toal engine rebuild.

**stormsearcher** · #1 30 Apr 2005

after my crank blew up had a dilema. to get the bike running or wreck it.wreckers wanted $500aus for it. had reikon bars,brand new chain sporckets, swing arm bushes.very good body.decided to rebuild the bike.new crank, cam chain, new piston, rings, clutch,gaskets everything.total cost $2800 aus.need new tyres, $200. bikes ready to rock and roll.happy that i know whats inside the engine andconfident the bike will take me for many a australian adventure. where can i get some aluminium panniers, a temp gauge and what can i do to eliminate the dipstick to check the oil level everyday? and what kind of mileage can i expect from a well done up engine?a RTW? thanks

**Matt595** · #2 1 May 2005

I think it is realistic to say 100 000 kms if you drive the 3AJ with care, like never going to low in revs on 5th gear.
Camchain could be changed at 50 000 kms to feel more sure about lasting of engine, anyway a 3AJ will probably have other problems at 100 000 kms, like the left crank bearing to often martyrised by the undecompressed 600cc when using the violent starter engine with all its toraue on that side, one day or another there will be play in that bearing = play in camchain.
I say its a good idea to fit a kick and start engine by foot and decomp mechanism the most often possible.
On 660, they made a great automatic decompressor integrated in the camshaft, so starter is less violent and torqy.

With care for this and care when driving in 5th gear, replacing oil pump every 100 000 kms + camchain 50-70 000 kms.
Then maybe it would last much longer..

Matt

**stormsearcher** · #3 2 May 2005

how can i fit aq kick start mechanism? from a xt engine?would eliminate the battery as well makin it more hazzle free.

**futronix** · #4 5 May 2005

hi mate, i had some really good quality paniers made from a aluminium fabricators in tempe sydney, i took in some tesch boxes and they copied them exactly... actually , a little better ....(sorry bernd)
give me a call if you need some help...
phil... 0415 558 372.

**stormsearcher** · #5 12 Sep 2005

bike baCK after total engine rebuild, done 1200kms changed oil +filter. noticed piting of the oil tank cover? heat?anyway do all the 3ajs when switched off go to rest with a loud clunk?new trailwings seem good.hope this bike is going to last me thro the aus trip sometime.cruises effortlessly at bout 90kmph. thinking should become better after running in bout 5k kms.is it ok to keep it in 5th gear from 3500 rpm?.