New AT owner! Rebuild, photo alert!



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  1. #1
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    New AT owner! Rebuild, photo alert!

    I finally found me an Africa Twin! Two months ago I bought this 1996 RD07A model Twin, it's not the best looking bike as it is a bit worn, rusty and tired. I'm now busy with a full rebuild and i'm hoping to drive it again in the spring of 2017. I started with the rebuild a month ago so thats why the tons of photos.














    Cockpitframe with complete wire loom, needs some repairs.






    Found a burned voltage regulator/alternator plug




    Broken crashbars, will be welded and painted.




    Removing the engine







    Bare frame








    Starting with the engine. To mission is painting the engine, replacing the countershaft, and checking all the parts for condition and cleanliness.






    Starter clutch still ok.






    Removing the camshafts, gears, clutch, gear shift mechanism, oil pump. Next step is splitting the engine cases.






    Camshaft chains




    Removing the valves from the heads




    Exhaust valve not looking good (white marks from fuel seeping through during leak test)






    Both exhaust valves




    Intake valves and guides looking good




    Front cil exhaust valve, allready lapped this valve a bit




    Rear exhaust valve not looking very good






    Lapped the valves and seats. Installed valves and leak checked with fuel in the head, still full after aprox 6 hours.






    Splitted the engine to replace the countershaft and bearing.











    Crankshaft bearings













    Replacing the countershaft













    What does this code mean?




    Some smudge on the oil pump filter, seems normal as compared with other rebuilds.








    Much better




    Rebuilding the engine


















    Manually checking the gears, offcourse did this before installing the heads.





    All bolts, nuts, springs, tools, rings etc etc have been plated by GTO Plating in Veenendaal.





    Sorting it all out, fun job




    Rebuilding the starter motor
















    Prepped the frame and swingarm and dropped it off with some other loose parts at Waayenberg Coatings in Barneveld. Should be finished after new years.
















    Upgraded the cockpit with a oil press meter and a over- and under voltage warning light from eBay. It's green when voltage is normal and will flash more red and faster when the voltage becomes higher or lower than the max allowed minimums. Also gave the cockpit a good cleanup.












    The warning light will look like this










    The thingy on the left is a USB charger with voltmeter








    Rebuilded the front forks with new seals, bushings and 10W oil .
















    Planning to buy a jack-up kit from Kitped






    Also started with the rims. Fortunately not much corrosion, just a small spot around the tire valve hole wich I reworked








    Sanded down





    Small spots seem to look like corrosion






    Professionally build stand to paint the rims





    Will be polished




    Rebuild the battery tray

    Last edited by Turbinerepair; 03-01-17 at 09:08 AM.

  2. The Following 11 Users Say Thank You to Turbinerepair For This Useful Post:

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  4. #2
    BobA is offline xRv PiMp ;-)
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    Re: New AT owner! Rebuild, photo alert!

    Looking great.

    I wish I had the workshop facilities you have I'm currently rebuilding my old RD04 in the hallway of my house!!

    Bob
    http://ukrp.musicradio.com/gold/live


    Cheap and reliable won't be fast...

    Fast and cheap won't be reliable...
    Fast and reliable won't be cheap...


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    Jammytask is offline Senior Member
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    Re: New AT owner! Rebuild, photo alert!

    You're making a great job of that so far, keep the pictures coming.
    Chris

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    thetimkirby is offline Senior Member
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    Re: New AT owner! Rebuild, photo alert!

    Quote Originally Posted by BobA View Post
    Looking great.

    I wish I had the workshop facilities you have I'm currently rebuilding my old RD04 in the hallway of my house!!

    Bob
    Yeah, but you've got carpet and central heating in your workshop. And I bet it's not far to the fridge...

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    Re: New AT owner! Rebuild, photo alert!

    fantastic that is some great work.. really enjoying the thread and happy new year!!!

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    Re: New AT owner! Rebuild, photo alert!

    Thanks guys! It's a fun job so that makes it much easier.

    On the last day of 2016 I polished the sideplates of the bashplate. I still have to polish the middle plate.


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    Re: New AT owner! Rebuild, photo alert!

    That's going to be one great bike when it's finished.
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    Re: New AT owner! Rebuild, photo alert!

    Great photos, what did you paint the engine cases and forks with?
    2000 - VTR SP1
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    Re: New AT owner! Rebuild, photo alert!

    Great work there keep it coming thanks

    Sent from my GT-I9195I using Tapatalk

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    Re: New AT owner! Rebuild, photo alert!

    Quote Originally Posted by Jeff Kirby View Post
    Great photos, what did you paint the engine cases and forks with?
    Hi, I used VHT paint, supposed to be heat resistant and designed for NASA . A bit overdone for the forks, but I heard this paint is tougher than normal paint. I had to bake the forks, pizza tasted a bit weird . Engine paint will be 'baked' when the it is running (if it will ever run ).


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