Geoff's 3AJ rebuilds....

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GeoffD
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Re: Geoff's 3AJ rebuilds....

Post by GeoffD »

Got a bit of a problem with no.5 ... stripping the engine today & found that one of the alloy nut things that hold the cylinder barrel on has corroded so badly that it's seized solid & not only that it's actually fused to the barrel itself.... I've seen these stupid nuts corroded before but this is the worst one I've come across.... tried undoing it today & the bolt head has snapped off.... it's gonna be a bastard to get off..... :banghead:

I'll take pics tommorrow
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Mezo
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Re: Geoff's 3AJ rebuilds....

Post by Mezo »

That happened on my 900ss years ago, sheared itself off flush with the casing (nothing to grab hold of) :foot_tap:

Ended up splitting the engine & milling it out. :mike:

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ActionManMelb
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Re: Geoff's 3AJ rebuilds....

Post by ActionManMelb »

Ouch, nasty problem.

I just took a look at a spare cylinder and the alloy nut.

You have 2 options as I see it....

1. Sacrifice the cylinder and two of the crankcase studs by using a thin 100mm cutoff wheel to slice through the lot.

2. Find someone with an EDM machine and make an annulus copper electrode and spark them out.

Good luck, our thoughts are with you. :shades:
"Don't worry," he said, "things could be worse ........."
So I stopped worrying and lo and behold, things did get worse!
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GeoffD
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Re: Geoff's 3AJ rebuilds....

Post by GeoffD »

I thought of a way last night, not sure it'll work yet
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keny72
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Re: Geoff's 3AJ rebuilds....

Post by keny72 »

I had one of mine also corroded badly, but got it out By drilling the nut head to a shape of a bolt and then smach on a tool on it and got it turning. Was a pain to get the old nut of the tool, Good luck whit the Project.
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GeoffD
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Re: Geoff's 3AJ rebuilds....

Post by GeoffD »

I did it..... using my trusty vibrating multi saw.... cost me three blades, but it worked.

Before....

Image

Image

After, I cut just above the thick washer...

Image

Image

Great piece of kit this is...

Image

Image
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Mezo
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Re: Geoff's 3AJ rebuilds....

Post by Mezo »

How you going to clean that up then? :wink2:

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GeoffD
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What Bike or Bikes Do You Own?: 7 x 3AJ Teneres
1 x 1VJ Tenere
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XT660 Tenere 4MY
Honda CRF1000 Africa Twin
Honda Monkey Bike
Honda Dax
Previously Owned Bikes: Triumph Tiger Cub, Garelli Tiger Cross, Triumph Trophy 650, Honda CB250 G5, Honda CB750 K7, Yamaha DT175MX, Honda CB250 Super Dream, Yamaha RD350LC YPVS, Honda XR250, Yamaha XT600, Suzuki PE175, Yamaha YZ125, Yamaha RD500 V4, Yamaha XT600 Tenere (3AJ), Kawasaki ZX10, BMW R100GS PD, Honda XR600, Honda Varadero, Honda Africa Twin, Honda Transalp, Triumph Thunderbird, Ducati 900 Superlight FE, Ducati 750 SS, Honda Fireblade, Kawasaki Versys 650, Suzuki GT750 Kettle, Super Tenere
Location: Tenereland, North East England.

Re: Geoff's 3AJ rebuilds....

Post by GeoffD »

Barrels are off to the powder coaters tomorrow Mez, he can clean it up :shades:
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ActionManMelb
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Re: Geoff's 3AJ rebuilds....

Post by ActionManMelb »

Good result Geoff! :star: :yay:
"Don't worry," he said, "things could be worse ........."
So I stopped worrying and lo and behold, things did get worse!
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jibber
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Re: Geoff's 3AJ rebuilds....

Post by jibber »

Well done Geoff, has the motor been apart before?
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