3EN2 work in progress ;)

[baldy]

hi all,

as part of my semi-restoration of my new 3en2, ive hit a stumbling block or two on the teardown.
im not a complete muppet with the spanners but

how the hell do you get the spark plugs out?
I only managed to get one of my few plug sockets (a 12mm) in there (once id removed all the leaves ) and even tho it felt like it was on, I couldn't get the plug undone

and how the hell do you get the tank off?
ive undone the two bolts at the rear and the two allens at the front, the middle transverse bolt but I really cant see how to disconnect the fuel feed?

I also have a Mystery Switch on the dash
there are wires for what appears to be an alarm under the seat with an led on the dash but this switch seems to do nothing? or does it do everything?

oh yes, on removing the side panels, I found the exup servo cables to be broken.
then I found the exup valve itself is, er, missing. all that's left is the mounting plate with a great big bolt blanking the hole in the middle

don't suppose anyone knows where I can get some cables, and a er, some exup gubbins?

[willandrip]

Always best to blow out the spark plug wells with the airline first if you can to prevent debris falling into cylinder when plug removed as you have done.
Plugs will be corroded in .Try again whilst engine is hot,careful though;they are easy to shear in half.Soak for a day with PROPER penetrating oil (not wd40)
You do need a thin walled plug socket as you have discovered.
Remove the cross brace tank mount from the frame and remove the fuel feed pipe from the carbs to remove the tank.The filter assy should be affixed to the tank itself along with the pump,remember the fuel pump power feed,dont just yank the tank off
Dont forget to remove the plastic fuel tap lever from the tap itself first if its not already bust off.,small crosshead screw internal to lever and pull gently.The tank wangles out.

Unable to advise on switch,its not standard.Maybe an auto tank ejector mechanism

Your best bet is replace the inners of the exup cables once you have the valve sourced and fitted.
Its very easy and cheap ;here is a link;
http://www.exup1000.co.uk/tech_info_are ... cables.htm
Boris stated Vehill now also do a specific kit for 400's in a previous topic.
There is a set of cables on the bay at present ,I would link them for you but you would be bidding against me so ...........
The valves themselves do surface occasionally,put an add up in wanted section;you may have more luck with a cheap set of headers c/w valve..

Kayla might have a set of cables and a valve (pretty sure she has actually)

[Evilchicken0]

Strip the bike down and then hose the plug recesses out. Take the radiator off for better access but they can be a bit of a faff.

Venhill do the cores but they're universal for all exup cables you'll need to know the length. Look for some downpipes but this seems to be the least of your prblems atm.

Pictures

[baldy]

awesome sir, thank you very much
I did see the cables on the bay, but since the exup is removed completely i'm not desparate to get it sorted

yesterday I managed to change the exhaust for a spare I had in the shed, reseat the airbox as the rubbers weren't even on the carbs, cleaned the filter and airbox out of all the crap that was inside.
probably from the holes drilled in it
the holes nearly lined up with the holes in the frame from the air ducting? some genius' idea of diy ram air maybe?
reassembled because it was getting dark (and I couldn't get the tank off ) tried to start it, no joy!
flattened the battery trying. put battery on charge and fired up the laptop for fuel system schematics to try and figure out what i'd buggered up....

only took me half an hour to remember i'd turned the fuel tap off

pics on the way
only my experia has died so im using the House Spare: an iphone 1. 2g only and the ios is about 1.durr

[baldy]

some pics


with the new (sort of) can


under the seat. please note the custom 'freestanding' flasher unit.


under the airbox. bleurgh...


holy airbox batman! ram air courtesy of Black and Decker.

[Evilchicken0]

Could do with a wash but it looks functional

[willandrip]

Good pics;
Looks to be a good un ,Baldy,just neglected a bit! Certainly was worth the trip to Carlisle anyhow.
That wont take you long or cost that much to get very tidy.

Just do a section of it at a time and dont sicken yourself.Try to have the stuff you need in advance of the work and ask on the set up of the particular task your going to attempt before you attack it if your unsure.
We like questions on here;most of the contributors have been in your situation.
Example;
Duct tape will fix the airbox holes temporary till you get some grommets to make a proper job of it,or a £5 airbox comes up ;then you have spare rubbers and probably a good filter with it.
Tip
I refit the tank first with the crossbar loose on its mounts and refit fuel supply to carbs then tighten tank fixings.Put the airbox spigot and rubber into the front mount and refit the crank vent pipe and the drain hose;then wiggle down the rubbers over the carbs and tighten clamps.

Subframe can be stripped out on a Saturday,,wirebrushed,rust converter,primed and painted and reassembled on the Sunday;
Not only will you have tidied it up and prevented further degredation but you will have learnt where all the relays are,what they do and cleaned the connections and tidied any mess on the harness.Many will say why bother! You would be able to tell them why when an electrical fault occurs and they are stranded whilst youre not.
That flasher unit will bounce about and get squashed and fail or short out battery if left loose.
Proper place is behind sidepanel ,the rubber mount rots away but a bit of foam and zip tied to subframe would fix it.
Most jobs can be done on the very cheap; its reliablity that is utmost.
Good thing about these is lots of other Yamaha bits fit and work.
"spare Micron from the from the shed" I like the cut of your jib already !

[baldy]

cheers will, was certainly worth the trip, just need to get the time to get stuck in to it.
had an nc24 3/4 years ago that mainly came as a box of rusty bits. 2 months later was one of the best bikes ive ever owned

we don't have a garage or even a drive here so I have to make the most of the good weather

got some stainless fasteners on their way to replace the complement of rusty ones its currently sporting.
as well as a decent alarm, speedo converter and full service supplies ( plugs/filters/oil/brake fluid/fork oil)
looking forward to getting the carbs sorted so it bloody starts cleanly
first push it burbles into life but any gas or choke and it dies
im guessing that as well as the ridiculous can and the drilled airbox that the mixtures been set richer/bigger jets/lifted needles

[willandrip]

No garage is a proper bummer
That must be the patio area then? in the pics.
Have you thought about one of those tent canopy things ? often seen at race meetings.
Tell the wife/girlfriend/mother it would be dead handy for the washing !

[baldy]

yeah I considered that but the washing line takes up most of the space
I cover the bikes with a big tarp, going to put some hooks on the wall to hang it from tomorrow night

could the missing exup be a factor in its terrible starting?
hoped the sensible can, resealed airbox and reseated rubbers would improve matters but if anything it seems worse?

only slightly offtopic, but is a speedo display in mph (converted or stickers) an mot requirement?