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Discussion Starter #1 (Edited)
RD03 Rebuild

New to here, just bought my first big bike to rebuild and restore while I take my direct access.

an E-Reg 88 Jap import RD03 Africa Twin. Needs a bit of work, back rim is badly corroded so bought a Transalp 650 wheel to replace it. Frame could do with powdercoating and it need a new countershaft and lots of bits replacing, battery, cables, tyres, ect and servicing.

It has no exhaust silencer, but has the down pipes so I'm going to have to find or get a link pipe fabricated. I have a couple of Delkevic 350 oval slip ons, a titanium one and a stainless steel one.

I have a XL125V-4 Varadero I bought as spares and repairs and fixed up as my workhorse, needed something a bit more powerful for rallies, camping and touring., I also have a couple of C90's, one I have restored and the other could do with a bit of tlc, I bought it to use whilst rebuilding the first 90 I bought after the cam chain snapped after using it for a week.
 

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New to here, just bought my first big bike to restore while I take my direct access.

an E-Reg 88 Jap import RD03 Africa Twin. Needs a bit of work, back rim is badly corroded so bought a Transalp 650 wheel to replace it. Frame could do with powdercoating and it need a new countershaft and lots of bits replacing, battery, cables, tyres, ect and servicing.

it has no exhaust silencer, but has the down pipes so I'm going to have to find or get a link pipe fabricated. I have a couple of Delkevic 350 oval slip ons, a titanium one and a stainless steel one.

I have a XL125V-4 Varadero I bought as spares and repairs and fixed up as my workhorse, needed something a bit more powerful for rallies, camping and touring., I also have a couple of C90's, one I have restored and the other could do with a bit of tlc, I bought it to use whilst rebuilding the first 90 I bought after the cam chain snapped after using it for a week.

Great news !
Show is some photos :)


89 HRC Africa Twin 650
 

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Discussion Starter #3
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She's been off the road for about 17 years, its an early Japanese spec model with the speed warning light, matching frame and engine numbers on a E reg.

It's going to take a while to rebuild but should be worth it, wanted to save it from being broken for spares. It hasn't got an exhaust silencer or handguards, everything else seems to be there though.
 

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This is great news, we all love a restoration thread!

Please feel free to post pics etc of every little detail:thumbup:
 

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This is mine I just bought from the sheep (member on here)

I'm not doing a full resto yet just all the jobs to make it road worthy, then I'm going to use it.

It's a 88 Italian model. tapatalk_1521308054540.jpeg

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Brilliant !
Just what that bike deserves. Sounds like we've got a few RD03 restoration threads to look forward to ...
 

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Discussion Starter #7
Started putting it together just to see what is there and what is missing.

Most of the loom and pipes are labeled ��

Trial fitted a FH011AA voltage regulator from a R1 but the cooling fins are too long to fit under the seat.

Have a fake FH020AA regulator which fits so I'll get a genuine one.
I'll wire the stator directly to the regulator and the regulator to the battery with a 30a maxi fuse in a sealed holder.
Thinking that will leave the stock loom connector for accessories like heated grips, sat nav, din power socket and auxiliary lighting.
 

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Discussion Starter #9
Think I've found a countershaft...
The NT400 (Bros) uses the same bearings, thrust washers, circlip, oil seal, sprocket and retainer as the RD03
Bought a complete gearbox with a good output/countershaft from a Bros 400 for the rebuild for £85, need a gasket kit and bearings.
I'll fit new bearings and oil seal.

Would I be better going for a new Honda sprocket and retainer and using Loctite bearing fit on the sprocket or fitting a KK Bike Red Cap Sprocket or a Steffter sprocket?
 

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I wonder if the shaft in an NT650 is the same?
 

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Discussion Starter #11 (Edited)
I wonder if the shaft in an NT650 is the same?
Would have thought so, I did think about what a supermoto'd shaft drive RD03 would be like using the output shaft, driveshaft and single sided swingarm from the NTV, but I'd rather keep it original if possible.

Need to go and pick up my gearbox today, if Argos is open.
GearboxBros400vsXRV650RD03.jpg
Left gearbox is the Honda Bros 400, right RD03

Front brake caliper is seized, front disc is bent so its shaped like the rim of a dinner plate, the pads are worn to a angle to match the bend.

Thankfully a few bikes have the same left hand two piston Nissin caliper.

