Dan's not another blue 1VJ

[cadno]

I've got some nice bits and pieces back recently.

Dropped some parts for vapour blast:
These are the original forks which I'll build up as a spare set.


Got a delivery from Wilbers so these fork springs will improve the front end:


Then I've made a start on the engine, top end basically apart and been vapour blasted.
Dismantling can always be a bit fraught with damaged and seized fasteners.

Magnesium side cover:


Cylinder head and barrel.
I'll get it rebored at Grampian in the next few weeks and sprayed up, then I can rebuild the top end.

[cadno]

I don't know how I forgot to post this!
Adjustable this time so we can reduce the seat height for my vertically challenged brother



The quality of finish on them is outstanding, all four of my Tenere's now have Wilbers in them.

[jibber]

Nice

[cadno]

Been tickling away of an evening recently.
One of the things you'll always find when rebuilding a 1VJ is that some or all of the airbox screws will be threaded, so you can't actually get a good seal when clamping the airbox back together.
The reason for this is that the screws used by Yamaha are self tappers into a plastic airbox.
I'm looking at ways to improve this by putting a metal insert into the lower of the old airbox.
There's basically two ways of doing this.
Brass heat inserted - so you use a bit in a soldering iron to heat the threaded insert up, and basically melt it into the plastic.
Threaded insert - almost like a timesert or helicoil but for plastic.
I've got both coming and I'll have a play to see which works best.

Brass heat inserted:

You have to drill a hole to the size of the bottom of the insert.
Then I'll use a stainless M5 cross headed screw.

[GeoffD]

You're still at it then Dan, looking good mate

[cadno]

Good to hear from you Geoff.
You got anything in build at the moment?

[cadno]

Took two barrels to Grampian in Liverpool for rebores this week.
A 1VJ and a later 3AJ, I'd never put the two barrels together before.

3AJ with much more cooling area side view:


Top view, the lower barrel is the 3AJ


Rebore:


Barrel and head reunited:


I'll get them cleaned off to get all the honing dusk off them, then they can be resprayed and rebuilt.

[cadno]

Interestingly when I was at Grampian the guy looking at them initially said they wouldn't be able to do anything.
He told a story that last month a guy came in with around 50 XT 600 barrels for rebore, and cleared them out of pistons, and that they wouldn't be getting anymore XT600 pistons in.
He went to check and came back with the pistons needed, saying that the guy must not have gone through with it. I got the feeling he'd used this story before, maybe as a way of relieving the boredom. It seemed an unlikely story, if someone had bought ten barrels in maybe it was believable. It was just a bit odd.

[GeoffD]

Good to hear from you Geoff.
You got anything in build at the moment?

I'm still working (slowly) on my final 3AJ..... it's almost a new bike it's got so many nos parts on it... should be finished soon.

Got to strip the carbs off Tenere 3 tomorrow, it's been stood for a couple of years & now it's running like a pig. One of the problems of having too many bikes.

I sold a couple of 3AJ's last year & considering selling a couple this year, I'm running out of room.

[cadno]

I know that feeling Geoff