very long 3aj rebuild

[gobo]

Nice build--is it that easy to find a stator- needing a spare for my Z

I would say it is rather difficult to find a functionning stator - the demand is strong.
Another option is to have yours rewounded.

[gobo]

any chance you can do a which wire goes to which guide? I have same switches to fit, if i remember rightly, on the light control there was only one different colour?

I've lost the notes taken while cutting/soldering but looking at the pics I was able to do the following mapping :


I remember that the TDM850 right hand switch had an additional connector for the brake light - just get rid of it. As I said earlier, I didn't test it on the bike as it is in pieces right now. However, when looking at the multimeter it shows that it should work.
Pawel

[jibber]

Mucho cheers

[GeoffD]

I've also used TDM switches on one of my 3AJ's too, great mod, they look and operate much nicer.... as do DT switches

[gobo]

Hello again

had some days off from family and work last week so I could progress a little bit faster on my project

Here is the result :





(my daily runner in the background)

where to put it ...?




maybe here ?



it seems that it fits so it will stay there








and back on (not) her wheels :

The wheels will be redone with the Excel rims and new spokes









my old muffler that was sand-blasted and then powder coated








and with the tank painted and protected while waiting for the stickers


Still needs to be done :
- paint all plastic parts
- put the stickers on (got them from http://www.tt600r.de/tt-kiosk/tenere.htm )

- put a transparent coat on the stickers
- finish rear footpegs
- do the wheels
- put the breaking fluid
- put the gasoline in and run

More progress hopefully in August
cheers,
Pawel

[Mezo]

Very nice work Pawel.

Mezo.

[gobo]

Hello
I have a little problem with the clutch : actually, pulling the clutch lever does nothing when in gear position, the rear wheel stays locked. I think the clutch plates got glued together as the engine hasn't been run for years probably.
What do you think I should do, try to separate manually the plates or just buy new clutch plates and replace the old ones ?

Cheers, Pawel

[Mezo]

Just put it in gear & get a mate to push you backwards & forwards & it should break it free.

Obviously with the chain on.

Mezo.

[ActionManMelb]

I had a XT with the same problem. I tried Mezo's suggestion without success.

The fix was to run the engine in 1st gear with the back wheel in the air and the clutch lever pulled in and taped to the bars.
After about 15mins of running, the heat and oil and engine vibration finally shook the plates free.

I was very relieved to not have to pull the side cover off to fix it. With regular riding the problem never came back.

Now if I store a bike for more than a month, I tape the clutch lever to the bar.

[Mezo]

Now if I store a bike for more than a month, I tape the clutch lever to the bar.

That`s a good tip

Mezo.