Scott's 3AJ restore

[Mezo]

So is this your 1VJ Scottie? are you going to weld that damage? and are you changing the bearings whilst its apart?

Mezo.

[scottieh]

No, this is from my moldy oldy 3aj ive been struggling with for all these years. The cases are stamped 1vj for some reason.

The case halves i bought have bearings in them. Gonna check for play and probably use them, although the case I’m splitting now has the newest bearings in them. Replaced in 2012 and not ridden much, but they did suffer the shock of the case cracking and locking up the engine while i was driving slowly through a parking lot. I wasn’t going more than 7 km/h but i worry about them. What do you think?

[Mezo]

The cases are stamped 1vj for some reason.

That's interesting, so 3AJ`s must use 1VJ cases? never knew that, bearings are pretty tough but don't take my word on that.

Mezo.

[scottieh]

That's interesting, so 3AJ`s must use 1VJ cases?

There actually is a difference between cases. The 3aj has starter motor mounts formed directly into the top of the right case half. The 1vj uses a bracket attached to the right case half cover and probably uses a different starter. Also there is an oil line hole on the top of the 3aj right hand case that doesn’t exist for the 1vj.

[scottieh]

I think the only item I need to wrap up my parts collection is a 1VJ starter motor. Anybody have one laying about?

[scottieh]

I got the engine split apart but as I was removing the transmission this lovely little fella came falling out of the engine and I never saw from where it came. Any help is appreciated on identifying this g&*^$*(%damn washer

[dzl]

Definitely the trans washer part 18. If it fell out when removing the trans I presume the retaining circlip has departed company with the drive axle?

http://www.firstclassmotorcycles.com.au ... on#content

[scottieh]

Definitely the trans washer part 18. If it fell out when removing the trans I presume the retaining circlip has departed company with the drive axle?

http://www.firstclassmotorcycles.com.au ... on#content

I initially thought so too, but i checked my gear shaft and saw the snap ring and washer are still attached. Is there another washer that is unlisted for this engine in the exploded parts diagram? Nothing large and chunky and remotely snap ring shaped was found floating around in the bottom of the engine.

[dzl]

ok..the dimensions of that washer is definitely part# 90201-20276. The only other place this washer is used on the XT600 is on kick starter shaft. Yours is 3AJ no kick start? http://www.firstclassmotorcycles.com.au ... er#content

Possible it may have been previously placed on the other side of the circlip on the trans output shaft to take up excessive shaft horizontal play. I have a 3TB that has approx 1.5mm play if you push/ pull on the trans output shaft which is excessive compared to other XT engines I have which have zero/ .5mm max play. One of these washers would bring it back to where it should be. Perhaps just install trans shaft assemblies into crankcase and button it up and check the output shaft horizontal play first before doing full assembly?

[Mezo]

Possible it may have been previously placed on the other side of the circlip on the trans output shaft to take up excessive shaft horizontal play.

That sounds very familiar, i`m sure i`ve heard a member doing the same.

Mezo.