Dazza's Tenere build
 

A few months ago, I bought a written off ex insurance 2013 Tenere. I was promptly told by the other half that I was mad and should never have bought such a wreck etc etc.

So this is what arrived at home:
https://farm2.staticflickr.com/1630/...3d13467c_z.jpg A sad tenere by DARREN MORRIS, on Flickr

The previous owner had had the bad luck of riding around the corner into a truck crossing the road. He survived the crash but was severely injured. He has asked me to look after his little baby, so I am trying to get it back to working condition.

The frame was bent in a few places, so I have had it straightened, along with one of the fork legs and the radiator. So the frame is all certified ready for reregistration. Now all I need to do is fix the rest of it.

http://advrider.com/index.php?attach...41-jpg.500930/

I had the good luck of contacting an inmate from this site and was able to get hold of a'08 front wheel and front brake line from England. It makes life so much easier having two round wheels...

From Ebay, I was also able to get a replacement '08 Fuel Tank. It actually cost more to have it sent to New Zealand from England than it cost to buy. But still way cheaper than a new tank. The '08 tank is slightly different from the '13 tank, so a little piping modification will have to be done here.

From Italy I got hold of second hand throttle grip assembly and switch units.

From Australia I bought a bash plate, Crankcase cover and water pump. I recently also got hold of a '14 front mudguard, hand guards, mirror and a newer front brake line.

https://farm8.staticflickr.com/7720/...d22ed50f_z.jpg New parts for the Tenere by DARREN MORRIS, on Flickr

I need a bit of time now to start reassembling the engine and radiator system.

A bit of spare time at work on night shift, allowed me to make up a new tail tidy, as the old one had been smashed.
https://farm2.staticflickr.com/1710/...00a06ee3_z.jpg New tail tidy for the Tenere by DARREN MORRIS, on Flickr

Now all it needs is a rego plate...

When I mounted the indicators, I had to test it. So turned the key on for the first time and yahoo, the indicators worked as did the tail light and brake light. Thank goodness something is working on it.

So now I am on the hunt for more parts. I still need to find a front brake master cylinder, radiator guard, headlight, speedo, left side indicator fairing panel and headlight surround as this area got demolished.

I have tried to repair the headlight and it may work but it's not a pretty picture... all the internal mounts have also been broken. As well as brake fluid damaging the clear surface of the front of the lens. I have been able to polish most of it out, but it's still a bit misty.

https://farm8.staticflickr.com/7468/...573b627f_z.jpg Headlight damage by DARREN MORRIS, on Flickr

I pressure tested the Radiator and found it had a hole in one of the cores. I have been able to patch this with some liquid metal resin and pressure testing shows it as all good again. I have remounted the bottom mounting pin which had been ripped off, so now can look forward to mounting in on the bike. I have replaced the radiator over flow bottle as this was also smashed and beyond re-welding.

The Side cover on the radiator bottle was also crushed, but I have been able to heat it up and straighten it and weld up the cracks.

So many things to do and so little time....

Wow, you have lots of guts.
Looking forward to the end result. Good luck !

very brave, your hard work looks like its going in the right direction for you, does your other half still think your mad or you not seen her yet as in the garage all the time. well done.

Thanks for the support. Yes she is talking to me again... It did take a while though.

Good luck with your amazing project.....and sometimes some peace from the wife is not a bad idea hehehe. After many years of bikes and marriage mine told me that "it was either me or the bikes"......so I took the bikes and left!!

