3aj prep tips
 

Hi all, I own a '89 3aj, 25000 miles on the clock and it's a well looked after bike. I'm planing a trip UK to India and my question is, should I look at the engine, or should I take it that it will still have plenty of life left in it?
Also if anyone could give me any ideas of things I should be checking on the bike (faults etc). I will be replacing brake pads, battery closer to the time, and if anyone has any prep tips for the 3aj
Many thanks

My dj02 has over 80.000km on it, and i use it from everything from dayly commute, to enduro-ish races, and everything in between. Its still going strong, and uses no oil.

I would probably replace wheelbearings, and go over all other "external" bearings. (lube or replace)

Then all the usual stuff, change oil and filter, new tubes and tyres and so on.

Do it all a couple of weeks before you're trip, so you have time to "test" the bike afterwards.

Rear shock. Somehow the designers missed the calculation for full travel clearance and the exhaust touches the rear caliper bracket when it bottoms out. We went through 3 of these brackets. I'd make a guard for it.

Well looked after 3AJ
 

Is it your 25k or 4 previous owners? For a trip of that length I would personally at least put in new clutch plates, and might even consider pulling it right down to check the state of the gearbox pinions: a mate bought a one owner XT from a friend with similar mileage and had to replace 4th and 5th ratios - it had been geared up for economy on a long trip and driven hard at low revs. By comparison, my 40,000 km, 4 owner imported 1VJ is still sweet (though I'd definitely take it right down before a proper overland trip longer than 3 or 4 weeks.) I'll be giving it a new clutch at least before Morocco next May. I'd fit new wheel bearings when you do the tyres, chain and sprockets, as they're cheap and easy to do. Have a really good look at the fuel lines: the new additives in UK petrol seemsto be disagreeing with some old pipes - my Guzzi sprang a scary leak in Spain last year and the newish hoses were effectively disintegrating!

yes the gearboxes do go after a while
you prob have about another 10.000 miles on ur gearbox but if ur doing a long multi country trip replace the engine with a xt600'e' engine which is much stronger and less likely to let you down

i too have a 3aj and about the same miles but mine locked in 5th gear and now well its shagged im rebuilding my 3aj engine with 2003 xt600e internals and got a 1993 xt600'e' in it at the moment well once buttoned up and moted itll be back on the road oh how i miss it :(

Thanks everyone
 

This is my first try at multi quotes!!!!
Have made a hole in the exhaust already from it bottoming out on the caliper, i have adjusted it to it's hardest setting which is alot better.

Would replace bearings, clutch etc and give it a good service, it would also give me a good chance to learn my way around the bike.

I did think the 3aj was abit more bullet proof, I was aware of possible gearbox issues. So a strip down or a shorter trip, at least I have 2 years to decide, or do I sell a 3aj in very good condition and buy a different bike to travel on?

Don't be too put off by all the horror stories - yes they wear out, but so do all these bikes after 20 or so years (and whatever you do, don't fall for the BMW hype that they are any different!!)
FWIW, if you're planning a big trip, I'd say take the XT. Get yourself a manual, some spanners and a gasket set, then tear it down to check out the wear, replacing worn bits as necessary. Then you'll be heading out on a bike that you are confident in, and will know how to fix if it does have a problem. If it's a shorter trip, just do the basics and go for it!! Good luck!