Dan's not another blue 1VJ

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Got the engine cases back and managed to get a new bearing in this very awkward blind hole.
Heated the case up to 100 degrees put the bearing in the freezer for half an hour, and very carefully tapped it in.

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Left hand side case with stator etc all back to square one...


Right hand view of engine side case, new genuine Yam filter and a fancy ceracoated oil cover. I'll probably change that back to standard black.


Here I've sorted out all the correct case fasteners in cap head stainless, I've put the easy bits back in, like strainer and bits and bobs. Next I'll get the gear packs sorted, with shifters and associated bits. I'm waiting for some of those stronger 5th gear pairs from Motoritz.
Basically I build it like the parts diagrams from Yamaha into the various sub assemblies and cross reference to make sure I haven't missed a part.

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Got a bit done on the engine over the weekend.
On to the engine, got a new pair of 5th gears from Kedo:
Showing new and old:

and the other side


Bit of a job to swap one of the pairs. It's all online on Youtube, but basically you have to measure the overall width of the gearset and the gap between 5th and 2nd. You then pull the second gear off and slide the fifth gear out and replace it. Then push everything back on to the width you'd measured

And the old knackered pair:

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At the same time I ordered the fifth gear pair from Kedo I ordered some longer gear levers.
Shown here on my 34L I always struggle with the shorter shaft when wearing MX type boots.

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I was after a simple quick job, so striped the kick start, got it in the ultrasonic to clean all the old gunk off, recut the threads, regreased and got it back together.
Here's the striped view before cleaning and rebuild.

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Got some new bits from Fowlers.
I had to butcher the old one so it deserved a new fastener and copper washer, luckily both still available.
Clutch shaft actuator retaining screw.

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And on to the cases.
Got the bearings back in the cases by the old method of heat the cases to 100 degrees in the oven and put the bearings in the freezer overnight.


Here's the other side:

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Shouldn't be too many headaches from this point onwards.
Get the two gear shafts in, the balancer shaft and shift drum and forks.
The cases can then go back together.
Get them in the frame and build the rest whilst in the bike.

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I always fit a new shift shaft as most Tenere's have had a hard life here, with the splined ends either being none existent or welded to the gear lever.



Got the cases back together again.
I used to build the engine right up and have the worry of manhandling it in without scratching anything. Last few I get the cases together and a few outer ancillaries and use the frame as a build jig.
My brother is over this weekend so he can help with the slightly tricky job of engine support - rear swingarm - get the bolts in quick balance.



Hopefully we'll get it together and I can post some engine in frame type photos. For once it's looking like I'll complete a build just in time for the nicer weather to get some shakedown miles on it

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I had been looking for a new fuel cap and had ordered one from Fowlers only to be told the item was no longer available. I had thought about making an order on CMSL but hadn't got around to it when this came up on EBay.
Brand new genuine Yamaha new old stock in it's original packaging.
I thought it would go up to somewhere near the £75 Fowlers wanted, but bought for £25 which is a bargain and not what I'd expected on EBay.