Dan's 1VJ resto mod

[cadno]

Had my brother up over the weekend, and managed to get him to give me a hand in the garage.
An afternoon spent on the following.

• Recheck all the wiring and make sure we're getting a spark....all good.

• Check all oil tank and oil unions before pouring oil in....all good.

• Pour oil into tank....not good

I had quite an amount of oil come from the bottom of the tank, so we drained the tank and checked the three O rings on the bottom oil pipe, expecting one to be missing. All good, although I had missed out the mesh strainer. Borrowed a strainer from another bike, refitted everything, torqued to 11Nm (should be 10Nm) and refilled with some more oil.
Same again
Striped all off and compared to another oil tank I have. It appears that original oil tank has an extremely small depression around where the bottom flange mounts which then allows the leak. I fitted the second oil tank and you could see straight away it wasn't leaking. So I'll have to try and improve how flat that area is on the original tank.
Now with an oil tight engine we tried to get oil flow. This was done by removing the spark plug and cranking the starter hoping to see oil on the bleed above the oil filter. Nothing came, so I removed the right side case and checked, there was a very small amount of oil by the strainer and oil pump but nothing else. Checked all the galleries for blockages but found nothing and tried cranking again. This time loads of oil came out, so I cleaned up and put the side cover back on. Cranked again and a geyser came out of the bleed screw, all good.
Then on to starting the engine.
Plug back in, a small separate auxiliary fuel tank with fresh fuel.
I left the fuel turned on and let the fuel fill the float bowls, pressed the starter switch on the Motogadget controls, and the engine started immediately.
It's always a massive point in a complete rebuild and even better when it starts on the button perfectly. To say I'm made up is an under statement
We started and stopped it a number of times. The Motogadget is set up for a single press of the right handlebar top button to start the bike, or remotely off my phone and a double tap of the same button switches it off.

[scottieh]

5 years in the making, nice work. Now break the engine in proper with a hard ride and post some photos!

[cadno]

where did those five years go

[Scumfrog]

So here we have some petcock types.
Starting from the right that's a KTM part that fits.
Middle is what I think is the correct original 1VJ tap, its a little longer and drops the lever lower. Making it easier to use whilst riding.
Left is what I think is off a later Tenere probably 3AJ?

going back to the correct fuel tap question..... neither of those are correct,

This is what I was thinking when I recalled the correct 1VJ one - you'll see the slight drop revealing a number - maybe a batch number? Incidentally there was no reserve on the 1VJ RHS tap.




the 3AJ is higher up, no room for the number.