Hey everybody. I got a package in the mail today that officially signifies the beginning of the restore of my 1988 Yamaha Tenere 3AJ. A new gasket set!



This past year of riding I have done about 25,000km and rolled over the odometer. I have ridden coast to coast, taken it on some hairy dirt roads, and generally beaten the crap out of it. On my last trip while I was riding home from New Orleans I discovered that somewhere on the highway my front axle nut had fallen off, leaving nothing to hold the sprocket and chain on. So when I got home I put the bike under cover and focused on restoring a 1995 DR650 in order to sell it and fund the restore of the Tenere. I still have the DR650 but I couldn't wait any longer so I got the gaskets. My list of repairs are as follows.

-Replace chain
-Replace front/rear sprocket
-Replace front axle nut
-Helicoil oil filter cover thread/replace missing bolt
-Replace starter cover/oil cover gasket
-oil change
-Replace chain guard
-Fork Seals/fork oil
-Replace piston/rings
-Check cam chain
-Check output drive shaft (the nut keeps coming off! need to know if it's stripped)
-Replace 5th gear in the gearbox (Ha! We'll see about that)
-Refurbish/repaint/resticker tank
-Fix mounting points on the tank
-Replace clutch plates
-Replace shift fork selector
-Check shift fork selector drum
-Replace CDI coil
-Find out why the electric starter won't work
-Replace 12V outlet
-Replace/relocate choke
-Replace broken/missing blinkers
-Title and register the bike!
-Replace front/rear brake pads
-Replace front/rear brake rotors
-Replace tacho cable
-Fix plastic fairing mounting holes
-Properly aim headlight/sort out headlight electrical issues
-Straighten fairing subframe
-Helicoil skid plate mounts/replace missing bolts
-Grease up the speedo cable
-Fix helmet latch

That's it for now. If I can get all this in order I'll have a smooth running bike again! Pictures and updates to come. I hope to finish this project by the middle of June upon which I will ride the bike another 5,000 miles to the 2012 Rainbow Family.

Good stuff, glad your going to give it a second lease in life.

So are you going to powder coat the frame Scottie? may as well.

Strip it down & everything that needs powder coat goes off to one guy & everything that needs zinc goes off to another bloke.
Your left with just the engine block to work on in the meantime.

Don`t forget to powder coat them ugly silver rims gold, or new ones if the budget will allow.

This will be the first North American Tenere rebuild, and possibly the last?

Mezo.

Good on ya Scottie, another 3AJ rebuild.....

Looking forward to this one ..


p.s. that 5th gear is easier than you think....

Need parts? Ask me. I will send if the Ebayseller won´t
I mean it!!!

Fred

Thanks everyone. Mez, I hope it's not the last. Unless the bike is swallowed by a whale I intend on rebuilding and repairing this bike for the rest of my life. Also the frame is in good nick. I don't think it needs a powder job. I will probably zinc plate the bolts just for good measure if I remember to. Geoff, I'll look to your guidance for replacing that 5th gear. I've never split a case before and I don't own a press or really know anyone who does. And Fred, I may take you up on the parts thing. Most of what I need I believe I can find from boats.net

scottieh wrote: Also the frame is in good nick. I don't think it needs a powder job.

The joys of not seeing a British winter

Oh look .... It's snowing.... AGAIN

Rick

One thing you never mentioned was the head Scottie, if that kit you have has valve stem oils seals? chuck them in the bin & order some factory ones.

Take out the valves & check the springs (specs) while your there, have a look at the seats (re-cut?) and check the valves faces & valve guides, but before any of that is checking the cam journal for wear.

Mezo.