Quick clutch push lever screw question
 

Just a quick one, hopefully :offtopic:

Can anyone tell me whether this screw really has a washer?

https://i.imgur.com/qLgZop2.png

Reason I'm asking:

1) I can't find it, and the screw already has some sort of washer built-in:

https://images.cmsnl.com/img/product...67-01_1c98.jpg

2) When I turn the screw it basically stops the push lever from turning? Like a stopper.

I'm a bit confused about the exact function of this screw? What is it for?

I can't find any info in the manual regarding this screw, except that you have to put it to 12nm.

Thanks

Yes...it is actually a thick copper washer to provide a good seal as can leak oil if not. i would say is going in too deep without the copper washer and hitting shaft?

That's what I'm thinking. However in that case, what is the purpose of this screw? To prevent wobble of the clutch push lever or something?

prevent part 21 from sliding up.
indeed, if it binds the shaft it's because a sealing copper washer is missing.

It locks the push lever shaft so that it cant move up once you have installed it. When you install the screw it sits in the bottom part of shaft and not allowing shaft to ride up,

Ah I see, that makes sense.. it falls in the smaller/slotted part of part 21. Thanks.

Now I'm on the subject of weird screws...

There's another weird one that I can't find on any of the exploded diagrams or in the manual, the one that goes here:

https://i.imgur.com/tNpNTfk.jpg

Don't have a pic of it now (and can't find it online), but basically it's a screw with another screw in it, like the clutch adjuster.
It looks like it presses against the geardrum or something? I'm not sure.

https://i.imgur.com/mhOdHDK.jpg

Looks like it comes in here, very close to the drum.

Thanks

Neutral switch goes in there

Aah... that's why I couldn't find it. It's under electrical 2.
It grounds itself on a piece of the drum, I'm guessing?

https://images.cmsnl.com/img/product...01-01_ade2.jpg

What about the screw? Special way to adjust it? You turn it in until the neutral light lights up :laugh: ?

No...no adjustment, there is a wire that goes to that screw...normally blue in colour. Just screw neutral switch all the way in. Wire is in the stator loom. There is a long slot in the stator/ flywheel crankcase cover for that wire to come out from the inside of engine to the neutral switch

Right, bit the pin at the end is touching something in on the gear drum right (at least when it's in neutral)? At least that's how the neutral switch on my other bike works.. it looks very different.

Yep there is a screw in the end of the drum that operates switch. You can see the screw on the parts pic of the shift drum itself

Have you got the rest of bike assembled? Close to getting it going? Should be good!

Ah, yeah I saw that screw in search of this one. That makes sense, thanks!

State of engine: added clutch

https://i.imgur.com/4CEM3uv.jpg

State of bike:

Stripping it...

https://i.imgur.com/dbQHePi.jpg

Carb is already rebuilt. New airfilter ready. When the engine is done i'll add it to the frame with only the basics and see what happens.

Engine top-end was hardlocked/top-end destroyed when I bought it, so never seen it run.

Next step, piston :)

Nice..... I should have made an engine stand long ago like you have. Would have saved a lot of handling dramas. I would like to add a 3AJ to my stable but its slim pickings here in oz even trying to find a restorer bike. Hard to come by anything.

More weird stuff....

This guy

https://i.imgur.com/FpH28BQ.png

Mine doesn't come with it - at least I can't find it.

Also, this guy doesn't seem to put them on:

https://www.youtube.com/watch?v=q95R4Drw_1U

2:10 and 13:50

Nut doesn't appear to be hitting the thread (bottoming out?) so now sure what the deal with this washer is?
From pictures it appears to be way thicker than regular washers.

Thanks

Yes they are thick. Dimensions of a spare I have are 11mm ID x 18mm OD x 5mm thick black steel

Thanks. Engine is done and inserted :clap:

https://i.imgur.com/5GYRbay.png

Got one more question. Many unknowns when you buy your first XT and the engine is already removed :laugh:

https://i.imgur.com/imO8xe7.png

So I'm quite sure the right tube is for the crank-vent -> airbox.
However what is the other one? It's not on the exploded diagram.

Thanks

congrats with the engine placement.
yes, right one is vent, smaller left is connected to the oil tank with soft pipe, it seems to be extra overflow escape route, maybe it is important only for filling tank during oil changes, but not sure about it.
by the way, where does your bike have oil tank?

