put all his effort and is passionate on the job rather than someone trying to mint money. Restoration is not like regular repair (especially when it comes to classic and vintage bikes). It needs a lot of attention & dedication otherwise we may end up with V2.0 or V infinity.

In case of DIY, find a dedicated place where you can work peacefully and without disturbing others at home. Otherwise, be prepared to get poisoned on the next meal

This was the condition of guest bedroom, hope you can understand the reaction from my better half:

When?

Right time for restoration is always "Now" or "ASAP" or "Immediately". After all, we are petrol heads and can't resist ourselves when it comes to cars and bikes. But depends mostly on the other preparation items:

Once what, why & how portion is clear
Detailed check on parts and fund availability is confirmed
Labor (mechanic, painter, etc.) availability (in case of DIY, tools availability)
Avoid summer and rainy season

My mechanic was kind enough to spend most of the Sundays at my home (opening the garage will have too many distractions):