1985 350x Build Up

[salisbury4573]

This is gonna be a slow build, but here is how she sits now.

Has a break in the left side of frame, TPC gusset kit has been ordered and is on the way.




Runs ok, little hard to start carb rebuilt kit is on way, but I am not riding it until frame is fixed right. Rear brake caliper bracket is broken, needs some attention, gas tank has patch, considering a clarke plastic tank. Thats the only major problems I am starting out with. Plan is to go through it all and make a trail runner, nothing pretty, but something I can hit the trails with and have some fun on and be reliable.

This is my 5th ATC, first 350x, I am excited for this one. Traded my street legal 95 xr200r that is in excellent condition for this ATC thats in OK shape...lol Had to have it. Good news is that it came with a title and an extra motor, have not identified the year of the spare motor yet, hoping for an 86' as I am reading there are some improvements on that year.

More pics and write up to follow.

[salisbury4573]

The spare motor is an 86'

[BOB MARLIN]

You can also tell the difference between the 85 and 86 engines by the clutch cable routing. They are on different sides.

[salisbury4573]

Carb got disassembled and dipped last night. New plug and this bike now starts on 2nd kick and idles great!

TPC gusset kit is on way!

[salisbury4573]

So I messed up, the bike was running great and I have been focusing on seemingly simple cosmetic issues like seat cover and fork boots and the exhaust is extremely rusty. So I decided to take the exhaust off and give it a high temp paint job.

BIG MISTAKE

The exhaust studs were flared out where someone cranked the exhaust flanges down super tight. I was able to get the header off, but the studs were in such bad condition I was basically left with no option but to try and take them out and replace them. 1 of the 4 came out nice, the other 3 were not so easy, twisted one off almost flush and the other two I quit on before twisting them off as well.

So long story short, motor is now out of the bike, head is off and at the shop. I am gonna let someone with more skill than me take a crack at it.




I am a bit mad at myself for letting something simple snowball into this, but once I started down that path, it led where it led. The plan now instead of putting the old exhaust back on is to order the DG header and pipe. Maybe.

[BOB MARLIN]

Those studs have given me problems on all my x's and I'm sure almost everyone else's too. Fix it and move on. By the way those dg pipes look and work good but are louder than +++k.

[DohcBikes]

Where's the extra motor? Looks like you were on your way to extracting the studs, what was the result of your welded nut? Kudos for taking it to a shop when you felt overwhelmed. More people should do the same. Like bob said, small bump in the road, move forward.

[oscarmayer]

What is your end goal for the build?


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[salisbury4573]

End goal for this build is a reliable rider for the trails.

Shop wound up drilling out studs, went up to a 3/8 grade 8 studs going in. I assume will need to drill flanges, hopefully no big deal.

[salisbury4573]

Good news is while motor is out of bike, gusset kit will get welded in.

[oscarmayer]

Why are you letting them tap studs to SAE? It should be metric only and you go to 8mm from 6mm



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[350xtrike.rider]

Why are you letting them tap studs to SAE? It should be metric only and you go to 8mm from 6mm

We arn't all as perfect as you jk but from a welders stand point most shops in America only work with American threads. Like me.

[salisbury4573]

Tried to re-tap to M8x 1.25, but threads were too loose. Steel threads were seized in aluminum. Only choice was to go next size up, so went 3/8 because that's what was available and made sense.

I'm looking into buying a 400ex head pipe now to possibly modify, but am running into a lot of seemingly misinformation online about fit and how to mod. And really, what is the gain using a 400ex header pipe?

All comments welcome, as I am trying to decide between this route and just buying the DG, or sticking with the OEM head pipe.

Thanks

[salisbury4573]

Without getting too technical and showing off my ignorance, what I am hearing is that primary head pipe length and diameter is why the 400ex head pipe is a good swap. Supposedly a longer primary pipe length before the collector will increase the bottom end and mid range power. I am going to assume the risk, I bought a 400ex header for $40 on ebay. Hopefully I didn't just waste $40 lol.

Anyone else do this mod? Am I barking up the wrong tree with this one? $40 is an acceptable risk, if it works then great, if not, then oh well. I tried. Maybe this experience will help someone else on their decision.

Thanks

[wonderboy]

Sorry to be picky, but if the shop was already in there working on the studs, they should have just used a thread repair kit, which in the end results in a stronger than new threads (stainless steel threads in the head + new 8mm studs in my opinion is better than 3/8" stud in aluminum). I'd be worried about socket access to the largers nuts on the larger studs especially with the already larger 400EX header.

By the way, I think the 400EX header is a good move.