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Hi Everyone, We (my dad and I) brought a written off Rebel a month back, so during the rebuild process i figured i would post here for anyone interested.

We managed to get it for 2500 NZD (1800 USD) so we have a bit of room for new replacement parts+repairs. My Dad builds Vintage replica motorcycles for a living so the know how is all there, and we have various contacts in the motorbike world who will be performing frame/fork straightening for us. . we feel confident we can get it back on the road pretty quick smart.

here is the current damage as it stands

Bent frame
Bent Forks (Straightened)
Bent front axle (straightened)
Bent radiator
Bent/Dented Left rear Shock (straightened But new replacement ordered)
punctured thermostat housing
bent handle bars (oem replacement in hand)
totaled throttle grip assembly (oem replacement in hand)
Snapped right mirror (oem replacement in hand)
punctured front brake line
Bent swing arm
Bent rear mudguard brackets (straightened and repaired)
Dented Fuel tank
cracked headlight surround

this bike is actually for my Mum who is wanting to get back into riding, the 500 ticked all the boxes - low seat height, abs brakes, awesome handling, strong 500 motor. . and to top it off, Honda reliability. New they are 11k, if we can get this back on the road for less than 5 we will be happy campers! at this point that goal looks easily achievable (fingers crossed) especially with the insanely low cost of Honda replacement parts

Ill try keep this post updated, but it wont be a daily thing.

Take a look at the pics of how it stood at the warehouse:)
 

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Jesus, did someone throw that bike off a cliff?! Holy moly!
I would venture a guess that most motorcycle wrecks that don't occur on a track or in a parking lot are pretty brutal and exposed to a lot of substantial forces.

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Just curious, how much would it have been to buy a new one? Or possibly even a used one? It seems with the amount of damage the price would get pretty near those prices, after repairs.
In the USA if something is Salvage you actually have to get an additional inspection before it is allowed back on the road as well.
 

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Just curious, how much would it have been to buy a new one? Or possibly even a used one? It seems with the amount of damage the price would get pretty near those prices, after repairs.
In the USA if something is Salvage you actually have to get an additional inspection before it is allowed back on the road as well.
Since his Dad is in the business of fixing vintage bikes, things that you and I would pay retail for are probably free or close to it.
 

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Discussion Starter #9
I would venture a guess that most motorcycle wrecks that don't occur on a track or in a parking lot are pretty brutal and exposed to a lot of substantial forces.

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Yep! Car pulled out on the previous owner, from what i can tell it hit on the front, then kart-wheeled onto the right side then flipped again onto the left side. . Funnily enough the flimsy plastic indicators survived unscathed!

Just curious, how much would it have been to buy a new one? Or possibly even a used one? It seems with the amount of damage the price would get pretty near those prices, after repairs.
In the USA if something is Salvage you actually have to get an additional inspection before it is allowed back on the road as well.
These bikes are Mega popular in NZ, Honda currently have a waiting list for second hand bikes so they aren't an option just yet. New they are 11,000. Second hand i would guess about 9,000? , at-least for a few years any way. Pricing it up we should be able to get it back on the road (including inspection and registration) for less than 5k. We work on it in the evenings so we can discount our time, and the tough work (straightening things) will be done by a good friend of ours who straightens motorbike frames for a living :) New parts are insanely cheap, we were shocked at some of the prices we were getting. So much so we are eventually going to order new inner fork tubes + a new left fork leg just for the sake of it.
 

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Discussion Starter #10
Rebuilt forks - Oil type / Level?

So the forks are fully rebuilt, now im stuck trying to find the fork oil level/type (should have measured before i tipped it out!) i assumed the internet would have all my answers but it seems no one has made the service manual available yet. Might try and order one online.

In the mean time, Does any here have access to a service manual? if so, any chance you might be able to help me out here?

Cheers!
 

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Discussion Starter #16
Busted,

I have some specs posted here: http://www.hondarebel3forum.com/forum/305-maintenance/8345-specs-capacities.html

The fork oil capacities are listed there.

-CG
Thanks for this! this will be a huge help during re-assembly.

Those pics are depressing. Glad you're ok

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Thankfully i wasn't the rider on this one, the Previous owner did make a full recovery though! apparently she went straight back to the Honda dealership and picked up a new rebel :grin2:
 

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Discussion Starter #17
Update - 22/04/2018

So we had a fairly productive weekend - The forks are straight, filled with 10W oil and installed on the bike, so its back on its feet for now! The forks are nothing surprising. One handles compression damping, the other handles rebound damping. Definitely out of the bargain bin from Showa.




The bent rear shock is back together with a roughly panel beaten cap - a little bit more work and it will be ready for paint! While i was at it, i straightned the brake lever also





electronics are gutted so its ready for straightening (hopefully this Tuesday) this was a bit of a mission, im really not looking forward to re-installing it. Ill try get some photos of the straightening process, i've never been through it in detail before now so im keen to found out more about it





And got some lovely new parts from mr honda :) a few more need to be ordered, but sounds like there is a massive lead time on those, up to 8 weeks apparently :(

 

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Discussion Starter #19
getting put back into line!

Its at the frame straightener today, Unfortunately i had to tend to this annoying thing called work so i was unable to hang around. I may be able to get some pictures tomorrow though.
 

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Discussion Starter #20
Noticed something interesting

While the frame is still being straightened we noticed the serial number on the steering head. Have a look at the image, the serial number is 000001. Not sure if serials are country specific, but pretty interesting if this is No.1 off the production line, at least for its batch? anyone know more about de-coding serial numbers?
 

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