very long 3aj rebuild

[Mezo]

Wow good find

Mezo.

[gobo]

thanks for your feedback. Concerning the front master cylinder, I managed to get out a metal plate that covers the inspection window from inside. Once done that, I could clean the window a little bit from inside. I saw the Chinese copies on the US ebay but I couldn’t find them in Europe, so I will stick to the one I have now until I find a replacement window or a Chinese copy here.

I installed also the rebuild kits for the front and rear master cylinders.
rear master cylinder before

old piston, spring, etc. and the new ones below


and installed


the same for the front master cylinder (the old parts are below):

[gobo]

for the front master cylinder I've finally ordered a chinese copy from China. Even if I have to pay the import tax it will be not so expensive. Waiting for the delivery now ...

[marcm]

Rear one looks the same as a 350 Ypvs if its any help?...

[gobo]

Hello
another update, this time on handlebar switches. Although I want the bike to be as close to the original as possible, I couldn't get used to the standard 3AJ switches. They are ugly and not very practical for me

So I've bought the TDM850 switches hoping that it would be a plug-and-play process to make them work on the 3AJ – it wasn't.
The TDM850 has different connectors


I started to compare the wiring diagrams for both bikes and I figured out the differences
Then the scissors and soldering tool came into action :


and 1 hour later :


and after another 30 minutes the TDM850 switches with the 3AJ connectors :



When I was doing that the bike was already in pieces so I had no chance to verify if it worked. My multimeter says however, that it did. We'll see when the bike will be assembled...

[xtjoe]

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

[jibber]

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?

[Mezo]

Jibber, a man of your talents could do that blindfolded.

Mezo.

[steveloomis]

One of the most important tools in wiring is a good, digital volt/ohm meter. Learn simple wiring basics and you can figure out which wire goes where. I recently bought a couple of headlight hi/low, horn, turn signal bar switches on ebay made in China. They are very good quality and with just a little checking with the ohm meter it is easy to discover the function of each wire. It does come with a wiring diagram or it is on the ebay page to print out. Cost is about 9 bucks shipped from china. There are several of these on there, look for the cheapest and free shipping....

Another good tool is a good wire crimper and wire stripper plus the bullet connectors. Look on Economy Cycle.com, you can get a good assortment. There are other sources elsewhere. Makes wiring changes/repairs look and function as well as OEM.

Steve

[jibber]

Jibber, a man of your talents could do that blindfolded.

Mezo.

Electrics were never one of my strong points