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Discussion Starter #1
Hi all,

Started the rebuild process last week at last! Thought I would start a tread about it as I do like to read a good rebuild post and happy to receive any suggestions that go along with it. Happy with my progress so far but I think this is going to take a long time before it's back on the road. So far i've got the engine mostly rebuilt following a stage 1 tuning kit which included boring out to 779cc, new pistons and cams reground. This has gone back in the freshly powder coated frame without to much hassle and i'm now in the process of fitting the engine covers back on. Also got new swing arm bearings and linkage bearings installed after a bit of a fight with them and fitted a new Nitron rear shock. All going well so far only one injury as I trapped my little finger in the swingarm and it's now in the process of turning purple. I'm also cleaning up a few bits that I forgot to send to the powder coaters such as the casing for the starter motor and the back part of the water pump. I'm cleaning up and painting the rads too. I bought a used set as my original ones looked like riverdance has been performed on the fins, they aren't perfect but managed to pick them up for £50 hopefully they will come up nice.

This sort of carries on from my tread about getting the engine out https://www.xrv.org.uk/forums/africa-twin/164594-rd07a-engine-removal-wtf.html

It begins - frame powdercoated by Maldon powdercoating
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Refitting the cylinders and new pistons
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Got the engine back in at last
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Replacing as many of the engine bolts as I can with stainless ones and a good coating of corrosion block grease
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Swing arm is back on
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Progress so far
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Hopefully make a bit more progress next week:toothy8:
 

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I see something very good soon coming out of this ;-) tell us about the front suspension... ;-)
 

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I see something very good soon coming out of this <img src="http://www.xrv.org.uk/forums/images/smilies/icon_wink.gif" border="0" alt="" title="Wink" class="inlineimg" /> tell us about the front suspension... <img src="http://www.xrv.org.uk/forums/images/smilies/icon_wink.gif" border="0" alt="" title="Wink" class="inlineimg" />
Thanks Massive Lee I got WP's from a 950 adv going on. I still need to service them with new seals and respring but just put the legs on tonight to see how they look.
 

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Hi
Looking good so far. Interested in your build l also have a 98 RD07 7A and will be starting a strip down shortly, being my first @ and rebuild this will be valuable information for the future
Cheers
 

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Discussion Starter #6
Got a set off ebay for the normal m6/m5 etc, for the frame bolts I got them from westfield fasteners.
 

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Discussion Starter #8
Managed to make a bit of progress this week :). Most of the loom is now back in place. The coil packs are back in, starter motor is sprayed rebuilt and fitted. Final coat of paint on the rads, water pump sprayed and fitted along with a good clean of the hoses and replacing the straighter ones with some silicone hoses and new clips. Got the rads fitted and checked the water system for leaks - all seems good (y) Carbs are back on after a full rebuild and some cerakote. New lithium ion battery fitted to and even got the back wheel on for a little preview of what it will look like. Unfortunately after having a look at the tank it's a bit of a mess the in-tank filter seem to have melted and there's enough rust in there to completely block the flow even with the petcock totally removed. This only highlights the importance of draining the tank if bike is not being used :rolleyes:. Does anyone know a good way to get the tank clean inside?

Here's some pics
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Discussion Starter #10
Anyone know if this looks like all the parts for the rear master cylinder? Looks like theres another seal in the parts drawing but I don't seem to have it.
164534
 

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Discussion Starter #11
Got the brake hooked up in the end, turned out i'd lost the correct spring :unsure: few more photos of the build attached. I got the fairing fitted to see what she'll look like it's starting to take shape now
 

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Discussion Starter #13
Got the Koso in place. Just need to finish the wiring now but so far so good.
164586


The magura clutch seems to be working well. Not tried it with the engine running yet as I got no fuel due to the lockdown. But it seems to be pulling enough to allow me to turn the wheel when in gear.(y)


164587
 

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Never even thought about an hydraulic clutch I bet you are pleased with the progress on you bike keep us all up to date and looking forward to the rest of your posts and hope to see it one day thanks for posting
 
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