Scott's 3AJ restore

[Mezo]

From memory

The breather pipe from the case goes to the airbox Scott & when people overfill there bikes with oil (very common) it normally fills there airboxes with oil.

Mezo.

[MaltaBike]

From memory

The breather pipe from the case goes to the airbox

That's correct! Good memory

[scottieh]

Anybody here on the forum living in France? I'd like to buy this airbox from French Ebay and have it sent to the states where I live but it seems this is only shipped to France. I'd be happy to make it worth your while I only really need the air filter holder but that's nearly impossible to find separate from the whole airbox assembly. Any kind hearted people out there willing to help a brother out?

http://www.ebay.fr/itm/BOITE-A-AIR-YAMA ... 4168e570eb

[Mezo]

What you just need the hinged wire clip that holds the filter in place?

Mezo.

[scottieh]

What you just need the hinged wire clip that holds the filter in place?

Mezo.

I need the whole thing that slides into the airbox. I've never actually seen it in person so I don't know what in total goes into the assembly. One of the forum members has offered to sell me his spare in Poland though. I'll post pictures once I get the thing.

I do need some help on another project however. I'm looking into sourcing a used set of 3AJ engine cases. I'm concerned that my uncontrollable oil leak was caused by the initial clang that put my electric starter reduction gears out of commission. I think in addition to breaking the inside of the aluminum case it also put a hairline crack through the outside of the case where the clutch rod goes into the top of the case and the subsequent 2,000 miles of riding has opened that crack up. My options at this point are to 1.) swap out engines with a kick start only engine from a 1985 XT600 and figure out how to make the differences in case width work in the 3AJ frame. 2.) split the cases to take everything apart and have a aluminum welder fix that crack and hope the fix holds and doesn't cause any other leaks. 3.) Swap engine cases.

I'm invested in the internal bits in the 3AJ engine due to the expenses incurred to rebuild it from the replaced transmission gears to the new cylinder/piston set and everything in between. I don't really want to do a straight swap because I'll feel inclined to replace a lot of parts in the new engine to make sure it's solid. I'm thinking in advance of a lengthy year long trip through north, central and south america next year. I want to know that everything in the engine is solid, which of course means taking most things apart, inspecting them, and then reassembling.

So, anybody have spare 3AJ cases? Geoff? Actionman?

[gobo]

What you just need the hinged wire clip that holds the filter in place?

Mezo.

I need the whole thing that slides into the airbox. I've never actually seen it in person so I don't know what in total goes into the assembly. One of the forum members has offered to sell me his spare in Poland though. I'll post pictures once I get the thing.

I put here some pics of "the thing" that slides into the airbox for future reference





cheers,
Pawel

[Mezo]

I think the general term for it is the airbox "snorkel" but check you have the wire bit that holds the air filter tightly in place Scott

Mezo.

[ActionManMelb]

Hey Scottie, nice set of crankcases in Germany,

here......
http://www.ebay.de/itm/MOTOR-GEHAUSE-BL ... 1c46cfe15a

[scottieh]

Hey Scottie, nice set of crankcases in Germany,

here......
http://www.ebay.de/itm/MOTOR-GEHAUSE-BL ... 1c46cfe15a

I don't think these work with the 3AJ engine. I might be mistaken but I thought the extra length of the 3AJ crankshaft due to the addition of the starter motor gears meant they had to redesign the cases. Plus there doesn't appear to be mounting points for the starter motor on the top of the case.

This seems to be more like what I actually need to buy. The 3TB engine cases.

http://www.ebay.de/itm/Yamaha-XT-600-3T ... 5b040b9e55



edit - I'm apparently a fool. 1VJ's did have electric starters.

[scottieh]

Well I bit the bullet and bought the cases. That means I will be splitting this darn thing for the third time. You know how the old saying goes: "third time's two times too many." This time I'll be doing the work myself with some help and hopefully avoid the curse of the shop. I've ordered a new set of gaskets and plan to replace the starter gears that took the initial blow to shatter the case. I'm expecting delivery in the coming weeks and hope to have a flywheel puller in by then as well.

What is your opinion about replacing the right side of the case as well? The only damage the cases experienced were on the left side, so do you think I should go through the trouble to remove the bearings out of the old case half if it is presumed to be okay?