Scott's 3AJ restore

[scottieh]

Got my order from Boats in the mail as well as the shift shaft oil seal that Boats doesn't carry (obsolete my butt). Still waiting on the gasket kit and the crank and then it all take a trip out to the farm where the boys become men

[scottieh]

Prizes came in the mail yesterday! The post man came by saying he had something heavy for me!



Heavy it was because it was filled with a new (used) crankshaft in very good looking condition




Cam chain sprocket


Thanks for sending it over OllI!

So today I took the whole lot to the mechanic who said he'll (hopefully) have it put back together in a week or two.

In the meantime I'm clearing out the "garage" a.k.a., the space under my desk of old parts and projects. Saying goodbye to a lot of broken and dirty engine bits to a bike I don't own anymore. Let the purge begin.

[Fred333]

Hi Scott,
nice to see the box survived the abuse from postmen.


I see a pink rim in the background.
Did have a flat or in need for a new tire on your scooter?

Good luck for the Tenere engine.
Olli

[socks]

I hope you guys are checking out the "run out" and the rod "clearance" on that crankshaft before fitting. I'm confident that you would have done this already, yet, I just had to ask!

Socks

[scottieh]

Hi Scott,
nice to see the box survived the abuse from postmen.


I see a pink rim in the background.
Did have a flat or in need for a new tire on your scooter?

Good luck for the Tenere engine.
Olli

Thanks again. Yes, Lola was given a new rim, however since the rim came from a different year bike, the drum brakes don't work because there's more space inside the rim then on Lola's. The old rim will have to go back on until a suitable replacement of the same year can be found. Lola's rear rim was warped from many instances of daredevil jumping and wheelying.

[scottieh]

Got some unpleasant news from my mechanic today regarding my crank replacement. While tearing apart the engine the guy noticed that the starter reduction gear had been violently hit while inside the engine and the result was a number of aluminum case chunks were broken off from the case and settled at the bottom of the engine. He pulled them out and showed me where the cases had cracked. It didn't look pretty




The last time I rode the bike I used the electric starter to try to start the engine and it made a terribly loud thwack noise. I tried again immediately afterwards and all I heard was the sound of metal grinding on metal. After that I assumed the crankshaft had gone out of round but it turned out it was the reduction gear that had suffered a terrible blow and sent casing pieces everywhere. My mechanic said that the engine was still useable, however it would never run on an electric starter again, not without the cases being replaced.

He also said that the replacement crankshaft that I had been sent by a fellow forum member was the wrong one! And sure enough it was. When compared side by side the crankshaft sent over by a forum member was about one inch shorter on the left hand side with the flywheel taper.

Here's the old crank. I took bad pictures and they don't compare the old vs. the new very well. I was just trying to figure out at the time why they were different using markings.

And here's the new one. Not very descriptive but it was the only part that had any numerical markings on it.


The reason this is so is because the crank assembly that was sent over was from a different bike, but some parts listings have it listed as the proper part. I checked my personal parts book and verified that I had the wrong assembly as I needed a 1VJ-11400-01 assembly, and had been sent a 3TB-11400-01. It didn't help that the parts list on the Tenere forum for the 3AJ was wrong for my 3AJ (http://members.iinet.net.au/~mezo/tener ... 0Fiche.pdf) Fig 03 shows the 3TB assembly as being correct, however my bike's manual says that the 1VJ assembly is needed. The difference is about one inch of taper on the flywheel side. With that now being a known problem, I am stuck because the only 1VJ-11400-01 assemblies available for purchase are about $1,000! I am in a tough place right now. My bike is in pieces, I have a broken case, and I have a need for a hard to find part.

Can anything go right?

[GeoffD]

Scottie.... I may have the parts you need, I bought a 3AJ bottom end at an autojumble a while back... got it for parts, it seems you need them more than I do.... however, the costs of shipping to you I imagine will be astronomical.... all my bits & pieces are at work, I'll check them out in the morning....

Failing that I know that Dave Lambeth will have a crank, not sure about cases but again the postage costs will be high....

Sorry to hear about your bad luck mate, it's a bummer....

[GeoffD]

Also I've just noticed... you say that last photo is a 3TB crank... are you sure it's 3TB?? looks to me like it has shims each side of the con rod, the 3TB doesn't have shims... also it's got 34K on the side??

I think you've got a 34L/55W crank... the reason it's shorter is because it doesn't have the sprag clutch for the starter motor...

Also .. I may be wrong here, but I'm sure the 1VJ part number for the crank is now superceded to 3TB....

The 1VJ & 3TB cranks I'm sure (apart from the shims) are identical...

[GeoffD]

This is a 3TB crank.....

[scottieh]

This is what I got in the mail that doesn't work. What do you think it is if not a 3TB? It's whatever Ollie sent to me.



Geoff, I'll gladly pay the shipping cost to get the right crank to me soon. If I can get a measurement of the right length of each half of the crank assembly and we can make sure it'll fit in, then I'd feel better about having another assembly sent over rather then risk it not fitting again.