I need new wheels as the rims are corroded, the rear is cracked round the valve.

I bought a Transalp 650 rear wheel that was a little pitted, but when I unwrapped it its badly corroded internally at the valve stem hole the metal has buckled due to the corrosion and the aluminium has separated into layers. need to get in touch with the guy who sold it to me described it as "The wheel has no cracks and is structurally solid and ready to use." also the bearings are shot.

The radiators are slightly corroded where the rubber seal sits on the outside edge, I'll get some aluminium ones instead.

found a 10mm allen key and removed the generator cover center cap, and the outer sparkplugs and lightly turned the crankshaft with a 17mm socket, the engine isn't seized :p

Bought some hand guards off a RD02 Dominator, I like they have Honda on them and I wanted used as they will go with the bikes other parts.
I'm going for a used look to the bike rather than showroom fresh.
dominatorguardsmall.jpg
 

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Joined and subscribed :) Will be very interesting to follow as I'll be taking a similar route with mine next winter :)


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Discussion Starter #13 (Edited)
V5 arrived, while I was down in South Wales, so I can now start to work on the bike.

First task is the engine strip and rebuild with the Bros400 gearbox counter/output shaft.

I have the gaskets, I'll buy bearings and seals as I strip it down and replace them.

Unfortunately my little Varadero didn't like the trip to Wales, I blew the fork seals on the level one trail at the Touratech Travel Event and then about a mile from home it started spluttering and cutting out like it had ran out of fuel but I should have had about 10 miles left in the tank according to the GPS. She isn't running right, coughing, spluttering and backfiring. some have suggested head gasket. I'm hoping it is a fuel issue, I changed carbs and rubbers but the carbs I fitted are unknown. The carbs removed are quite dirty so I'll clean and refit. got a Bluepoint Compression recorder Press800 digital compression gauge coming, along with a Laser Vacuum/Pressure tester/brake bleeder which will be handy for testing the compression/leak down and the carbs and PAIR system.

Unfortunately until the little Varadero is fixed I won't be doing much to the RD03 as I am reduced to busses, unless I can find the V5 for my Honda 90 and get it MOT'd and Taxed.
 

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Discussion Starter #15
Re: RD03 Rebuild

I've been looking out for one myself. Think I'm going to have to get a custom rack, or modify another rack.


I need something Givi PL/Kappa KL Monokey compatible, as I have Kappa K-Venture KVE37A Aluminium Panniers that match the Givi Trekker Outback OBK58A Top Box on my little Varadero that I want to use on the RD03.
varderolugage.jpg


I have seen one rack on ebay but it doesn't look that strong to me and doesn't have a brace between the racks so when the bike falls over its probably going to bend the rack.


MMoto make "Whole-welded rack systems" which look nice and strong. They list a rack for the RD07,
mmrack.jpg
Whole-welded luggage rack system for Honda XRV750 Africa Twin.
They don't list a rack for the RD03 or RD04 but they do make custom racks, so that might be an option.


I considered the Givi Wingrack system but I don't think my K-Venture panniers would fit, the lower mounts are designed to go round a tubular frame and I don't want to cut or grind the plastic lugs off.

The upper mount uses the same bracket as the Givi Trekker Dolomiti DLM36A panniers which doesn't look like it will fit the Wingrack.
 

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I can ride all day.
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Discussion Starter #18
Re: RD03 Rebuild

Heavy Duties rack does fit the RD03 but I'd rather used the cases I already own. I've started fitting a Givi monokey plate which is handy for front end servicing as you can put some stuff in the top box to counterbalance the rear end to lift the front wheel off the ground on the center stand.

I've done that a few times on the varadero for front end fork, wheel, and brake servicing.

This is the only rack I've round so far...

650monokeyrack.JPG
https://www.ebay.co.uk/itm/Africa-twin-650-rd03-porta-valigie-portavaligie-88-89-hands-suitcases-Maletas/272288143326?hash=item3f65a357de:g:iEAAAOSwubRXILUJ
 

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Re: RD03 Rebuild

Ok when out for a longer run about 40 miles. And the bike did a strange thing.
I slowly lost the neutral light. Then the bike would only start with the clutch lever in. ??

Just been out to it after a hour and all back to normal.

I had this before on my rd07 with the dieode going.

Dose the rd03 have one? Or any other ideas

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