Scott's 3AJ restore

[Eric66]

Hi Scottie, the cases are machined as a matched set, if you look at the back of the cases (where the swing arm bolts through) you should see some numbers engraved by the factory they should be matching numbers on each case. You must use a matched set of cases so all the shafts and gears etc have the right tolerances. Good luck,they are a simple engine to work on.
Regards Eric

[gobo]

right, below you can see the example of what Eric talks about

[psahd]

I have spent 3 weeks reading Scott's 3AJ restore and it just ends like this???? Not cool! What happened? new casings? what!!!!!!

[jibber]

hello

[scottieh]

I have spent 3 weeks reading Scott's 3AJ restore and it just ends like this???? Not cool! What happened? new casings? what!!!!!!

Sorry for the massive time delay gentlemen. The short of the long is that I still haven't removed the blasted flywheel. After the bolts stripped out in the flywheel and I couldn't use the three point puller I tried to use a three-jaw gear puller, but all that did was warp the flywheel inward and it still didn't come off. So I began to cut the flywheel off with an angle grinder and dremel tool and haven't completed the job yet. My workshop is an unheated garage and the average winter temperature in Utah is approximately cold as hell so I'm less inclined to go out there and hack away than normal. I bought a case set from a 1VJ but still need a 1VJ clutch side cover to mount the starter motor that I haven't ordered yet.

[scottieh]

Okay, I'm back at it. Now that I have a garage again and a little bit of money I'm putting time back into this poor, neglected motorcycle. The years it spent outside have done some damage.

I tried turning the handlebars yesterday but found them stuck. Once I broke them loose they had that memorable feeling of seized bearings, so out the steering stem came. This is what I found.



Hideous



A lot of water had gotten into the stem column and sat for so long that it was eating the steel stem.



That's some bad corrosion. Luckily it hadn't really devastated the stem so I cleaned it up with the wire wheel and pounded the bearings out to see what was underneath.



The bearing seals did their job and there was no water under them so no rust had accumulated.

I also drove out the bearing races quickly and easily for the first time thanks to Geoff's note that the stem column has indents for a drift punch, which I used with great success. Thanks Geoff!

I'm working on cleaning out the gas tank and fitting in an XT600's monoshock from the parts bike I just broke down. Looking forward to seeing this old girl stand on two wheels again.

[jibber]

[scottieh]

Hey all, I'm on the hunt for a replacement left hand control switch assembly for my 3AJ. One day, once upon a time, the button for the horn popped off. Odd.

Any suggestions? I know these are becoming harder and harder to find.

[Mezo]

Cheapest option is a generic switch that fits a 22mm bar.

THIS ONE.

Or an alloy REPLICA.

Mezo.

[GeoffD]

Hi Scotty... I always use later switches now, they're much better.. all the wires are the same colours but you'll have to change the plugs....

XT600E, XT660's, Super Tenere's… I've even used switches off TDM's … tons of them will fit


My current rebuild

Left switch XT600E




Right switch is off an early R1