Scott's 3AJ restore

[itchywheels]

Scottieh pictures would help

[scottieh]

I'm about to go on a little vacation with my mom to the Texas desert and soak up the sun for a few days. Back on Thursday. I won't get a picture up till then at the earliest. Joel set the piston to TDC and then advanced it slightly to set timing. Very close to perfect, erring to the side of caution.

Big Bend is where my avatar photo was taken and the last time I was there I put a hole in my engine case on a rock. No scheduled riding this trip, but if the opportunity arises...

[Dirtybrit]

A pic of the rivit might help determine your best corse of action.

We do not want to see the "Golden Rivit" thank you.

[HawkGT]

Well I realized that setting this engine at TDC and then setting the cams indexing marks parallel with the top of the engine would be incorrect. I marked where the timing hole is with tape on the top end and then removed the stator cover and the lines that are closest together are further counterclockwise from the taped location. Why can't I find a proper service manual, exploded diagrams are great, but why can't I find a manual that has the technical writing as well. Nothing about the manual that I have tells me which marks are the correct timing marks. Are the indexing marks on the cam sprocket supposed to be even with the top of the head when the timing marks are in the viewing window?

Anywho, long story short....If I cant get this cap off the viewing window, I can't time this engine. Either a mechanic with a degree wheel and the dial gauges will have to do it or this Bike is dead in the water. I did read in the Specifications that timing at idle is 12degrees BTDC. It looks as if thats where the timing hole is picking up. So that means my setup would be wrong.

[Mezo]

If you had a Clymer manual it would help you, ive not got mine here & its been two years since i timed mine up.

There is a method & im sure Geoff or Dave will chime in & explain, my memory is no so shit hot & id hate to tell you the wrong thing (Mr Valve meets Mr Piston)

I seem to remember there is more than one mark on the flywheel? the cam is self exploratory as long as your first stroke is the inlet valves opening (piston dropping).

Wish i could help more but ive only done it once two years back, Geoff`s gone to the island (IOM) & Dave`s is still in Europe i think (but due back anytime).

Mezo.

[Jimmie]

http://i2.photobucket.com/albums/y23/co ... _0007w.jpg

That's the best I can do I'm afraid, as I lack a scanner. In the drawing the flywheel is removed.
TDC mark on the flywheel is the little |T mark, the right most of the three.

[HawkGT]

Well, that would have been handy information to know before I put this engine completely back together. Now I can't remove thise flywheel again as it has been f-ed with too much too remove it the first time. This manual I have is crap and I'm about to set fire to it, out of spite. Hell I put so much Loctite on the flywheel nuts' threads that IDK if an impact wrench will remove it. Oh, and I don't have an Impact wrench. I'm about to set fire to this bike and be done with it

[Jimmie]

I'm sorry about being a bit late with the information but wouldn't it be possible to use the TDC marking on the flywheel? I've never done this myself, so please excuse my ignorance if there's something important I've overlooked.

[Mezo]

You only need to take the cam cover off, tilt the cam itself towards the cog end & slip the chain off.

Just make sure you put a bit of wire to stop the chain falling down, this is how i did mine & i got the timing lined up.
That method wont be in any book i guess it was just a quicker method i stumbled upon.

Mezo.

[Eric66]

I has a qweestion. How are you guys timing the top to the bottom? My inclination is to set the piston to TDC and then put the Head on and set the cam w/o moving the bottom end. This would have all the Lobes facing downward of course with the holes in the cam facing up and the sprocket with the indexing dot facing up and the two lines on the sprocket even with the top edge of the head.

I should elaborate, the Timing hole cover won't unscrew, it looks as if someone had to rivet it permanently closed. I'm gonna go get the widest flathead bit tomorrow to try and Ratchet it off tomorrow. Otherwise I would use this as my indicator to time the top to the bottom.

This method will work fine, the timing marks on the fly wheel and cover are just an easy way to verify TDC, but you can set TDC by other means. Here are some photo's which may help.
The crank keyway is TDC
The fly wheel keyway is in line with the T mark ie TDC

This shows roughly where the indicator mark on the cover would point, it is perpendicular to the cylinder base.


As long as you are confident that you have TDC (could use the old screw driver down the spark plug hole) setting the cam up as you have described is correct. Remember to wind the engine over by hand to make sure nothing is wrong. P.S These photo's are from my 83 model but should be the same.
Regards Eric