Geoff's 3AJ rebuilds....

keny72
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What Bike or Bikes Do You Own?: 1990 + 1989 Yamaha XT600Z Tenere, 1986 Yamaha IT200S, 1986 Honda VFR750F, 1995 + 1997 Honda CR125R, 1988 SUZUKI TS250X
Previously Owned Bikes: 1984 RG250W, 2000 Honda VFR800FI, 1991 Honda VFR750F, 1987 Honda VFR750F, 1987 Kawasaki GPZ500S, 1982 Suzuki GS500 Katana, 1982 Yamaha RD125LC, 1983 Yamaha DT125LC, 1985 KTM125GS x3, 1987 KTM125GS, 1989 KTM250GS, 1996 KTM400SC, 1994 Kawasaki KX125, 1996 Suzuki RM250, 2006 KTM250SX, 2002 CR125R
Location: Finland

Re: Geoff's 3AJ rebuilds....

Post by keny72 » Mon Oct 01, 2018 2:10 pm

:popcorn2:
As always
:shades:
:tenere:

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GeoffD
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What Bike or Bikes Do You Own?: 6 x 3AJ Teneres
2 x 1VJ Teneres
55W Tenere
XT660 Tenere 4MY
XTZ750 Super Tenere.... Ratty one
Triumph Tiger 955I
Triumph Thunderbird sport
55W Tenere
Kawasaki Versys 650
Suzuki GT750 Kettle
Previously Owned Bikes: Triumph Tiger Cub, Garelli Tiger Cross, Triumph Trophy 650, Honda CB250 G5, Honda CB750 K7, Yamaha DT175MX, Honda CB250 Super Dream, Yamaha RD350LC YPVS, Honda XR250, Yamaha XT600, Suzuki PE175, Yamaha YZ125, Yamaha RD500 V4, Yamaha XT600 Tenere (3AJ), Kawasaki ZX10, BMW R100GS PD, Honda XR600, Honda Varadero, Honda Africa Twin, Honda Transalp, Triumph Thunderbird, Ducati 900 Superlight FE, Ducati 750 SS, Honda Fireblade... all I can remember for now...
Location: Tenereland, North East England.

Re: Geoff's 3AJ rebuilds....

Post by GeoffD » Fri Oct 19, 2018 11:49 am

Attempting to make 1 ignition switch out of several :lol:

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Anyone wanting to fit the later r/h handlebar switch to their Tenere... this is how you wire them, although the wires are the same colours, you don't join them colour for colour as the switches are different... the wiring on the left shows the new switch, one of the red/white wires has to be joined to the blue/white then connected to the blue/white on the existing bike wiring.

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The future is not what it used to be....

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scottieh
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What Bike or Bikes Do You Own?: 1988 XT600Z 3AJ
1985 XT 600
1980 TT500
1981 TT250
Previously Owned Bikes: 1982 XT550
1989 Yamaha Virago 750
1994 DR650
1980 Suzuki GR650
1997 KLR 250
1986 Honda Spree
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Re: Geoff's 3AJ rebuilds....

Post by scottieh » Thu Nov 01, 2018 2:43 am

GeoffD wrote:
Thu May 03, 2018 8:57 am
scottieh wrote:
Wed May 02, 2018 11:54 pm
Ah! I didn't know there were race cutouts in the frame. That makes me feel like a fool. I tried using a drift but I never felt the depressions and ended up having to weld a cross brace over the race and hammering it out from above.

Oops..... :bag:

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You can see the cutout on this pic with the race still in...

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Not sure if you remember my troubles with my headset bearing race while in Mexico and how i ended up welding a cross brace to pound it out? Well due to neglect and time i needed to replace the bearings again, but i figured with your tip about the cutouts in the frame pounding out the old race would be a breeze this time.

Wrong.

I don't think this frame came with cutouts!

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What the hell? My Tenere had the cutouts but not this 43F? Am I missing anything?

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Mezo
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Re: Geoff's 3AJ rebuilds....

Post by Mezo » Thu Nov 01, 2018 7:34 am

The only way to get that out is to cut a slot with a carbide burr & then belt it with a chisel to collapse the race, its the same way my late farther would use to remove a valve seats (and he did thousands like this) :nod:

Mezo.

Eric66
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Re: Geoff's 3AJ rebuilds....

Post by Eric66 » Thu Nov 01, 2018 8:47 am

If you run a small bead of weld from a mig around the bearing face the outer shrinks and falls out. :shades:
Regards Eric

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GeoffD
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Joined: Sun Mar 27, 2011 7:19 pm
What Bike or Bikes Do You Own?: 6 x 3AJ Teneres
2 x 1VJ Teneres
55W Tenere
XT660 Tenere 4MY
XTZ750 Super Tenere.... Ratty one
Triumph Tiger 955I
Triumph Thunderbird sport
55W Tenere
Kawasaki Versys 650
Suzuki GT750 Kettle
Previously Owned Bikes: Triumph Tiger Cub, Garelli Tiger Cross, Triumph Trophy 650, Honda CB250 G5, Honda CB750 K7, Yamaha DT175MX, Honda CB250 Super Dream, Yamaha RD350LC YPVS, Honda XR250, Yamaha XT600, Suzuki PE175, Yamaha YZ125, Yamaha RD500 V4, Yamaha XT600 Tenere (3AJ), Kawasaki ZX10, BMW R100GS PD, Honda XR600, Honda Varadero, Honda Africa Twin, Honda Transalp, Triumph Thunderbird, Ducati 900 Superlight FE, Ducati 750 SS, Honda Fireblade... all I can remember for now...
Location: Tenereland, North East England.

Re: Geoff's 3AJ rebuilds....

Post by GeoffD » Thu Nov 01, 2018 10:16 am

Same if you heat one spot to cherry red with a welding torch, let it cool and the race will just fall out... it's how I used to do truck hub bearings...
The future is not what it used to be....

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