3AJ rebuild ... at last

[welshlamb]

Jibber, Hope your OK, if you haven't visited messages recently I've PM'd you

[welshlamb]

well I think I know where this would have been headed



When Kev Thomas took my engine apart this is what he found. Apparently NOS 5th gears are just about EXTINCT now (mine came from USA!) so need to treat this baby right , regular oil, no chugging in gears etc!! No doubt part of the reason my bores and pistons looked shite as well and were replaced. Engine should be better than new now.

[welshlamb]

So I think I should fit the oil return (engine-cooler) pipe before fitting the starter.
Just really noticed how the sharp bend at the engine end seems to be. It looks really restrictive as its not radiused just 'bent' and flattened as a result.





Is this normal? Do they all look like this or has this been abused? I fear the latter

Please advise

ALSO...... I'm still looking to decide the debate on the sequence for the washers at the starter gear end of the starter motor. Is it fibre nearest the windings then metal or vice versa. Been looking for a clear image in various threads but haven't found it yet

[welshlamb]

and the last (for this evening!) query



This secured by the rear/bottom engine mounting bolt. Has anyone please got a picture of this in place and the routing of the oil line ?

PS Seat sent of to 'Saddlecraft' (up in Geoffs neck of the woods) for recovering last week and I'm part way through the next round of itemising yet more missing fasteners and rubber parts for ordering no doubt.

Next job will be to swap over the blue 660 clocks into the 3AJ instrument housing.
It would be nice to say I'm doing a little each day but other shite keeps getting in the way.... Doing this thread is one motivation for trying to make progress though, so please excuse the frequent calls for help from the wiser hands out there

[jibber]

That pipes shagged, have a search on here for a pic of the bracket and oil line

[dzl]

This a pic from a 34L which will be the same. Hose goes from bottom of engine then goes under retainer as pictured and then straight up and then to bottom of oil tank.




I wonder if your crimped over oil return hose contributed to the engine damage? i havnt seen a 5th gear that bad! Would have been very noisy.

[welshlamb]

Cheers Both. Yep I only really noticed it as I was painting it. Looks even worse in Silver than in Black/dirt! Ah well something else to purchase and hold up the rebuild!

[welshlamb]

That pipes shagged

yes sir,

Managed to find a used one and cleaned and painted it yesterday.
Spot the difference. Quite how it got like that God knows but no doubt that would have starved oil supply and hastened the engines 'hari-kiri'

[welshlamb]

HI guys, found someone local who I think can do me a good paint job (I'll get him to spray the RAL5005 and then laquer after I've put graphics on) but before I do I want to sort out the RHS sidepanel fixing. I know that my frame seems to be missing a fixing (see above) but also I believe my RHS panel may also be a bit 'compromised' (see the images I posted on the 24th May) I am missing a lug just below the small tab that has a rubber cover on it (the 'intact' frame /lug can be seen in the picture of Geoffs white bike)

I can see the front mount and the screw mount and the tab on the frame that pokes through the small slot in the sidepanel but what other fixing point should there be on the LHS?

Has anyone with a late model 3AJ (just in case it changed!) got a picture (or could take one) of the INSIDE of the panel to compare mine with. Would be a great help.

[Mezo]

Looks about right, bit worn but aren't they all after 30 yrs.

Mezo.