OVERLAND - maintenance program -

[goodwoodweirdo]

Hi folks,

I have a '92 65,000 km RDO4 which is running very well, I've only had the bike for a few months and want to start a maintenance program for a long trip next year. Apart from the obvious what else should I check eg timing chains, bearings, compression maybe, chassis corrosion ? clean and drain the tank. I'll replace the water hoses but don't plan on dismantling the engine for items like oil pump.

Am I right in saying RD04 don't suffer from fuel pump problems?

Is there a common spot for the chassis to crack when overlanding fully loaded ?


Kind regards
Matt

[chronyx]

Can't advise but I think this will be an interesting thread once the AT gurus post up their knowledge.

[Hagrid]

Agreed Chronyx...

Gurus Go... I could do with knowing this to )

[Shep]

ATGreg has an RD04 in Australia with 280,000KM on the clock and a lot of that in the outback on dirt roads. I would not bother to do anything apart from

Spare regulator/rectifier - this is the weak point
Fuel pump- They go but it does not seem as widespread as the later RD07

Look at Headstock, wheel and swingarm bearings replace if neccasry

Check radiators and hoses

Check the choke mechnism carefully as these can jam on and the bike will then at best run terribly at worse not at all. Read Wheelies thread about this on his RD04.

Then just give it all a very thorough clean and checkover. Also check the consumables Tyres, Chains, sprockets, brake pads, air filter, definetly give it an Oil and filter change THIS IS ALLWAYS THE MOST IMPORTANT, check the tappetts i doubt they will need doing and spark plugs

It may also be worth thoroughly checking your rims for corrosion, and brake calipers and throttle and clutch cables and brake lines

Frames are good as are timing chains, hope this helps, pistons/rings and heads and cylinders are bulletproof as is the crank as long as you run it with oil !!!!

KEEP IT SIMPLE

[GSPD750]

ATGreg has an RD04 in Australia with 280,000KM on the clock and a lot of that in the outback on dirt roads. I would not bother to do anything apart from
KEEP IT SIMPLE

Good post Ceri. You summed it up nicely. Having just split the cases on my '99 AT (63,000 kms) for a knackered output shaft bearing I then put everything back together after having done absolutley nothing else to the engine. It was obvious that the previous owner did all the scheduled oil changes, which is probably most important maintenance of all for the longevity.

Even my piston ring end gap was still within the standard limits and not even close to the service limit. Their was also evidence of cross hatch in the cylinders from the origonal hone.
Honda has impressed me with the guts of this bike.

[Shep]

one BIG thing to watch CHAIN TENSION. It should be hanging, if it is too tight and with the long travel suspension it is easy to do, it will wreck rear wheel and sprocket bearings and the output shaft and output shaft bearing.

Thats a serious rebuild GSPD you have got guts !!! i noticed frm the pics how clean the motor was internally. I am positive that regular oil and filter changes are 95% of keeping a motor going a long time. I allways change and never skimp here.

[piguglyshandydrinker]

Hi folks,

I have a '92 65,000 km RDO4 which is running very well, I've only had the bike for a few months and want to start a maintenance program for a long trip next year. Apart from the obvious what else should I check eg timing chains, bearings, compression maybe, chassis corrosion ? clean and drain the tank. I'll replace the water hoses but don't plan on dismantling the engine for items like oil pump.

Am I right in saying RD04 don't suffer from fuel pump problems?

Is there a common spot for the chassis to crack when overlanding fully loaded ?


Kind regards
Matt

If you are heading off on a big trip next year it gives you plenty of time to get a "feel" for what's right and what needs attention, sure, stuff like C&S, bearings and cables need a thorough check.

I wouldn't touch the motor unless it really need's it.

Don't fix what ain't broke.

Phil

[Dilbert]

Replacing the hoses is probably a good idea they may not need it, but rubber and time do not have a good relationship, for the same reason I would check out all the electrical components these are what has caused me most problems; just due to age and neglect ( the bikes, but the same could be said of me ).
If the engine is making any untoward noises then yes have a poke around (camchains, bearings, etc) but I suggest you check the tappets, change the oil and balance the carbs first, these are the things that usually worry people unnecessarily.

[Muckybill]

Like shep said a spare regulator/rectifier. I had three go on a RD04.
I fitted a bigger heat sink and it solved the problem.

Bill

[anton88]

Something i've read a couple of times is the rear shock absorber.

Especially if your going to be loading up the bike with extra weight and doing any off roading.

If you dont know if its been replaced or re-built, budget for a replacement or re-build before you go, as you dont want this to collapse in the middle of nowhere

Ant.