2003 complete restauration

[GoldPower]

Hello everyone, first I must tell you that I am newbe in this 1800 forum. I already did two complete 1500 restoration and I prepare to do the same with a 1800 next spring. It is a new to me 2003 with 176000km (110000ml) on the clock.I wonder if others here in this class have already done that. I will also need advice on the parts that I will have to replace for a good restoration. I will have to remove all the parts for them installed on another chassis (cause frame issue). I would like to replace the parts that need maintenance. Other tips would be helpful to improved the comfort and handling of a 2003. )
Thank you in advance
Joce

[AZgl1800]

??

I have a 2002 with 114,000 miles that runs like it just rolled off the showroom floor.

what is it, that needs "Restoration" ?

something that is just cosmetic I presume?

[GoldPower]

Az1800 as i said on my post ,i have the replace the frame so i want to rebuilt the entire bike with new parts like fork seal, wheel bearing,o,ring,all fluids ect ect... and cosmetic to .

[AZgl1800]

Az1800 as i said on my post ,i have the replace the frame so i want to rebuilt the entire bike with new parts like fork seal, wheel bearing,o,ring,all fluids ect ect... and cosmetic to .

I think you need to review your 1st post, you never said you replaced the frame.
you mentioned replacing items with new parts, and I asked why?

[MikeB]

Az1800 as i said on my post ,i have the replace the frame so i want to rebuilt the entire bike with new parts like fork seal, wheel bearing,o,ring,all fluids ect ect... and cosmetic to .

I think you need to review your 1st post, you never said you replaced the frame.
you mentioned replacing items with new parts, and I asked why?

Actually, he did say that there was a frame issue.

Hello everyone, first I must tell you that I am newbe in this 1800 forum. I already did two complete 1500 restoration and I prepare to do the same with a 1800 next spring. It is a new to me 2003 with 176000km (110000ml) on the clock.I wonder if others here in this class have already done that. I will also need advice on the parts that I will have to replace for a good restoration. I will have to remove all the parts for them installed on another chassis (cause frame issue). I would like to replace the parts that need maintenance. Other tips would be helpful to improved the comfort and handling of a 2003. )
Thank you in advance
Joce

[GoldPower]

Azgl1800 sorry for what I said. My english is not perfect and I use translator to explain my request .

[GoldWingrGreg]

Many of your parts still have good life left in them. On the other hand, certain parts are known to fail. For example, you might want to replace the final drive unit. Another is the drive shaft. Since the engine is out, you might consider replacing the alternator drive gear. I can also tell you that pulling an old stiff wire harness through the frame's cross sections is certainly do-able, but be aware that there 5th gen Wings have many crimps hidden in their harness, and transferring an old stiff harness can cause problems with those crimps.

[GoldPower]

Thank you GoldWingrGreg for the advices !!! It's appreciated

[2003Cobra]

Just out of curiosity, Since I have a 2003, what is wrong with your frame? I just read a thread where someone has a 2003 and it was cracked in a couple of places. I just want to be pro-active if it is a problem with the 5th gen bikes. Thanks

[GoldPower]

Hi 2003cobra. This is a new to me 1800. There is a recall for that problem. 2001-2004 are included in this recall. But the previous owner had a hitch on the bike and mother Honda don’t want to pass it on warranty. So he sold it to me very cheap..

[keithg64]

Since your going to have the engine out I would seriously look into the alternator drive gear replacement. The 01-05 had that issue as well as the frame braking issue, but I believe you have to split the case to do it.

[2003Cobra]

Thanks Goldpower, I just had that whole area apart installing an air filter and a new CB. But I will keep my eye on it. Good luck on your restoration.

[Techdude2000]

Hi 2003cobra. This is a new to me 1800. There is a recall for that problem. 2001-2004 are included in this recall. But the previous owner had a hitch on the bike and mother Honda don’t want to pass it on warranty. So he sold it to me very cheap..

The recall for the frame issues never included these small tube fractures, only the lower crossmember welds and joints. Honda won’t do anything about them, hitch or no hitch. Good luck with your rebuild.

[Butty]

I have a 2007 GL1800 and have just covered 80,000 miles of quite hard riding in the U.K. and Europe. The following are the main parts replaced and approx failure mileages. All the best with your renovation. Peter Butterworth.
Rear brake disc 50k: Oxygen sensor 60k: Heated grips 65k (when one grip fails seat heater also ceases until a new set is fitted): New battery 65k (planned maintenance) New Satnav LCD display panel, ouch!!! 68k: New alternator 70k: Front fork seals and race head bearings tightened 76k:

All the above are obviously in addition to the regular service items. The bike is oil and filter changed every 4,000 miles. It was fitted with too many 'fairy lights' and 'permanently on' headlights, together with generous use of the seat heaters; which might account for the alternator change.

[GoldWingrGreg]

Az1800 as i said on my post ,i have the replace the frame so i want to rebuilt the entire bike with new parts like fork seal, wheel bearing,o,ring,all fluids ect ect... and cosmetic to .

The main harness is littered with crimps positioned on the inside of the harness. Over time some crimps go bad. You might consider replacing the main harness, too. Once your engine is removed, and the back tire and rear inner fender, it will be a lot easier to pull the harness through the frame. However, in doing so, any crimp that is on its way to going bad, may. Harnesses that are old, and have taken a particular shape over time, don't like to be reshaped as they get pulled thru a small area. Also, the harnesses are still available.

[pocketchange]

Hi 2003cobra. This is a new to me 1800. There is a recall for that problem. 2001-2004 are included in this recall. But the previous owner had a hitch on the bike and mother Honda don’t want to pass it on warranty. So he sold it to me very cheap..

The recall for the frame issues never included these small tube fractures, only the lower crossmember welds and joints. Honda won’t do anything about them, hitch or no hitch. Good luck with your rebuild.

Yep, the weld failed, and you decide to change frames(?) Damn.. why not simply re-weld the broken weld? pc

[GoldPower]

Hi 2003cobra. This is a new to me 1800. There is a recall for that problem. 2001-2004 are included in this recall. But the previous owner had a hitch on the bike and mother Honda don’t want to pass it on warranty. So he sold it to me very cheap..

The recall for the frame issues never included these small tube fractures, only the lower crossmember welds and joints. Honda won’t do anything about them, hitch or no hitch. Good luck with your rebuild.

Yep, the weld failed, and you decide to change frames(?) Damn.. why not simply re-weld the broken weld? pc

Yes Pocketchange, that's what i'm gonna do .
Thank you

[Techdude2000]

The recall for the frame issues never included these small tube fractures, only the lower crossmember welds and joints. Honda won’t do anything about them, hitch or no hitch. Good luck with your rebuild.

Yep, the weld failed, and you decide to change frames(?) Damn.. why not simply re-weld the broken weld? pc

Yes Pocketchange, that's what i'm gonna do .
Thank you

The problem is the thinness of the tubing and the short gusset it’s welded into. The frames were changed starting with the very late built 04s by adding a longer gusset and an extra plate on the bottom of the tubes on both sides near the passenger footrests.

[MikeB]

Yes Pocketchange, that's what i'm gonna do .
Thank you

Which is probably the best idea if you intend to keep the machine. Looking at the pictures it appears that the material failed and not the welds.