Haha, hope that was the better choice? It's all good here, just really bad timing as we are trying build a house at the same time... Part of my reasoning to buy it was so she could ride as well. She doesn't like to ride my other bike as it's too big and heavy for her. And I wanted a lighter trail bike

Goodness you are a glutton for punishment to be sure......and yes it was the correct decision as I then met another lady and I have never been happier,,,,,,

I removed the Headlight frame today. It's a bit out of shape...
https://c7.staticflickr.com/8/7346/2...7bd4825d_z.jpg Bent frame by DARREN MORRIS, on Flickr

So I have straightened it up and welded up a couple of cracks in the tubes. I will have to check it is OK once I put the headlight into it...
https://c1.staticflickr.com/8/7114/2...6429ab72_z.jpg Repaired frame by DARREN MORRIS, on Flickr

I have got the old headlight shell in it at the moment which I have been repairing, but I have given up on that and ordered a new headlight, which will hopefully be here this week along with a few other parts. Looking forward to putting them on the bike.

all that for a head light & a few bits of plastic...

no wonder the dam things weigh near a 1/4 ton fueled and loaded...

looks like yer have it on the road for summer.....


..

:finger: Here's hoping... The Clarence is calling me...

The clarence is over rated... Be better off doing the
rides in the north island :025:
and avoiding passport control....



...

I received some more shiny bits this week, so I was able to put a new headlight and surround onto the subframe. I spent a couple more hours on it trying to get the mounting points into the right places, but to no avail. when I get one point Ok, the other side has gone out of shape...
https://c2.staticflickr.com/8/7301/2...117741ce_z.jpg Frustrating non alignment by DARREN MORRIS, on Flickr

So I have decided to order a new sub frame so that all the mounting points are where they should be. Also ordered a new master cylinder for the front brake, which will be handy to be able to use the brakes.

As I was mounting the fuel tank, I had to reposition the Key barrel. I knew the bezel ring was broken, but on closer inspection, Disaster! I realised the bezel is in fact the arial for the key ID sensor!!! And the arial is stuffed.
https://c7.staticflickr.com/8/7335/2...01e951b3_z.jpg Disaster by DARREN MORRIS, on Flickr

This is a pretty pricey component and unfortunately, the original owner doesn't have the red key. I only got a bent black key with the bike so I might be looking at alternatives...

1) Buy new key sensor.
Easiest option but most expensive option
2) find second hand key sensor.
Possibly cheaper, but not sure if it will match my existing key or if this is done in the ECU?
3) rewind the arial and hope for the best.
This might work but the bezel is still broken and it'll be time consuming. And at the end of the day, all three options above still only give me 1 key, and it's not a master key...
4) replace the key sensor with a immobilise emulator.
This option looks the cheapest, but not sure if it works on the tenere's?

Has anyone had any experience with these components? Or know of any other options?

I received the new headlight subframe and mounted it on the bike. It was quite nice just bolting it on without having to use a hammer. The headlight fitted in too.

I replaced the broken brake lines with a second hand set I got and mounted the new brake master cylinder and lever. It took a bit of fiddling, but I eventually got the lines filled with brake fluid and bled of air. Yahoo, brakes, front and back.
https://c4.staticflickr.com/8/7204/2...4bd735ce_z.jpg Headlight mounted by DARREN MORRIS, on Flickr

looks good...

can't be to far from on the road now....




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Yeah, feels like it's close. But still got to get the engine turning over yet...:smilies0942:

Ten out of 'Ten' for persevering! Steve

When I got the bike, the water pump had been ripped off the engine. Not a pretty site:

I was able to source a used pump and crankcase cover from Australia, and so removed the damaged ones. I checked the runout on the end of the crankshaft in case it had received a blow. It was 0.1mm off center. A quick tap with a soft head hammer soon had it at 0.01mm. Much better I feel.

The replacement cover and pump are now on the engine and it is full of oil again. The radiator went back on and I filled it with water for testing.

I hooked up the fuel pump and had charged up the battery, so put the key in it and turned it over.... And over... And over...

I will now have to work out if the immobilizer is not allowing it to work or if the fuel pump is not working.... Arch! So close....

you should hear the fuel pump prime for a few seconds when you turn the key on....
can check for power at the green plug on the bottom of the pump
again only for a few seconds after you turn the key on...



..

