Head is cleaned as valves, looked good bacok together
And then cylinder as head back on the engine, some cosmetical fine tuning and engine is ready to be mounted in the frame.
New cam chain, and valves are adjusted.
My 3AJ rebuild
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keny72
- Three to collect
- Posts: 209
- Joined: Mon Oct 27, 2014 6:20 pm
- What Bike or Bikes Do You Own?: 1986 Honda VFR750Fx2, 1997 Honda Transalp 600, 1995 Honda SevenFifty, 2001 Kawa ZR7S, 1994 Kawa Zephyr 550, 1985 Yamaha FZ750
- Previously Owned Bikes: 2004 Suzuki DL650, 1990 Yamaha FZR600, 1986 Yamaha IT200S, 2006 WR250 Husky, 2010 Yamaha XT1200Z, 1984 Suzuki RG250W, 2000 Honda VFR800FI, 1991 Honda VFR750F, 1987 Honda VFR750F, 1985 Honda CBX750F, 1986 Honda VFR750F, 1987 Transalp 600,, 1992 Honda CBR600F, 1997 Kawasaki KLE500, 2001 Suzuki Bandit600S, 1987 Kawasaki GPZ500S, 1982 Suzuki GS500 Katana, 1990 Yamaha FJ1200, 1982 Yamaha RD125LC, 1983 Yamaha DT125LC, 1990&1989 Yamaha XT600Z Tenere, 1981 IT465, 1985 KTM125GS x3, 1987 KTM125GS, 1989 KTM250GS, 1996 KTM400SC, 1994 Kawasaki KX125, 1992 Kawasaki KDX200, 1996 Suzuki RM250, 2006 KTM250SX, 1995, 1997 & 2002 CR125R, 1996 CR250R, 1981 Suzuki PE175, 1989 Suzuki TS250X, 2011 BMW R1200GS, 2005 KTM EXC250 Racing, 2009 Yamaha XT125X, 1995 XRV750, 1990 CBR1000F, 2000 Yamaha TRX850
- Location: Finland
Re: My 3AJ rebuild
Some updates if someone intrested......
Head is cleaned as valves, looked good bacok together
And then cylinder as head back on the engine, some cosmetical fine tuning and engine is ready to be mounted in the frame.
New cam chain, and valves are adjusted.
Head is cleaned as valves, looked good bacok together
And then cylinder as head back on the engine, some cosmetical fine tuning and engine is ready to be mounted in the frame.
New cam chain, and valves are adjusted.
Last edited by keny72 on Sun Dec 11, 2016 12:01 pm, edited 1 time in total.
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keny72
- Three to collect
- Posts: 209
- Joined: Mon Oct 27, 2014 6:20 pm
- What Bike or Bikes Do You Own?: 1986 Honda VFR750Fx2, 1997 Honda Transalp 600, 1995 Honda SevenFifty, 2001 Kawa ZR7S, 1994 Kawa Zephyr 550, 1985 Yamaha FZ750
- Previously Owned Bikes: 2004 Suzuki DL650, 1990 Yamaha FZR600, 1986 Yamaha IT200S, 2006 WR250 Husky, 2010 Yamaha XT1200Z, 1984 Suzuki RG250W, 2000 Honda VFR800FI, 1991 Honda VFR750F, 1987 Honda VFR750F, 1985 Honda CBX750F, 1986 Honda VFR750F, 1987 Transalp 600,, 1992 Honda CBR600F, 1997 Kawasaki KLE500, 2001 Suzuki Bandit600S, 1987 Kawasaki GPZ500S, 1982 Suzuki GS500 Katana, 1990 Yamaha FJ1200, 1982 Yamaha RD125LC, 1983 Yamaha DT125LC, 1990&1989 Yamaha XT600Z Tenere, 1981 IT465, 1985 KTM125GS x3, 1987 KTM125GS, 1989 KTM250GS, 1996 KTM400SC, 1994 Kawasaki KX125, 1992 Kawasaki KDX200, 1996 Suzuki RM250, 2006 KTM250SX, 1995, 1997 & 2002 CR125R, 1996 CR250R, 1981 Suzuki PE175, 1989 Suzuki TS250X, 2011 BMW R1200GS, 2005 KTM EXC250 Racing, 2009 Yamaha XT125X, 1995 XRV750, 1990 CBR1000F, 2000 Yamaha TRX850
- Location: Finland
Re: My 3AJ rebuild
Its been a while, and its a sad reason why. I eventually got the engine in the frame, had to take it off because the frames lower engine bolt faster was cracked. Engine out, a friend did weld the crack, engine back, all slowly put back and one day vola time to start the engine. It did start BUT had a terrible knocking sound from the top, like a woodpecker in there. I had some other things to do so I did just roll it out from the garage and into the shed and a month later did take the trusty VFR to ride, but that's no dual sport... So I have wondering what the knocking sound is. Mostly thinking I have messed up whit cam chain timing. But today I did push the Tenere back to the garage, and opened the valve cover. From what I understand the timing is right... What to look at next? Head off? Engine has a different head than before, whit old head it had no knocking noise. The knock is hard as loud, but no noice as you turn engine around from the flywheel.
