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Thread: Restoring Yamaha 100cc (YB100, model:1980)

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    Smile Restoring Yamaha 100cc (YB100, model:1980)

    Hi everyone,

    I have decided to restore my dad's old YB100. It has been lying around in the garage for 10 years or so. I would also like to mention that I have absolute ZERO experience regarding bikes or engines and not even remotely related to those, this is my first ever project.

    PS: Since I am a bit busy with my own projects, the progress on this is going to be a bit slow (probably only weekends). And this project can even fail due my lack of experience !


    OK enough talk, let's get started:

    Original condition: The bike appears to be in a pretty bad shape:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685650134 9507a2cc25 b


    Special thanks: I would like to thank our respected pakwheels member @
    vickytulla (Waqar) for the much needed initial guidance.


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    Quote Originally Posted by hidalgo View Post
    good going . i suppose u not that new to bikes u can do it easily .
    I am totally new to bikes. Just 2 weeks ago @vickytulla (Waqar) told me the difference between head and cylinder !!! I just have a bad habit of doing prior research and googling everything out

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    Quote Originally Posted by fakhir View Post
    I am totally new to bikes. Just 2 weeks ago @vickytulla (Waqar) told me the difference between head and cylinder !!! I just have a bad habit of doing prior research and googling everything out
    we all went through this stage its called learning .0342 5092095 here is my number cntct in person for any help .
    legend will revive soon

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    Quote Originally Posted by hidalgo View Post
    we all went through this stage its called learning .0342 5092095 here is my number cntct in person for any help .
    Sure, thanks a lot

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    Ripping the bike apart

    The first thing I planned to take off was the seat:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684531711 d375f7cece b

    But this proved to be way trickier than I imagined. Apart from being extremely rusty and crumbly, few of the bolts were virtually inaccessible. For example the rear seat mounting bolts which bind the seat to the frame. These are located vertically above the rear indicator light shafts. Due to very little clearance it is extremely difficult to get any decent sized spanner in there and loosen the bolts up:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685649050 27979963d8 b

    Applying some WD40 in order to soften up the rust:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684531577 89a460f3ed b

    Removing relatively easier bolts:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685648872 44dd2a6f51 b

    And I don't know why but I removed the rear shocks because I thought it would give me more clearance to the rear seat bolts. The bike carrier at the back end was also getting in the way, so had to remove that as well:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684531443 96eb308ce0 b

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    Carrier: (I think this is what its called!)

    Restoring Yamaha 100cc (YB100, model:1980) - 8685648432 4ab6997ce1 b

    Closeup shot. As usual huge amount of rust:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684531049 73d913f6b7 b

    Those damn rear seat bolts were driving me crazy. Tilted the bike flat on the ground for better access:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685648404 e7318cb148 b

    Somewhere in there lies the devilish rear seat bolt:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530909 b23025fd61 b

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    After banging my head on the wall for about 2 hours at last the seat is dismounted:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530849 ee0b4ff02d b

    Seat closeup, Rust:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685648284 2d70234e9d b

    The carrier is also off and the bike looks like this: (which in my opinion is pretty cool. I think I should put a much smaller seat):

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530929 2964b0833c b

    Check out the rust at the bottom end of the tank. I think there were a few holes in it as well:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685648216 23a7c8a415 b

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    Showing off the tools again :p

    Restoring Yamaha 100cc (YB100, model:1980) - 8684531765 70e3991860 b


    Very important: Always use an impact screw driver when ever you are opening up exterior engine parts. The impact driver has extremely high torque. It loosens up even really soft and rusty screws easily and without deforming them. If you use the traditional mechanic recipe of normal screw driver and a hammer, you will literally "screw" up all your screws.

    Trying the impact driver on right side of the engine cover. Very soft rusty and deformed screws. Specially after applying WD40 they were as soft as butter. Fear not, impact screw driver to the rescue:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685648998 6f88d97b90 b

    Dismounting chain covers. Loads of rust on the chain:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684531363 cc01427fcd b

    The chain covers are in a very bad shape due to rust. Specially the bottom cover is dissolved from underneath and has huge holes in it:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684531385 d75e38400d b

    Restoring Yamaha 100cc (YB100, model:1980) - 8684531325 590ff4b438 b

    Check out the amount of rust:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685648666 c72b86bb61 b

    Restoring Yamaha 100cc (YB100, model:1980) - 8684531115 05f9a0718d b

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    Rusty chain:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684531209 af39aac2b6 b

    Taking off generator cover:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684531541 8694b8e315 b

    Loads of gunk in there as well:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685648658 a5bdc2fb48 b

    The rear number plate is off. Looks like someone had put a foam for the support lol:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685648516 4d2c26b429 b

    Rear fender is in a real bad shape:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685648420 65d6742d1b b

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    yar its really rust bucket . buy you can make it cool still .and about small seat see this . i did this to my bike once
    Attached Images Attached Images   
    legend will revive soon

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    Quote Originally Posted by fakhir View Post
    I am totally new to bikes. Just 2 weeks ago @vickytulla (Waqar) told me the difference between head and cylinder !!! I just have a bad habit of doing prior research and googling everything out
    That's how I roll. Best of luck and may I say.......Nice camera
    Restoring Yamaha 100cc (YB100, model:1980) - thats how i roll postcard p239281473680155081b21fr 210
    Keep in touch with @vickytulla and @hidalgo.
    Bikes don't leak oil, they mark their territory.