Thanks Pete.
Yea... Nah, no pump priming, but I'll have to check for voltage at the plug first before I rule that out. But I also need to prove the pump works as it was damaged in the crash as well... Lots of priority jobs on the go at the moment.

i have replaced my pump...yamaha wants $830 for a complete unit..
but you can get the pump only off E-bay for around $40nz on yer
door step...
the pump houseing just unclips to get at the pump...


..

What can I say... not many have the time and courage to handle such a big repair process.
Congrats!

Yes, I've seen the prices. Unfortunately the pump housing may have bits missing off it, as it was smashed inside the tank, just something else...

Garcya. Cheers mate for the support. It's been a slow process.

Following these builds is better than watching the best mini-series! Ever. Very keen to see the end result. And we all learn from these brave mechanics out there who have the balls to make the inquiries and the mistakes for all of us!

Nice work..

Thanks Graemet. I hope not to make too many mistakes... But suspect the first one was to buy this bike in the first place. But I am enjoying the learning phase of how this bike is put together... Intimately.:YellowWow_KKPB92:

great work
any more news?

I'm currently waiting for a fuel pump to arrive. We watched it leave the UK, arrive in Auckland..... sat there for a week and half.... then promptly turned around and went back to the UK.:cussing: The guy sending it, ended up away on holiday for four weeks.... So now he has it and we are hoping to get it back on its way here soon.

A very frustrating 2 months.:BangHead:

It has helped that I have been busy building our house, but summer is virtually here, And the missus has actually sounded interested in when it will be running...

And the saga continues... Royal mail has lost the fuel pump in the UK somewhere. :093:

In the meantime, I ordered a replacement fuel pump kit and installed it into my housing. On installation, I found there was no seal between the 2 halves of the fuel delivery pipe, so made an O-ring to seal that. Putting a pressure gauge on the line, I am only getting 20 psi and the manual states it should be 46 psi.

The over pressure relief valve has been damaged as well, so I think it might be leaking past it in the tank. So I still need a complete unit. I have ordered a used one off eBay, so hopefully this time I will get it in the next 2 weeks.

And the Battery has died and won't take a charge, so I've had to order a new battery as well... At least my bathroom project is progressing nicely...

I just got a new complete plug & play unit for $183NZ
off Alliexspress only took a week to arrive...



...

Douh! :eusa_shhh: I didn't want to hear that. Admittedly the first pump did get to NZ, but our customs/NZ Post people stuffed something up and returned to sender, almost.

Just been looking at the alliexpress listings. The pump for the XT660R has a different fuel level gauge unit than the Tenere. There was a listing for the FZ6R that looked very similar, but the parts numbers are different so not sure what the differences are.

fuel gauge.... over rated... the XT is the first bike i have owned with a
fuel gauge/light.... not needed..

I'm pretty sure the unit is the same and the fuel sender of a XTZ pump would fit on it.....



...

I continued with the Fault finding last night and tested the spark plug. It measured 800Kohms, which I thought was way too high, so I bought a new one this morning, chucked it in.... And with 4Kohms reisitance, we now have spark:angel8:

https://youtu.be/0pf6RsflBtk

That's a BIG box ticked well done mate.

Well done there, DazzaXT !
Looks like you're over the last big hurdle. Should be on the road soon :)

Cheers Guys. It is a huge relief having it running. I am looking forward to the finishing touches and riding it.:deathmetal[1]:

The Mail man (or should I say woman, as my wife is the postie, makes it hard to sneak something in through the mail :Mandy:) finally arrived today with a fuel pump assembly, yay. Only 4 months to get it!

Haven't had time to swap it out yet, but it will be done in the next day or so. I did get the bash plate on tonight so its coming together nicely.

I got time today to put the fuel pump in the tank:
https://c4.staticflickr.com/1/666/31...09edb82a_z.jpg 20161219_145654 by DARREN MORRIS, on Flickr
Then once that was in, I put all the rest of the bits on to the bike, so now it's complete! Now all I need to do is get it recertified and registered :VeryHot_FWSGAA:
https://c7.staticflickr.com/1/374/30...471a72f1_z.jpg 20161220_120515 by DARREN MORRIS, on Flickr