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Mezo
- Dashingly Handsome
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Re: My 3AJ rebuild
Is there any oil getting up to the cam/valves, open one of the two inspection on the rocker cover & see if there is oil coming up.
Oil should piss out all over the floor if its OK.
Mezo.
Oil should piss out all over the floor if its OK.
Mezo.
"A wise man makes his own decisions, an ignorant man follows public opinion"
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keny72
- Three to collect
- Posts: 209
- Joined: Mon Oct 27, 2014 6:20 pm
- What Bike or Bikes Do You Own?: 1986 Honda VFR750Fx2, 1997 Honda Transalp 600, 1995 Honda SevenFifty, 2001 Kawa ZR7S, 1994 Kawa Zephyr 550, 1985 Yamaha FZ750
- Previously Owned Bikes: 2004 Suzuki DL650, 1990 Yamaha FZR600, 1986 Yamaha IT200S, 2006 WR250 Husky, 2010 Yamaha XT1200Z, 1984 Suzuki RG250W, 2000 Honda VFR800FI, 1991 Honda VFR750F, 1987 Honda VFR750F, 1985 Honda CBX750F, 1986 Honda VFR750F, 1987 Transalp 600,, 1992 Honda CBR600F, 1997 Kawasaki KLE500, 2001 Suzuki Bandit600S, 1987 Kawasaki GPZ500S, 1982 Suzuki GS500 Katana, 1990 Yamaha FJ1200, 1982 Yamaha RD125LC, 1983 Yamaha DT125LC, 1990&1989 Yamaha XT600Z Tenere, 1981 IT465, 1985 KTM125GS x3, 1987 KTM125GS, 1989 KTM250GS, 1996 KTM400SC, 1994 Kawasaki KX125, 1992 Kawasaki KDX200, 1996 Suzuki RM250, 2006 KTM250SX, 1995, 1997 & 2002 CR125R, 1996 CR250R, 1981 Suzuki PE175, 1989 Suzuki TS250X, 2011 BMW R1200GS, 2005 KTM EXC250 Racing, 2009 Yamaha XT125X, 1995 XRV750, 1990 CBR1000F, 2000 Yamaha TRX850
- Location: Finland
Re: My 3AJ rebuild
The head do get oil.
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Yami
- Financial
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- Location: Helsingborg, Sweden
Re: My 3AJ rebuild
Well, it usually knocks if the valve adjustment is out of range. I don´t think I have to ask if you did one but check it again.
I did a mistake a while ago with this and it was knocking terrible. When I was in the process of doing the valve adjustments I must have been confused turning it clockwise to get to the TDC.
I adjusted and got the hard knocking. Then I thought what a hell happened, worse then before adjusting. So I started all over and found myself going clockwise again.
Did it anti clockwise as it´s supposed to be, adjusted the valves and knocking stopped when running the engine.
Hope this helps.
I did a mistake a while ago with this and it was knocking terrible. When I was in the process of doing the valve adjustments I must have been confused turning it clockwise to get to the TDC.
I adjusted and got the hard knocking. Then I thought what a hell happened, worse then before adjusting. So I started all over and found myself going clockwise again.
Did it anti clockwise as it´s supposed to be, adjusted the valves and knocking stopped when running the engine.
Hope this helps.
