[Roflhat]

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.

Cheers,
Seumas

 

[Roflhat]

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

 

[Roflhat]

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.

 

[Roflhat]

Needed 3 posts for the photos...

Here's a couple photos of the bike as it sits just now:

 

[Suzukiscottie]

Nice little project! Good luck!


Sent from my iPhone using Tapatalk

 

[Roflhat]

Nice little project! Good luck!

Cheers!

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.

 

[Easy Rider]

Welcome and good luck with your project.

That bike is approaching an age where it might be worth a few bucks as an "antique" collector model.
As such, it might be better in the long run to keep it as near to stock as possible.

But if you think you will be able to resurrect a bike that has not been used in about 40 years on a zero budget........I don't think that's gonna happen; not even close.

 

[Roflhat]

Thanks.

Yeh keeping it stock looks like a decent option just now, works out cheaper too. I know £0 isn't possible, but the cheaper the better.

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?

 

[Roflhat]

Had another look at it but couldn't match up the wires. Here's the wires from the ignition switch (now removed):


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.

 

[Ernest]

nice pics.

 

[Roflhat]

Anyone got a spare ignition barrel kicking about?

 

[phillygoat]

Looks like a fun project. I like the color, is it kinda light orange? I have a '76 a100 that the blinkers do not work. If you happen to find your blinker relay could you tell me where it is located, maybe even a picture? I cannot find one on my bike.

phillygoat

 

[Roflhat]

Hi Phillygoat,
thanks, yeh it is a sort of light metalkic orange. Sure no worries, I'll have a look this afternoon
Cheers

 

[Roflhat]

Heres a photo of the relay (I think)

Top right side

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.

 

[Roflhat]

had a go at starting it today, took the carb apart and cleaned everything, then put it back together.
carb was flooding so I took it apart again and changed the level of the float which solved that. Wouldnt start so I put some oil in the cylinder to raise compression and managed to bump start it down our driveway. Ran for about 100 meters before it ran out of fuel. Took it back to the shed, refuelled but then after a few kicks it seized up.
So I removed the head, removed exhaust then the barrel and took the piston out. The piston was seized in the barrel. Cleaned them all up but the piston has seen better days. The bottom ring is gone and the top one is compressed to the same size as the piston. There's also a chip from the bottom of the piston so I think it's worthwhile replacing the whole lot.

 

[Roflhat]

I put the top end back together today, got the piston assembled and put back on. Made up a new gasket for between the barrel and crankcase, really I should have bought one but the home made one from gasket material worked out very nicely. Also when I took the head off it one of the nuts was completely off and the other three were fairly loose, probably not helping the compression much... Now all done up tight.
Changed the gearbox oil too, the old oil looked very clean but better be safe.
I've marked on the 2 stroke oil tank the level of the oil in it, so I can tell if the oil pump is working after the engine has been running for a while. For now I've put 2 stroke in with the fuel, premixed, at 40:1. Test run hopefully tonight, let me know if there's anything else I should do/check!

 

[Roflhat]

Tried again tonight, wouldn't start so I tried putting some fuel in the cylinder and it would start and then stop. So checked the fuel line and there was a kink in the line just before the carb, sorted that and it started first time!
Took it out just down the road and some off roading, ran really well! I don't think the oil pump is working, the level is the same so I'll run premix fuel for now. It's incredibly slow but incredibly cool 8o)
I was driving it without the cover over the carb, which I've now put on. I noticed it has a rubber gasket around it, so I'm assuming air isn't meant to get in there, so maybe it was running far too lean. I tried starting it again with the cover on and it seemed to idle better, will hopefully try it again tomorrow. Heading down to Glasgow on thursday so won't be working on it until I'm home at Christmas.

 

[QZephyr]

Looks like you're making progress.

 

[Albertus]

Hi Rolfhat. From the tank, it looks like a '73. This thread contains links to cmsnl and cycleparts microfisches: http://www.motorcycleforums.net/forum/mechanics-corner/732-parts-microfiche-2.html. Hope your build goes smoothly. Keep us updated on your progress.


Your build is being featured in the BikeBuilds.net directory here: Roflhat's Suzuki A100 Build.
We’re currently displaying only a reduced-size photo (similar to what you’d find in Google Images).
We'd like to ask for your permission to publish the original full-size image with your build listing.


If anyone would like to have a build of their own listed, just shoot me a PM with a link to the build thread and we’ll take care of the rest.
If you wish to add your build personally, please feel free to peruse our Submit feature. No registrations required.


Admins, kindly delete this post if deemed inappropriate.


Al

 

[Roflhat]

Hi Al,

I'm more than happy to have it featured on bikebuilds. If you want any more details or photos please let me know.

Cheers,
Seumas