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BikeMaster Rebuild: 1980 Suzuki RM100 – Wiring and Muffler

BikeMaster Rebuild: 1980 Suzuki RM100 – Wiring and Muffler
By Steve Mayes December 14, 2017

During a restoration project such as our RM100 rebuild, you may find yourself installing things sooner than anticipated. Our bike has a front number plate that the throttle cable routes through. Typically, we save the body pieces to install last, but because the carb slide and cable was next in the installation process, we went ahead and installed the front number plate.

We decided to use new aftermarket plastic body parts as the old plastic was in very rough shape. The new plastic is fairly straightforward to mount, needing a few measurements and drilling the mounting holes.

Since we had already installed the front number plate, we went ahead and installed the rear fender. This let us measure where we needed to mount the new muffler. We decided to use the universal two-stroke muffler from FMF. Not only was this muffler time period correct for our RM100, it was also very easy to install as it came with mounting brackets.

The previous owner of the RM100 did some “custom” wiring with the old kill switch, so we went with a BikeMaster O.E.M. Replacement Kill Button (P/N 530603) that plugged right in to the stock wiring harness. This brings our wiring back to O.E.M. standard.

Up next will be restoring the plastic fuel tank and it'll take a lot of elbow grease to take off 37 years of sun and weather. Stay tuned, as we're on the final lap of our RM-100 project!


Throttle cable, carb slide and front number plate installed.


Rear fender and kick starter now in place.


Muffler and bracket ready to go!


Kill switch, front brake cable and side number plate bracket adjusted.


Front fender installed.


Up next: Adding the fuel tank.