Current in the stable: 2x34L, 36A, 2KF, Raptor 350, R6, R1, XJ900S, MT07 Tracer
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keny72
- Three to collect
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- What Bike or Bikes Do You Own?: 1986 Honda VFR750Fx2, 1997 Honda Transalp 600, 1995 Honda SevenFifty, 2001 Kawa ZR7S, 1994 Kawa Zephyr 550, 1985 Yamaha FZ750
- Previously Owned Bikes: 2004 Suzuki DL650, 1990 Yamaha FZR600, 1986 Yamaha IT200S, 2006 WR250 Husky, 2010 Yamaha XT1200Z, 1984 Suzuki RG250W, 2000 Honda VFR800FI, 1991 Honda VFR750F, 1987 Honda VFR750F, 1985 Honda CBX750F, 1986 Honda VFR750F, 1987 Transalp 600,, 1992 Honda CBR600F, 1997 Kawasaki KLE500, 2001 Suzuki Bandit600S, 1987 Kawasaki GPZ500S, 1982 Suzuki GS500 Katana, 1990 Yamaha FJ1200, 1982 Yamaha RD125LC, 1983 Yamaha DT125LC, 1990&1989 Yamaha XT600Z Tenere, 1981 IT465, 1985 KTM125GS x3, 1987 KTM125GS, 1989 KTM250GS, 1996 KTM400SC, 1994 Kawasaki KX125, 1992 Kawasaki KDX200, 1996 Suzuki RM250, 2006 KTM250SX, 1995, 1997 & 2002 CR125R, 1996 CR250R, 1981 Suzuki PE175, 1989 Suzuki TS250X, 2011 BMW R1200GS, 2005 KTM EXC250 Racing, 2009 Yamaha XT125X, 1995 XRV750, 1990 CBR1000F, 2000 Yamaha TRX850
- Location: Finland
Re: My 3AJ rebuild
Thanks Yami, helps a lot! As I had it running for a while to check the oil flow to the head, I had it running fuel from a old 1l oil can. I did notice it had some oil in it as I did puor the gas/petrol in the can. In the end of the running the engine started to smoke badly! Wounder if the leftower oil in the 1 liter can can couse this or do I have a second bad head!? It was about 1cm of oil in the bottom of the oil can I added the fuel to. As I did take out the sparkplug, it had a oil drop on it! 
And I that was told of many the XT600 is a simpel reliable engine.......
And I that was told of many the XT600 is a simpel reliable engine.......
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ActionManMelb
- Founding Member
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- Location: Melbourne, Australia
Re: My 3AJ rebuild
Yes, a small amount of oil goes a long way!keny72 wrote: Wounder if the leftover oil in the 1 liter can can cause this or do I have a second bad head!? It was about 1cm of oil in the bottom of the oil can I added the fuel to. As I did take out the sparkplug, it had a oil drop on it!
They are...... in the right hands.And I that was told of many the XT600 is a simple reliable engine.......
"Don't worry," he said, "things could be worse ........."
So I stopped worrying and lo and behold, things did get worse!
So I stopped worrying and lo and behold, things did get worse!
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keny72
- Three to collect
- Posts: 209
- Joined: Mon Oct 27, 2014 6:20 pm
- What Bike or Bikes Do You Own?: 1986 Honda VFR750Fx2, 1997 Honda Transalp 600, 1995 Honda SevenFifty, 2001 Kawa ZR7S, 1994 Kawa Zephyr 550, 1985 Yamaha FZ750
- Previously Owned Bikes: 2004 Suzuki DL650, 1990 Yamaha FZR600, 1986 Yamaha IT200S, 2006 WR250 Husky, 2010 Yamaha XT1200Z, 1984 Suzuki RG250W, 2000 Honda VFR800FI, 1991 Honda VFR750F, 1987 Honda VFR750F, 1985 Honda CBX750F, 1986 Honda VFR750F, 1987 Transalp 600,, 1992 Honda CBR600F, 1997 Kawasaki KLE500, 2001 Suzuki Bandit600S, 1987 Kawasaki GPZ500S, 1982 Suzuki GS500 Katana, 1990 Yamaha FJ1200, 1982 Yamaha RD125LC, 1983 Yamaha DT125LC, 1990&1989 Yamaha XT600Z Tenere, 1981 IT465, 1985 KTM125GS x3, 1987 KTM125GS, 1989 KTM250GS, 1996 KTM400SC, 1994 Kawasaki KX125, 1992 Kawasaki KDX200, 1996 Suzuki RM250, 2006 KTM250SX, 1995, 1997 & 2002 CR125R, 1996 CR250R, 1981 Suzuki PE175, 1989 Suzuki TS250X, 2011 BMW R1200GS, 2005 KTM EXC250 Racing, 2009 Yamaha XT125X, 1995 XRV750, 1990 CBR1000F, 2000 Yamaha TRX850
- Location: Finland
Re: My 3AJ rebuild
So I guess I made most ones day right ..... 
Strange, I have had open a LC4 KTM engine as a YZF250, no problem ever. (even more 2 strokes!)
But I have hope, can be its just a new valve check and I can start to use this bike!
I´m surprised how much oil fog a small amount of oil can do, even I had a few 2 strokes, still! I was already ready to open the engine again and start working on head #3....eventually I will some day to finnish Tenere #2. Its tank as plastic is at a paint shop right now
Strange, I have had open a LC4 KTM engine as a YZF250, no problem ever. (even more 2 strokes!)
But I have hope, can be its just a new valve check and I can start to use this bike!
