New Project 88 XRV650 RD03 Africa Twin

Anything else ya ride!
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Toby Leröhne
Posts: 362
Joined: Sun Jun 07, 2015 9:54 am
Rides:: X/00 C90MT 107cc 4spd, N/96 C90MP, 04 XL125V4 Varadero, 93 NTV650P, 88 XRV650J
Location: Teesside

New Project 88 XRV650 RD03 Africa Twin

Post by Toby Leröhne » Sun Jun 03, 2018 7:53 pm

Wanted an Africa Twin when I take my direct access

Found an 88 Jap import, which means it has H4 headlights instead of the BA20D bulbs the Euro models had, a Speed warning light, and all the warning decals are in japanese.

I bought it as a rolling frame with parts in boxes, unfortunately it has been stored outside, on grass, under a tarp so the rims are unusable as they are corroded from the inside out and splitting at the spoke holes :shock:
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Toby Leröhne
Posts: 362
Joined: Sun Jun 07, 2015 9:54 am
Rides:: X/00 C90MT 107cc 4spd, N/96 C90MP, 04 XL125V4 Varadero, 93 NTV650P, 88 XRV650J
Location: Teesside

Re: New Project 88 XRV650 RD03 Africa Twin

Post by Toby Leröhne » Sun Jun 03, 2018 8:25 pm

I have since put the bike in storage, reassembled it to see what is missing and what needs replacing.
reassembled.jpg
Main issue other than the wheels is the gearbox countershaft splines are stripped, usually caused by over-tightening the chain, using non Honda front sprockets and not using Honda Moly 60 Paste/Molykote G-N paste on the splines.
countershaftsplines.jpg
Thankfully I have found a Honda Bros 400 gearbox with a unworn countershaft, So I'll rebuild the engine with that.

I plan to fit a KKBike Superpinion which uses the whole splined section of the countershaft to reduce the chance of wear.
TAVOLA-1-1024x869.jpg
http://www.kkbikeinternational.com/red-cap-superpinion/
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George
Posts: 1348
Joined: Tue Dec 01, 2009 3:07 pm
Rides:: 2015 NBC110XD Cross Cub; 2000 C90T Super Cub; 1998 C90CWV Super Cub De Luxe.
Location: Royal Leamington Spa, UK

Re: New Project 88 XRV650 RD03 Africa Twin

Post by George » Mon Jun 04, 2018 11:19 am

I know the spline problem very well! Used to deal with a lot of Transalps and even my 700 suffered from the shaft issue. All Transalps and Africa Twins suffered from this spline issue... I am keeping an eye on the CRF1000L to see if it will develop it. Greasing it regularly as it's an expensive fix.

Your AT looks amazing! Apart form the rims, I'm sure it will clean up nicely. Good luck with the build and can wait to see it when it's all done.

:D

Toby Leröhne
Posts: 362
Joined: Sun Jun 07, 2015 9:54 am
Rides:: X/00 C90MT 107cc 4spd, N/96 C90MP, 04 XL125V4 Varadero, 93 NTV650P, 88 XRV650J
Location: Teesside

Re: New Project 88 XRV650 RD03 Africa Twin

Post by Toby Leröhne » Tue Jun 05, 2018 7:23 pm

Haven't tried the electrics yet...
Decided to fit the battery from the C90 e start and turned the key and nothing. Bridged the starter solenoid and it started to crank but no power from the ignition key.

Removed the Speedo and rev counter to access the ignition switch loom connections and they are corroded and snapped.

Looks like I'm going to have to replace a lot of terminals.

Don't have either of my multi meters with me so I'll see if I can get a car battery up here and start testing the wiring and replacing terminals as nessasary.

It has been of the road for at least 17 years.

Bought some Molykote G-N Plus paste for the new countershaft.

Will be handy for the C90 drum brake cams and center stand/brake pivot pin too

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