YB100 Restore : 1980 model (100cc) :)

[fakhir]

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, this is my first ever project.

OK enough with the intro, let's get started:

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

[fakhir]

Another angle:

Yet another view:

Looks like it was a heaven for spiders:

[fakhir]

Cleaning the bike. There was loads of gunk and dried out mud underneath the engine. Probably that resulted in huge amount of rust.

Lesson: Always clean off dirt and mud from your bike frequently.

I used soap and some scrubbing brushes. Majority of the gunk is gone. Only very tough patches still remain under the engine which I plan to remove later. Bike looking a lot better now:

[fakhir]

Bought some tools:

Damage inspection

Time to do a close damage inspection. Battery acid appears to have damaged the side cover:

Battery acid is probably spilled every where. Huge amount of rust everywhere:

Chain cover is full of rust:

Odo meter is in a bad shape. Flasher covers are broken, bulbs probably fused:

Right side of the engine: Rusty, soft and deformed screws. It is going to be a total nightmare while opening these up:

[Airhead]

What chance have you of getting this done in Pakistan fakhir?, here in UK we have lots of enthusiasts, ebay and internet forums...what have you got?

[fakhir]

Right side of the bike:

Some major damage in the rear fender:

Rear view, some more rusty parts, broken components:

Dents in the tank:

And loads of rust at the rear end of the fuel tank. There are probably some holes as well:

Gear shift pedal appears to be deformed:

Getting battery out of the bay:

Rectifier mounting plate has almost disintegrated:

Mouse droppings LOL. Looks like the mouse has been chewing wires and battery container, explaining acid leakage:

Electrical system is a total mess:

[fakhir]

What chance have you of getting this done in Pakistan fakhir?, here in UK we have lots of enthusiasts, ebay and internet forums...what have you got?

Well I certainly don't have advanced tools but I've got determination and will power . I won't be able to order brand new original parts but I am doing this project for learning. I think i will be able to repair existing parts and get the bike in running condition. I do have access to internet forums!

[Airhead]

Determination and will power...well I guess without them you would have no chance....Good luck with it

[fakhir]

Determination and will power...well I guess without them you would have no chance....Good luck with it

Thanks

[fakhir]

Spark plug seems to be in healthy condition. There are no oil, deposits or erosion on the electrodes, probably hinting that the engine was also in healthy condition (but let's see). By the way before taking out the plug or the battery I tried to start the bike (10-15 kicks) and there was absolutely no spark in the plug electrodes.

[fakhir]

More broken parts:

[slice]

Stick with it Fakhir, strip it down and remember label/photo of everything as you go, bits get moved and mixed up so make it easier for yourself from the start. What can't be repaired can be replaced but try to keep as much as possible, surface rust can be taken off with wet and dry and new paint will make it pop, take one job at a time that way you wont be overwhelmed by looking at it as a whole, good luck mate let us know how your doing.

[Sacha]

Cool project bike! Looks like a pressed frame. ? Might be interesting trying to fix the battery compartment where it's rusted out. ? Keep the progress photos coming.

[fakhir]

Stick with it Fakhir, strip it down and remember label/photo of everything as you go, bits get moved and mixed up so make it easier for yourself from the start. What can't be repaired can be replaced but try to keep as much as possible, surface rust can be taken off with wet and dry and new paint will make it pop, take one job at a time that way you wont be overwhelmed by looking at it as a whole, good luck mate let us know how your doing.

Thanks a lot . Yes I am labelling everything and trying to be as organised as much as possible.

Cool project bike! Looks like a pressed frame. ? Might be interesting trying to fix the battery compartment where it's rusted out. ? Keep the progress photos coming.

Thanks . As soon as I disassemble everything, specially the engine, after that I will concentrate on the frame and stuff.

[fakhir]

Ripping the bike apart

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



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:



Applying some WD40 in order to soften up the rust:



Removing relatively easier bolts:



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:

[fakhir]

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



Closeup shot. As usual huge amount of rust:



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



Somewhere in there lies the devilish rear seat bolt:

[fakhir]

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



Seat closeup, Rust:



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):



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

[fakhir]

Showing off the tools again




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:



Dismounting chain covers. Loads of rust on the chain:



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:





Check out the amount of rust:

[fakhir]

Rusty chain:



Taking off generator cover:



Loads of gunk in there as well:



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



Rear fender is in a real bad shape:

[fakhir]

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