You Brits have the luxury of switches that come with a lights on/off option from the factory. None of the USA switches have that option, only low and high, and I have to order from UK or European ebay sellers to get that feature.
I may go for the classic Tenere look with a new alloy switch that Mez mentioned above
https://www.officine08.com/p60231_left- ... black.html
Scott's 3AJ restore
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scottieh
- Financial
- Posts: 796
- Joined: Wed Mar 30, 2011 3:58 am
- What Bike or Bikes Do You Own?: 1988 XT600Z 3AJ
1987 XT600Z 1VJ
1985 XT 600
1980 TT500
1980 XT250
2001 KTM 300XC - Previously Owned Bikes: 1982 XT550
1981 TT250
1989 Yamaha Virago 750
1994 DR650
1980 Suzuki GR650
1997 KLR 250
1986 Honda Spree - Location: Salt Lake City
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GeoffD
- Founding Member
- Posts: 1700
- Joined: Sun Mar 27, 2011 7:19 pm
- What Bike or Bikes Do You Own?: 7 x 3AJ Teneres
1 x 1VJ Tenere
55W Tenere
XT660 Tenere 4MY
Honda CRF1000 Africa Twin
Honda Monkey Bike
Honda Dax - Previously Owned Bikes: Triumph Tiger Cub, Garelli Tiger Cross, Triumph Trophy 650, Honda CB250 G5, Honda CB750 K7, Yamaha DT175MX, Honda CB250 Super Dream, Yamaha RD350LC YPVS, Honda XR250, Yamaha XT600, Suzuki PE175, Yamaha YZ125, Yamaha RD500 V4, Yamaha XT600 Tenere (3AJ), Kawasaki ZX10, BMW R100GS PD, Honda XR600, Honda Varadero, Honda Africa Twin, Honda Transalp, Triumph Thunderbird, Ducati 900 Superlight FE, Ducati 750 SS, Honda Fireblade, Kawasaki Versys 650, Suzuki GT750 Kettle, Super Tenere
- Location: Tenereland, North East England.
Re: Scott's 3AJ restore
scottieh wrote: Fri Sep 21, 2018 8:17 pm You Brits have the luxury of switches that come with a lights on/off option from the factory. None of the USA switches have that option, only low and high, and I have to order from UK or European ebay sellers to get that feature.
I may go for the classic Tenere look with a new alloy switch that Mez mentioned above
https://www.officine08.com/p60231_left- ... black.html
UK switches only have low and high now... we have to find older switches with the on/offoption
The future is not what it used to be....
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scottieh
- Financial
- Posts: 796
- Joined: Wed Mar 30, 2011 3:58 am
- What Bike or Bikes Do You Own?: 1988 XT600Z 3AJ
1987 XT600Z 1VJ
1985 XT 600
1980 TT500
1980 XT250
2001 KTM 300XC - Previously Owned Bikes: 1982 XT550
1981 TT250
1989 Yamaha Virago 750
1994 DR650
1980 Suzuki GR650
1997 KLR 250
1986 Honda Spree - Location: Salt Lake City
Re: Scott's 3AJ restore
New progress yesterday.
I finally got the *(*@^#@$^damn flywheel off last night.
Cut deep into the crank end past the flywheel until I could hammer the end of the crank off, which I assumed would release most of the pressure of the flywheel on the crank, and it did.
Now with the flywheel off I can actually split the cases. I have a 3TB crank, case halves and a new flywheel in the bins so I'm going to order new bearings for the case as I'm sure all of the cutting and hammering has done more damage inside the case than I can see.
Progress that takes years to accomplish is still progress, right? Right?!
I finally got the *(*@^#@$^damn flywheel off last night.
Cut deep into the crank end past the flywheel until I could hammer the end of the crank off, which I assumed would release most of the pressure of the flywheel on the crank, and it did.Now with the flywheel off I can actually split the cases. I have a 3TB crank, case halves and a new flywheel in the bins so I'm going to order new bearings for the case as I'm sure all of the cutting and hammering has done more damage inside the case than I can see.
Progress that takes years to accomplish is still progress, right? Right?!
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ActionManMelb
- Founding Member
- Posts: 1052
- Joined: Thu Mar 31, 2011 7:50 am
- Location: Melbourne, Australia
Re: Scott's 3AJ restore
The operation was a success, but unfortunately the patient died! 
"Don't worry," he said, "things could be worse ........."
So I stopped worrying and lo and behold, things did get worse!
So I stopped worrying and lo and behold, things did get worse!
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Patrick
- On the ladder
- Posts: 74
- Joined: Wed Nov 14, 2012 8:58 am
- What Bike or Bikes Do You Own?: 1988 Yamaha 3aj Tenere.