Thanks! Makes sense.
The oil tank is on the right side (can't see it on pic), on the same spot where the black box is on the left side.

aha, remembered tenere-ish setup, together with couple other also nice jobs...

Yeah, read about your starter gear clearance issue. I appear to have the same clearance on mine.

So one last "where does this go" question, hopefully.:innocent:


1) Where does the crank breather hose actually connect on the airbox? Manual says there should be 2 "rubber plug caps" on the airbox, but mine has 3 (taken from the left of bike):

https://i.imgur.com/WJnxkzL.png


2) On the carb, is this the carb vent tube that just hangs somewhere and doesn't go anywhere?

https://i.imgur.com/EcFX6cR.png

3) On the carb I only have three tubes, apart from the short one between the carbs themselves:
1. vacuum line on the intake rubber
2. main fuel line
3. the one on pic above.

Did I miss anything?

Unfortunately the manual is quite useless in this regard.
Thanks:clap:

1). since your airbox is somehow different from other xt's, before someone better aware will answer, I'd think about appropriate diameter - one to which hose fits best, and it should not be at bottom of the airbox.

2). yes, but should have locking valve at the end.

3). still not sure if carbs on tenere and xt are same..

Thanks.

1) I don't think there's any other places for it to connect on the airbox. On my GSF400 it's also connected at the bottom.
The tenere airbox sits above the carbs instead of behind it.

2) You mean like it's closed off?

3) Looks be small differences, 3TB for example has extra pipe

https://images.cmsnl.com/img/partsli...98289_0684.gif

https://images.cmsnl.com/img/partsli...88724_7723.gif

Problem is, the exploded diagrams never show where the pipe actually connects. Even the manual "cable routing" doesn't for most carb/airbox pipes...

sorry, being at better internet / browser, just discovered that your previous post #21 also includes pictures.

seems that your airbox has two drain plugs for accumulated liquids.
preferably, these plugs should be lower then breather connection.

about carb breather, its #50 here, end valve is also visible.
https://images.cmsnl.com/img/partsli...98289_0684.gif
it goes "hanging", but preferably as high as possible.

and your carbs indeed look somehow different from mine, but in my opinion, that connector indicated as "carb breather?" might be for fuel intake, while lower one for overflow but again, not sure about it...

Yeah, but mine had 3 plugs, so now I don't know where the breather hose goes. Not that it really matters, but I'd just like to get it the way it's supposed to be.

https://i.imgur.com/zkpClgy.png
On this pic (not mine, but 3AJ) it looks like it's the bottom one (because that one is free) but that one would be too far for my pipe.
Also you can see they are all on the same height.

Regarding the carb, I don't have that pipe connection. I have the carb from the 2nd link (3aJ):
https://images.cmsnl.com/img/partsli...88724_7723.gif

I'm assuming it must be 22. (the lower 22, apparently there are 2x 22 on the pic... uhh )

Yep that outlet you call the breather is the breather for the fuel bowl itself. I have had muddy water get sucked up into this line at a river crossing when I had it hanging low, must be a very slight vacuum on it? I now keep it fairly short and place a wood screw partially into the end of it to make it harder to suck any thing up into it but still allow breathing

Thanks. Guess I'll stick it somewhere high up under the seat.

Regarding airbox,

Upon close expection of exploded diagram it appears the left connection (16) has a plug, and one of the outer two has the other.
So I'm assuming the picture of the airbox I posted earlier is correct. I guess my tube was shortened a bit.
If anyone knows that'd be great, in the mean time i'll try to stretch it and connect it to the right tube.

https://images.cmsnl.com/img/partsli...88723_f179.gif

simply route it all the way to the back of the bike with a longer tube, that's what i do in all my race bikes.



making it exit under the seat will make everything oily with vapors coming out

No what I meant was: I will put the carb vent under the seat.
I will connect the crank vent to the airbox. Just curious on which of the three connections on the airbox it's supposed to go.

since your airbox has three same sized connectors, and you will need a longer tube, I'd choose one from coupled, taking in regard height difference (if there will be any) and ease of draining.
if you have some free space & time, maybe you'd like to consider adding small steel based filter / oil separator in the middle of that tube - probably will never have to care about wet airbox and your carbs will stay cleaner as well...