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9 Dec 2010
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Join Date: May 2009
Location: Western Australia
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Gearbox Upgrade on a Tenere 34L
Hello fellow Tenere heads,
I am nearing the end of my Tenere 34L rebuild and have left the worst til last.... I have now split my cases to discover a knackered gearbox (no suprises!
It has the original oil pump which needs to be replaced. For those Tenere adicts who want a refresh check out this link on the HUBB http://www.horizonsunlimited.com/hub...ce-needed-5769. Given I have a 34L, this link recommends moving to a 1VJ oil pump which is 50% greater output than the original 34L. However I am tempted by the 3AJ pump whic his double the output than the original! Its even cheaper at just over $100USD from Park Shark.
My next problem is the gearbox. The gears on the countershaft look very useable, certainly no chips and the hardening hasn't broken through. The mainshaft is a different story with two gears well and truely knackered. Perhaps the previous owner replaced a couple of gears on the countershaft as things don't really add up to me. Problem is I think the whole mainshaft has to be replaced as one unit ($$$) and I don't think its available anyway.
Has anyone fitted later (XT600E ?) gearbox internals into such an early model? I hear the hardening is much more durable, the ratios are better and the oil delivery is better. (Especialy with the 3AJ oil pump)
I'm sure others have been here before ?
Many thanks,
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9 Dec 2010
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Join Date: Nov 2007
Location: Lancashire
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I was faced with this problem a couple of years ago.
I was rebuilding a XT600 43F,same as a 34L apart from tenere tank/seat /sidepanels.On my bike all the gears needed replacing as they were were starting to pit  .
I ended up taking the expensive route and going to Dave Lambeth.
I only live a couple of hundred miles from DL so I decided it would be better for me to take the motor to him,he fitted a later gearbox modified to fit in the cases.Dave rebuilt my motor with the later oil pump and a host of other stuff done,rebore/new valves etc.
Obviously this is'nt practical for you, but you should ask him how much would it cost to get the modified gearbox sent to Oz.
If you do'nt want to go down that road,you could always fit the original gears & replace them again when they start to wear,obviously that's just swapping like for like.The oil pump is a straight swap.
Here's a link to the rebuild My XT600 project.. - ADVrider
Mark
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9 Dec 2010
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Join Date: May 2009
Location: Western Australia
Posts: 25
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Cheers Mark,
I've just double checked the Partshark website and I can get the dodgy gears replaced for a few hundred bucks and just whack it back together.... hhmmmm.... :confused1:
Great thread you have there - I'll re-read that one later and comps on the photos.
I see you went the 3AJ oil pump - so if Dave is recommending that then I'm sold  I might fire him an email and see what the damage would be for the upgrade. Nothing that can't be done with some international freight. I wouldn't send the entire bottom end - just the shafts so it wouldn't be too bad. I know he's a busy guy though!
Do you know what Dave put in with the gearbox?
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9 Dec 2010
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Join Date: Nov 2007
Location: Lancashire
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Sorry Bugz,I forgot what specific parts he put in the gearbox.
One thing I can remember was that on the clutch side of the crankcase, one of the gearbox bearings was worn-out & he reckoned that every time he's split the cases this particular bearing is shot,so I'd check the gearbox bearings before you go shopping for spares.
Mark
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9 Dec 2010
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Join Date: Nov 2009
Location: christchurch newzealand
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I replaced my two 5th gear wheels when the whining started and its pretty straight forward,I found the gears from my yam dealer were very well priced and now its as good as new........
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10 Dec 2010
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Thanks guys,
I figure I will keep it simple and replace the gears. The shafts look great and I have done the maths on ParthShark.com
If I can find someone to split the mainshaft I will replace both pairs on the 3rd 4th and 5th gears. Cost for the bearings would be $378 US which isn't bad for six gears!
I'll replace all the bearings (apart from the one on the crank half that can't be removed) so with a high output pump it should be good as new
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