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3aj - 4pt engine swap 3aj - 4pt engine swap
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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by George Guille, It's going to be a long 300km... Bolivian Amazon

I haven't been everywhere...
but it's on my list!


Photo by George Guille
It's going to be a long 300km...
Bolivian Amazon



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  #1  
Old 14 Aug 2010
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3aj - 4pt engine swap
dear all,

will the 4PT XT600e engine fit the 3AJ Ténéré straight on? they look similar...

thx,

R
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  #2  
Old 26 Oct 2010
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I'd like to know as well if anyone has info...

I want to use an XT600e motor from a '96 model into a 3aj Tenere '88 model...

Help please!

Cheers,
Dave.
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  #3  
Old 6 Nov 2010
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Hi Dave ...I,m thinking of doing the same from a 2002e to an xt600 tenere,....if you find any info let me know and I ll do the same....I think there is a difference due to the airbox being moved....
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  #4  
Old 7 Nov 2010
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Here's a link to the German XT600 site for swapping a 3TB engine into a Tenere.
I know why you're looking at this Kenny
www.xt600.de
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  #5  
Old 13 Nov 2010
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hey maybe it is easier for me just to swap the front forks and rear suspension from my 87 tenere to my 600e! the front forks will be easy but I think I will have problems with the rear part...maybe the shocks will be different or the wheel size could be a problem so I might start messing about with it later this week....heres the details...


xt 600 tenere 23l large tank and longer suspension but no electric start.

2002 600e ....needs longer suspension and bigger tank....electric start..
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  #6  
Old 4 Dec 2010
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yes the 4pt and 3tb xt600'e' engines will fit although you need to take the fly wheel off the origional 3aj engine and put it on the new 'e' engine

ive already done this mod
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  #7  
Old 4 Dec 2010
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I thought there was a 10 mm difference in the width of the engines ? making the 4pt too wide for the earlier models....
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  #8  
Old 13 Dec 2010
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XT600 engine swap
I installed the engine from a 96 XT600E,

into the 84/5 XT600 Tenere,

The engine fits perfectly,
You need to take the front spocket, fit it with the Shoulder towards the engine, and "Shave off" about 3-4mm in order to get it closer to the engine.
there is one m6 bolt you have to replace with a Counter sink bolt, else the chain will eat it up.
Space the rear sprocket out by about 3mm.

Also need to make small changes to the plumbing from the oil tank to the engine. (The 96 have the oil in the frame versus the 85 where the oil tank is on the rear subframe - left.

I also used the complete wiring harness off the 96 XT, which meant I did not have to do any changes to the charging system, and I fitted the 96 XT battery below the rear carrier. It's too big for the original batt box.

Exhaust is exactly the same,
Tubes from the airbox to the carbs had to be modified slightly.





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  #9  
Old 13 Dec 2010
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Outstanding...........you know good struff....
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  #10  
Old 18 Dec 2010
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Nice looking job! Did you make the screen, or is a standard item off another bike?
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  #11  
Old 19 Dec 2010
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The screen was on the bike when I originally bought it,
So I don't have any idea where it comes from.
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  #12  
Old 28 Mar 2011
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:-)

Thx!
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