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    Important:
    Always be organised. Put everything separately and if possible, label them:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685648714 c62407e2e6 b

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    i really wish u were in my city so we could do it to gether , there are max options you can do with this bike , restore it modify it what ever u think u can do . see this latest of my bike .
    Attached Images Attached Images   
    legend will revive soon

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    Quote Originally Posted by aximaxim View Post
    That's how I roll. Best of luck and may I say.......Nice camera
    It is just a normal point and shoot camera (canon). I used ISO 100 at minimum aperture opening (I guess 14-ish, and sometimes aperture priority mode), and yes the magic recipe: I used a stand and built-in camera timer to minimize shake and maximize details! Furthermore you need to keep in mind the direction of light and shadow state. Avoid direct sun and hard shadows specially on the front side. In my case sun was not a problem, there was plenty of natural diffuse light for cool photography.

    DO NOT EVER
    use a flash except in rare cases.


    Quote Originally Posted by hidalgo View Post
    i really wish u were in my city so we could do it to gether , there are max options you can do with this bike , restore it modify it what ever u think u can do . see this latest of my bike .

    Are these disk breaks in the front? Pretty cool! Since this is my first project I intend to keep it very simple and just replace original parts. Modifications and advanced stuff like that will have to wait till the 2nd project

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    yes its a disc brk , exhaust n rear suspension is changed as well . nd yes keep it simple bro . its easy
    legend will revive soon

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    I forgot to attach pictures of the lower chain cover:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685647584 d4451d20c4 b

    Taking off fuel c.o.c.k assembly from the fuel tank: (sorry but the annoying automated pakwheel language guard was replacing c.o.c.k with *** . So I had to put dots in between)

    Restoring Yamaha 100cc (YB100, model:1980) - 8685648152 c7a6c76c93 b

    Another view:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530757 025c0b1c57 b

    The tank itself was relatively very easy to dismount:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530549 510bfdc427 b

    Spiders living in the tank LOL :

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530639 600a002b93 b

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530741 dc170db3f2 b

    With the tank and seat off this is how the bike frame looks like. Amazingly there was no visual or rust damage at all on the bike frame. The frame appeared to be in a very good health:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530675 81e4715a50 b

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    In general all over the bike the wiring appears to be totally messed up. It is going to be a nightmare sorting this out:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530669 b7f757447f b

    Opening up right engine cover and draining the oil. Impact screw driver is your friend:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530449 96e31a15c2 b

    Loads of oil came out, given the fact that it is 10 years old. Amazing !

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530451 c8eb4b050e b

    Taking out the carburettor was an absolute nightmare. The rubber pipes providing fuel were as hard as steel which unfortunately had to cut using a sharp knife. As you can see some idiot mechanic had already taken +ve steps towards the destruction of the carb. I don't know what the hell was he thinking at the time:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685647810 a8bba2a122 b

    Back side:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685647854 4fde86f070 b

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    Slacken off clutch cable adjuster locknut to gain better access to the oil pump. Then take out the oil pump as well:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530441 c50257c3bd b

    Detaching gear shift pedal was a nightmare. In order to have better access I had to remove the front footrest assembly. Furthermore the gear change pedal was badly jammed into its splined shaft. I had to strike the spline shaft with quite a bit of force to get the pedal out. In short it was a decent amount of work. As you can probably see the crankcase cover is also damaged:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685647738 96cbbb43c3 b

    Engine underside:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685647736 f52f8db53b b

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    Taking off crankcase cover and exposing the rotor/generator assembly:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685647780 56acf9f69c b

    Closer look at the crankcase cover. It is rusted and fairly damaged from one side:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684530149 2d4c1839b9 b

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    Quote Originally Posted by hidalgo View Post
    yes its a disc brk , exhaust n rear suspension is changed as well . nd yes keep it simple bro . its easy
    Did you modify your bike yourself? I mean installed disk breaks etc? If yes then that is pretty awesome!

    One thing I really like to know is that how the local mechanics or "kharadias" bore the cylinder? Do they actually measure it using micrometer or bore gauge etc? Or do they work mainly on "guesses" ?

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    Rotor assembly closeup. The rotor wheel also has huge amounts of rust on it:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685647510 9161a1f859 b

    View of the drive sprocket. Some wise zen-master mechanic has already tried to mess it up real bad. You can see the damages on the main nut. Also the area surrounding the gear change spline shaft is full of rust and gunk:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685647540 1d182608e7 b

    Air filter, or what's left of it lol:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685643466 e376cf1d0b b

    Another view of the electrical mess:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685647506 a883ffac88 b

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