A 3AJ Rebuild getting ready for Sandraiders 2026

[JohnXT5T]

Did 5th gear not make a noise when riding her?

I'm thinking about Morocco Sandraiders next year.. Wanted to make my own way there though - maybe ferry to Morocco or trailer the bike to Gibralter then ride from there. I hate flying!! Riding there would also considerably add to the adventure.

[cadno]

Any updates Phil?

[firestarter_phil]

Yes, my apologies for going dark on the forum for a while, work got in the way after the sumemr as is so often the case and I have been pretty much away from home / workshop since.

That said, we have made a bit of progress and uncovered some challenges.

From a build perspective - engine all back together and whilst I didn't go through the full paint / cerakote process, I did throw a lick of VHT over the barrel / head to tidy them up a little.








I also managed to get engine etc back into the frame and get the wiring loom mostly in place, but seem to have hit a bit of a snag








Whilst I managed to get power through the system



I am struggling with a spark issue which I have resurrected in another post "1spark" seems I have a break or bad connection in one of the CDI generator wires.
viewtopic.php?p=39905

[firestarter_phil]

Depsite this, I did also manage to get a bit of paint on the panels before the weather in the UK took a final turn for the worse and as I don't have a spray booth, I took the opportunity to purchase a Temu style 'greenhouse' and extractor fan and this has worked well.

[firestarter_phil]

It's been a long time since I threw a spray gun around the place, but and after a fairly stressful decal applciation session and a healthy dose of lacquer I was fairly please with the outcome.

I didn't have the decals for the side panel and bearing in mind I am 99% certain I am throwing this bike down a track in the next 6 months I wasn't too fussed about that.

[firestarter_phil]

I did also get my wheels rebuilt.

I spoke with a good few people and went with a larger set of stainless spokes, so these are now with 4mm across both wheels. I am very aware that thsi will increase the unsprung weight, but in the whole grand scheme of life, we are not on the race track and I prefer 'sturdy'

Mike at Salisbury Wheel Builders did these for me and I am genuinely delighted by his craftmanship and turnaround times.....plus he's a top bloke who knows more about wheels than the wheels themselves!

https://www.facebook.com/Salisburywheel ... cale=en_GB

[ollieburton]

You are making seriously quick progress! Thanks for sharing.

Picked up a non registered, non runner yesterday and came across your post when doing so research in to where to start with the project and what upgrades to do. Aiming to do some Wales trips next summer and aim for SR 2027.

Keep up the good work.

Ollie

[firestarter_phil]

Based on some of the recent issues I had with the ECU and sparks I have decided to go through and ‘upgrade’ some of the connectors on the bike.

I am aware that this will cause ‘plug and play’ challenges but will preempt that and take some spares with me.

I am much more comfortable knowing I’ve got solid waterproof connectors than worrying about what happens if I need to change over a part.

I went with this style of connector as they are pretty easy to work with.

[cadno]

they're referred to as AMP type connectors, really good, arguably the best solution.
Make sure you have the correct crimper.

[AndyL]

Hi all,
I am new here because I too have bought a 3AJ for Sandraiders 2026 in Morocco.
My bike is a Red/White UK bike and has just completed 76K miles. It's in good condition for 1990 bike with high mileage.
The engine is out and has gone for stripdown and assessment.
I've just readthrough the posts and was debating what to do about the wheels - as they seem ok!!! - but I think a rebuild should be the correct thing to do. The other issue is suspension.....I am thinking of just servicing the front forks...fresh oil new seals and leave the springs as original.
I'd like an opinion on what is best. (Cost is a factor for me). Also, I've read that a lot of people install a Wilbers rear shock. What type of Wilbers is recommended. I'm now going back into the garage to renew all the linkage bearings and wheel bearings.
As for a battery I've been told to use Lead/acid as Lithium doesn't perform well in the 36 Degrees heat of the dessert...apparently. I will post some photo's up and hopefully meet some of you in the dessert next year.
Andy