Scott's 3AJ restore

Post Reply
User avatar
scottieh
Financial
Financial
Posts: 476
Joined: Wed Mar 30, 2011 3:58 am
What Bike or Bikes Do You Own?: 1988 XT600Z 3AJ
1985 XT 600
Previously Owned Bikes: 1989 Yamaha Virago 750
1994 DR650
1980 Suzuki GR650
1997 KLR 250
1986 Honda Spree
Location: Salt Lake City

Scott's 3AJ restore

Post by scottieh » Wed Feb 08, 2012 8:29 pm

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!

Image

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.

User avatar
Mezo
Dashingly Handsome
Dashingly Handsome
Posts: 5223
Joined: Wed Mar 23, 2011 11:01 am
What Bike or Bikes Do You Own?: XT600Z 3AJ
Previously Owned Bikes: Honda SS50, Suzuki TS50, Honda CB100, Honda CR125RZ, Yamaha YZ125, Kawasaki KX250, Suzuki TL1000S, Ducati 900SS, Ducati 900SL, a few Tenere`s.
Location: KYOGLE
Contact:

Re: Scott's 3AJ restore

Post by Mezo » Wed Feb 08, 2012 10:22 pm

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

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. :popcorn2:

User avatar
GeoffD
A Very Friendly
A Very Friendly
Posts: 1527
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: Scott's 3AJ restore

Post by GeoffD » Wed Feb 08, 2012 11:37 pm

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

Looking forward to this one .. :popcorn2: :popcorn2:


p.s. that 5th gear is easier than you think....
The future is not what it used to be....

User avatar
Fred333
A Very Friendly
A Very Friendly
Posts: 743
Joined: Sun Mar 27, 2011 6:42 pm
What Bike or Bikes Do You Own?: Yamaha XT 600 Z Tenere, 34L, 1984
Yamaha TT 600 1984
Honda C 90 , 1980
Previously Owned Bikes: Vespa Rally 200, Vespa SS 50 and alot more old (real) Vespas!!!
Yamaha RD 250, Suzuki GT 380 , Suzuki GSX 1200, CBR 600, DT 175, DT 250, DT 400, Kawasaki Z 200, Honda Varadero 1000, VFR 800, Honda ANF 125 Innova,
XR 600, BMW XChallenge 650, Dr Big, Suzuki GS 500 (four cylinder)
and.....?
Location: Hamburg , Germany

Re: Scott's 3AJ restore

Post by Fred333 » Thu Feb 09, 2012 10:07 am

Need parts? Ask me. I will send if the Ebayseller won´t
I mean it!!!
:popcorn2:
Fred
Yamaha XT 600 Z 34L
Yamaha TT 600 36A59X3SW - Mix
Restauration have a click here: http://www.tenere.co.uk/forum/viewtopic.php?f=4&t=82

User avatar
scottieh
Financial
Financial
Posts: 476
Joined: Wed Mar 30, 2011 3:58 am
What Bike or Bikes Do You Own?: 1988 XT600Z 3AJ
1985 XT 600
Previously Owned Bikes: 1989 Yamaha Virago 750
1994 DR650
1980 Suzuki GR650
1997 KLR 250
1986 Honda Spree
Location: Salt Lake City

Re: Scott's 3AJ restore

Post by scottieh » Thu Feb 09, 2012 9:14 pm

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

User avatar
xtzrick
King of Posting
King of Posting
Posts: 1051
Joined: Sun Apr 17, 2011 3:41 pm
What Bike or Bikes Do You Own?: '97 Yamaha XTZ660 Tenere, '79 Suzuki GS750
Previously Owned Bikes: Yamaha RS125, Suzuki GT125, Suzuki GT185, Honda CB250 G5,Kawasaki Z1000J, Kawasaki KL250, Yamaha TZR125, Yamaha XT600E
Location: Socialist Republic of S.Yorks.

Re: Scott's 3AJ restore

Post by xtzrick » Fri Feb 10, 2012 1:35 am

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 :nod:

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

Rick

User avatar
Dirtybrit
Financial
Financial
Posts: 443
Joined: Tue Mar 29, 2011 4:42 am
What Bike or Bikes Do You Own?: 1982 XT 550, 1981 YZ250, 2010 Triumph Tiger 1050, 1981 XR 200
Previously Owned Bikes: Honda SS50, Yamaha RD2501973, Honda XL125, Yamaha DT175, Kawasaki KE175, Yamaha YZ250D, CT90, Suzuki RM400, Yamaha YZ250H, 1981 Yamaha RD250,1982 XT 550, 1979 XS 750, 1979 YZ 400 F.
Location: Calgary Alberta Canada

Re: Scott's 3AJ restore

Post by Dirtybrit » Tue Feb 14, 2012 5:07 am

:popcorn2:

User avatar
Mezo
Dashingly Handsome
Dashingly Handsome
Posts: 5223
Joined: Wed Mar 23, 2011 11:01 am
What Bike or Bikes Do You Own?: XT600Z 3AJ
Previously Owned Bikes: Honda SS50, Suzuki TS50, Honda CB100, Honda CR125RZ, Yamaha YZ125, Kawasaki KX250, Suzuki TL1000S, Ducati 900SS, Ducati 900SL, a few Tenere`s.
Location: KYOGLE
Contact:

Re: Scott's 3AJ restore

Post by Mezo » Tue Feb 14, 2012 5:36 am

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.

User avatar
Danjet600
Founding Member
Founding Member
Posts: 381
Joined: Sun Mar 27, 2011 12:36 pm
What Bike or Bikes Do You Own?: xt600z 3AJ Tenere
xt600e 1991 ex australian army
XL600v honda transalp
Location: QLD Bogan City (logan city)

Re: Scott's 3AJ restore

Post by Danjet600 » Tue Feb 14, 2012 11:43 am

:popcorn:
I don't make mistakes. I make prophecies which immediately turn out to be wrong.
Murray Walker

User avatar
55W1985
Almost there
Almost there
Posts: 769
Joined: Sun Apr 03, 2011 6:46 am
What Bike or Bikes Do You Own?: XR 650L 1994,XT 600Z 55W 1985
Previously Owned Bikes: CX 500 1981,R-80G/S PD 1987
Location: Buenos Aires,ARGENTINA
Contact:

Re: Scott's 3AJ restore

Post by 55W1985 » Wed Feb 15, 2012 4:14 am

:nannawave: :popcorn2: :popcorn2: :popcorn2: :confetti: :sherlock:
XR650L(1994) 55W (1985)

Post Reply