2009 KTM 570 EXC - Location: Canberra, Australia
Re: Scott's 3AJ restore
I can only imagine your heart breaking a little bit more with every hammer strike
If it doesn't involve scotch, bikes or progressive metal then you're doing something wrong.
'09 570 EXC.
'88 600 Tenere project.
R.A.G Endurance Racing.
'09 570 EXC.
'88 600 Tenere project.
R.A.G Endurance Racing.
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dzl
- On the ladder
- Posts: 134
- Joined: Tue Mar 29, 2016 1:03 am
- What Bike or Bikes Do You Own?: 2001 TT600R, ex army XT600, 34L Tenere, 2001 FZ1, FJR1300
- Location: South Australia
Re: Scott's 3AJ restore
Always use high quality high tensile bolts when pulling the flywheel!
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Patrick
- On the ladder
- Posts: 74
- Joined: Wed Nov 14, 2012 8:58 am
- What Bike or Bikes Do You Own?: 1988 Yamaha 3aj Tenere.
2009 KTM 570 EXC - Location: Canberra, Australia
Re: Scott's 3AJ restore
Absolutely. But I can relate to the above. I used the correct puller and bolts removing the flywheel in my project 3AJ and it still took me tens of goes over a few different nights to get it. I think it was the first time it had been pulled in its entire life. Never come across something so stubborn. Not even my wife.dzl wrote: Sun May 19, 2019 1:22 am Always use high quality high tensile bolts when pulling the flywheel!
If it doesn't involve scotch, bikes or progressive metal then you're doing something wrong.
'09 570 EXC.
'88 600 Tenere project.
R.A.G Endurance Racing.
'09 570 EXC.
'88 600 Tenere project.
R.A.G Endurance Racing.
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GeoffD
- Founding Member
- Posts: 1700
- Joined: Sun Mar 27, 2011 7:19 pm
- What Bike or Bikes Do You Own?: 7 x 3AJ Teneres
1 x 1VJ Tenere
55W Tenere
XT660 Tenere 4MY
Honda CRF1000 Africa Twin
Honda Monkey Bike
Honda Dax - Previously Owned Bikes: Triumph Tiger Cub, Garelli Tiger Cross, Triumph Trophy 650, Honda CB250 G5, Honda CB750 K7, Yamaha DT175MX, Honda CB250 Super Dream, Yamaha RD350LC YPVS, Honda XR250, Yamaha XT600, Suzuki PE175, Yamaha YZ125, Yamaha RD500 V4, Yamaha XT600 Tenere (3AJ), Kawasaki ZX10, BMW R100GS PD, Honda XR600, Honda Varadero, Honda Africa Twin, Honda Transalp, Triumph Thunderbird, Ducati 900 Superlight FE, Ducati 750 SS, Honda Fireblade, Kawasaki Versys 650, Suzuki GT750 Kettle, Super Tenere
- Location: Tenereland, North East England.
Re: Scott's 3AJ restore
I had a flywheel that took weeks to come off, I left the puller on it & tightened it up a touch every couple of days... eventually it exploded off.... but unfortunately even this one wasn't as stubborn as my fuckin missus.....Patrick wrote: Sun May 19, 2019 4:10 amAbsolutely. But I can relate to the above. I used the correct puller and bolts removing the flywheel in my project 3AJ and it still took me tens of goes over a few different nights to get it. I think it was the first time it had been pulled in its entire life. Never come across something so stubborn. Not even my wife.dzl wrote: Sun May 19, 2019 1:22 am Always use high quality high tensile bolts when pulling the flywheel!
The future is not what it used to be....
-
scottieh
- Financial
- Posts: 796
- Joined: Wed Mar 30, 2011 3:58 am
- What Bike or Bikes Do You Own?: 1988 XT600Z 3AJ
1987 XT600Z 1VJ
1985 XT 600
1980 TT500
1980 XT250
2001 KTM 300XC - Previously Owned Bikes: 1982 XT550
1981 TT250
1989 Yamaha Virago 750
1994 DR650
1980 Suzuki GR650
1997 KLR 250
1986 Honda Spree - Location: Salt Lake City
Re: Scott's 3AJ restore
Reboot!
Finally gathered the courage to split the cases. Taking it one step at a time.
The reason I’m splitting the case. Flywheel went out of round and cracked the starter motor mount inside the case. The bike continued to run as a kicker only.
What seals should i go ahead and preorder as i start the disassembly? Should i just go ahead and get a full gasket kit?
Finally gathered the courage to split the cases. Taking it one step at a time.
The reason I’m splitting the case. Flywheel went out of round and cracked the starter motor mount inside the case. The bike continued to run as a kicker only.
What seals should i go ahead and preorder as i start the disassembly? Should i just go ahead and get a full gasket kit?