Asalam O Alykum...!
Eid Mubarak Every One...!
It can't get better to share the sweet story of childhood favorite two wheeler restoration than the occassion of "Meethi Eid" (Eid Ul Fittar 2023).
Indeed this 'restoration project' thing can not be completed without tireless efforts, lots of persuation, decation and un conditional love torward the machine (bike). But there is one more thing apart from all this, i.e., group of like minded people who are ready to help you out happliy. Lucky enough I was already among such people.
Well 1st things 1st
Credits:
Can't thank you enough @imranbhatti (my Bhatti bhai) for love | expert opinions | guidance and support. Special thanks to @vickytulla (Our 'Ustaad').
The mechanic (Muhammad Usman not a Pakwheels member) is a mastero of 2 Strokes (specialist of KAWASAKI GTO). Any body who had issues or struggle with mechnics must give him a chance (Highly recommended).
Chapter 1 - Episode: 1
Don't really remember the time "Jab We 1st met" (somewhere in early 80's) q k tab wo Nau jawan thee aur hum abhi bachay thay.
Aj Hum Jawan Hain aur wo "CLASSIC" category men aa chuki ha.
Being child 'Red' color was my favourite. Lekin iss k LAL rang men to kuch "KHAS" tha aur rahi sahee kasar uss ke awaz (exhaust's sound) ne nikal dee, I fell in love with her at 1st sight.
Humein iss se dur rehney ka kaha geya (coz that toy was not for under 10 (yrs old) kid). My cousin rode me around (in Rawalpindi) on that beauty. Those rides on the zig zag, curvey, uneven, down hill roads (of Rawalpindi) were on another level.
By the time I reached the 'RIGHT' age, the bike was long gone and it was difficult to find a well kept bike in the local market.
We fast forward the story to land in 2013, one day I was surfing the internet when I came across the ad for the sale of "Suzuki TS 100 Trail". Wohi Khas "LAL" rang lekin Years gone by had their effect and impact and she needed proper care. The deal was locked with seller and I became the proud owner.
I believe that a "Classic" should be restored to factory spec (keeping the bike stock). In those days it was relatively difficult to do restoration project as it was not common in Pakistan. Main hurdles included, Time constraints (being a job person), Sourcing OEM (Original Equipment Manufecturer) and NOS (New Old Stock) parts, Finding the right skillful (2 stroke) mechanic.
No to mention we used few part from other Suzuki models that provided better utility than the orignal ones. how ? you will come to know as the thread progresses.
Episode: 2
After a gap of almost one decade, few failed restoration attempts, in between (Thanks to so called ustads and 'expert' mechanics), My passion for 'Cildhood favourite's' restoration was refuled by some vlogs and fellow biker's success stories who completed their projects.
I decided to initiate the project at home and started disassembling bike myself untill it reached to the bare skull (Chassis). At this point the real "adventure" began, which originally was not in my wildest of dreams. Adventure of sourcing the required parts.
Let me clear it, the most painful part of the whole process was not sourcing of parts but the attitude and unhelpful behavior of those who either had those parts or knew from where / how to get them. At time they will ask not the money or gold but an arm or leg or may be a kidney to give you the parts. I know its not uncommon or anything new for those who already have been through the process. As they say, "Shukar Karo Mil raha ha" so, you have no choice but to 'Thank' them instead.
Episode: 3
Engine was the main focus of restoration in stock condition. Although I was told not to touch it and let it be the way it was untill and unless it creates any 'problem' (shows the sign of wear n tear). But My point was jab restoration krni he ha to "HEART" of machne ko kaisy untouch chor don?.
Engine was 1st to be torn apart in redo of the bike.
One of the first (OEM - SGP) parts I got.
Being 2 Stroke the bike had an Oil pump (still needs some case) and Oil bottle was already installed but the old bottle was pale (mobil oil remains), more over the lense was missing, So, from an vetran mechanic of Suzuki in Lahore I got the new bottle, whereas the lens was separately purchased from another source.
petrol Fuel Petcock Shut Off Valve was of some local bike / manufecturer and need the replacement. So, got a new SGP petrol Fuel Petcock Shut Off Valve (one of the very high price product being original).
Now the concern was the cylinder and piston size, bike was already having "50" size piston. But I think luck was on my side,
I got a hand on brand new 2 stroke cylinder from a friend. which added to the joy of restoration.
A "0" Zero size piston was purchased,
This little piece from gear box mechanism took the most of search time. Ultimately it was sourced from another city.
Old clutch box had some wear n tear (one of the teeth was broken), so new Clutch box was mandatory.
Got the pair of new clutch plates (Japani)
Even the gear shifter had one - two teeth (dandey) damaged, so it was changed also.
Mechanic suggested to use the 'CDi magnet' instead of 'Point magnet', so we used CDi of Suzuki GP.
when it comes to bikes, generally, there are two options:
1 - Brand New Engine:
Not available in the market anymore.
2 - Rebuild Engine:
The decision to rebuild engine went well, overall.
Chapter: 2
Purchased some brand new and some used but genuine parts from various local sources e.g., scrap market (Bilal Gunj), including, clutch and brake levers, race, brake, clutch cables.
Tail light fitting was missing when I purchase the bike so got one.
While engine was in rebuild process, Bike frame and other parts were sent for furance paint (Bhathi ka Paint). So that the bike looks fresh n just like new.
Once the paint job was completed, engine was fittied to the frame.
Purchased 2nd hand (kabli) Genuine 150 Shock Absorber as they were the only available socks absorber that were equal in size and better in performance to the already used shock absorbers that were creating issues of leak and wear n tear.
As you can see in the 2ndt picture shared above, previous owner was using 18 X 18 tyre size where as the original specs are 19 X 18 or 21 x 18 for wheel size. So, I bought the 19* rim and then tyre accordingly. Sourcing the tyre was not an issue, actual issue was to source the spokes for 19" tyre (as it is not a common rim / tyre size in the local market).
one of the rods was having leak and rust spots on it, so chnged the rods and Front fork was buffed for shine and fresh look.
Got new pair of shoes.
Installed the tyres on frame.
Found, grabbed immidiately, the rear view mirror (Made in Japanese) in mechanic's workshop.
Mechanic suggested to add new handle grips form Suzuki GP, although, Original Ts Grips were doing fine. His point was the recommended grips are relatively new (although they brand new) and Japan made.
This Clutch side (Left Side) grip comes with a built in "Choke", but we removeed the lever as it was not needed.
Turn Signls - Indicatros of are bit different from all other trail / bikes of this era. So, Originality was the main focus. (Below image is from Web)
By now the bike is in running condition, but I am still finding few original / OEM cosmetics parts to replace the local ones.
One such purchase is this Oil tank Cap.
After a long journey starting back in 2013 - Now is the time for the end Result (Destination)
Had FUN OUTING - 1st Off Road after the completion of bike.
Here is the Finish Product. Still one or two cosmetic parts missing but overall bike is as below:
Very Recent Click after complete Wash post Off Road Outing.
One of Marketing Ads for Suzuki TS100
Thank you all for your Love n positive Feedback is always welcome - - -