I´m surprised how much oil fog a small amount of oil can do, even I had a few 2 strokes, still! I was already ready to open the engine again and start working on head #3....eventually I will some day to finnish Tenere #2. Its tank as plastic is at a paint shop right now
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keny72
- Three to collect
- Posts: 209
- Joined: Mon Oct 27, 2014 6:20 pm
- What Bike or Bikes Do You Own?: 1986 Honda VFR750Fx2, 1997 Honda Transalp 600, 1995 Honda SevenFifty, 2001 Kawa ZR7S, 1994 Kawa Zephyr 550, 1985 Yamaha FZ750
- Previously Owned Bikes: 2004 Suzuki DL650, 1990 Yamaha FZR600, 1986 Yamaha IT200S, 2006 WR250 Husky, 2010 Yamaha XT1200Z, 1984 Suzuki RG250W, 2000 Honda VFR800FI, 1991 Honda VFR750F, 1987 Honda VFR750F, 1985 Honda CBX750F, 1986 Honda VFR750F, 1987 Transalp 600,, 1992 Honda CBR600F, 1997 Kawasaki KLE500, 2001 Suzuki Bandit600S, 1987 Kawasaki GPZ500S, 1982 Suzuki GS500 Katana, 1990 Yamaha FJ1200, 1982 Yamaha RD125LC, 1983 Yamaha DT125LC, 1990&1989 Yamaha XT600Z Tenere, 1981 IT465, 1985 KTM125GS x3, 1987 KTM125GS, 1989 KTM250GS, 1996 KTM400SC, 1994 Kawasaki KX125, 1992 Kawasaki KDX200, 1996 Suzuki RM250, 2006 KTM250SX, 1995, 1997 & 2002 CR125R, 1996 CR250R, 1981 Suzuki PE175, 1989 Suzuki TS250X, 2011 BMW R1200GS, 2005 KTM EXC250 Racing, 2009 Yamaha XT125X, 1995 XRV750, 1990 CBR1000F, 2000 Yamaha TRX850
- Location: Finland
Re: My 3AJ rebuild
I did rechecked the valve adjustment and seem I had miss whit the adjustment mark as there was way to big gap! So that's the reason for the nocking noise then? Have not restart it yet, did run out of time and I need new fresh petrol/gas as well! A fact is that I need to approve the fact I need to use my glasses more regular than I want to...
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keny72
- Three to collect
- Posts: 209
- Joined: Mon Oct 27, 2014 6:20 pm
- What Bike or Bikes Do You Own?: 1986 Honda VFR750Fx2, 1997 Honda Transalp 600, 1995 Honda SevenFifty, 2001 Kawa ZR7S, 1994 Kawa Zephyr 550, 1985 Yamaha FZ750
- Previously Owned Bikes: 2004 Suzuki DL650, 1990 Yamaha FZR600, 1986 Yamaha IT200S, 2006 WR250 Husky, 2010 Yamaha XT1200Z, 1984 Suzuki RG250W, 2000 Honda VFR800FI, 1991 Honda VFR750F, 1987 Honda VFR750F, 1985 Honda CBX750F, 1986 Honda VFR750F, 1987 Transalp 600,, 1992 Honda CBR600F, 1997 Kawasaki KLE500, 2001 Suzuki Bandit600S, 1987 Kawasaki GPZ500S, 1982 Suzuki GS500 Katana, 1990 Yamaha FJ1200, 1982 Yamaha RD125LC, 1983 Yamaha DT125LC, 1990&1989 Yamaha XT600Z Tenere, 1981 IT465, 1985 KTM125GS x3, 1987 KTM125GS, 1989 KTM250GS, 1996 KTM400SC, 1994 Kawasaki KX125, 1992 Kawasaki KDX200, 1996 Suzuki RM250, 2006 KTM250SX, 1995, 1997 & 2002 CR125R, 1996 CR250R, 1981 Suzuki PE175, 1989 Suzuki TS250X, 2011 BMW R1200GS, 2005 KTM EXC250 Racing, 2009 Yamaha XT125X, 1995 XRV750, 1990 CBR1000F, 2000 Yamaha TRX850
- Location: Finland
Re: My 3AJ rebuild
Had the Tenere running for a while today. Good news is the knocking sound was the valve adjustment but....even I did take out the old fuel from the carb and one more time as the engine fired up to take out the old possible oil content fuel and did put new fresh fuel in the 1liter can, well the bike smokes...badly. So what to check next? The cylinder is in good condition, piston rings in new spec and it doesn't smoke from the breather tube, not hardly any pressure in the tube. The head has nev seals on the valves. I did check into the engine from the spark plug hole whit the small wire sneak camera I have borrowed and top of piston is wet of oil.....any ideas?