Rebuilding a 55W from scratch. Any suggestions?
 

Hey,

I’m rebuilding a 55W 1985 Tenere from scratch. The bike is completely stripped down and every thing is in peaces, including the engine http://www.horizonsunlimited.com/ubb/smile.gif. So I guess this is the time to make all the necessary and cool modifications possible. This is my first Tenere so please make suggestions to what could or should be done.

I’ve read Klaus’s very helpful and insightful posts and plan to:
· Install the newer and stronger oil pump and it’s plastic sprocket.
· Get a firmer suspension. I’ll see if I get afford Ohlins after rebuilding this thing http://www.horizonsunlimited.com/ubb/smile.gif.
· Relocate the CDI in front of the tank for cooling. I know it’s going to be tricky modifying the harness but It gets really hot in the desert down here and the Tenere CDI is in the worst possible place inside the frame when it comes to cooling.

Any other ideas?

Klaus, I would really like to do something about the 5th gear. I checked your site but I don’t speak German. I would appreciate it if you explain to me what to in English. Thanks

The 55W engine that came with the bike was in pretty bad shape. It needed new cylinder head, camshaft, valves, valve guide and an output shaft (the one that the chain sprocket attaches to). So I bought a slightly used 1986 34L engine from which I will take what I need. I will eventually (slowly) rebuild the 34L with a new top end and high compression piston to race with it in the Rally Of Egypt next year. Wish me luck.

Thanks

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A.B.
www.ShortWheelbase.com

5th gear:
-avoid revs lower than 3000 in 5th gear
-avoid revs higher than 5500 in 5th gear (at least don't use them longer than necessary)
-install chain kit with 14/40 ratio
-install additional oil jet in the left side crankcase above 5th gear. connect it to the overflow pipe of oil tank. i can make such oil jets, contact me if you are interested. this modification works only if you ride always with maximum oil level.
regards
klaus

Does the chassis need any frame reinforcements? I plan to carry a decent amount of luggage while travelling and later on race with the bike.

Thanks.


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A.B.
www.ShortWheelbase.com

Hey there, we just took a 55w from Holland to Khartoum by way of Libya (Ghat), so winter time. CDI box holds out just fine. We have the 14:40 ratio, heavier spokes. Only 'problem' is the air filter clogging up much faster than on the other XT, 3DS from 89. This because intake positioned above rear wheel.

Auke

A good and cheap alternative to Ohlins are Italians "Bitubo" shocks (www.bitubo.com) also because they are still making even for old XT 500 and 550 ... for the 55w motor I would look at the bolts for fixing cylinder and head to the basement , and eventually make an Helicoil fixture on them (much stronger than the originals) I don't think that the CDI will suffer a lot from heat , normally these parts MUST endure 80 or 90 c° ...I think that vibrations are more dangerous; for rack you will need something to strenghten the rear rack & subframe , like two rods that connect rear pegs with rack ..

I got the idea that the CDI is prone to heat since I saw 2 of them on different bikes burn under racing conditions in the Rally de Pharon a few years ago. Also a friend with a 96 Tenere also burnt his CDI. So I think I might as well do the modification since everything is apart and I have to work on the harness anyway (it’s in bad shape). Thanks for ensuring that it will not be a problem. I will however try to mount it with vibration mounts to reduce vibration.

About the filter getting clogged: That’s probably why they moved the filter under the tank on later models. I’ll try to see if I can relocate the air entry point. Thanks for the warning.

Thanks

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A.B.
www.ShortWheelbase.com