1986 350x build

[sledcrazyinCT]

22 years ago I traded some walk behind mowers for a 350x with a bunch of extra parts.
I enjoyed riding it til 2015 when the frame cracked.
https://uploads.tapatalk-cdn.com/20240202/e7eb9ee3aa0cc03858da566ebeb218d2.jpg
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The engine ran strong, but valve seals leaked so it smoked like my fooler.
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Anyhow the bike needed repairs so it has been sitting for years.
I bought another engine for it in 2017.
I bought a gusset kit of Matt85350x member here in 2020.
Finally had some free time in 2022 so began tear down to bare frame. Rodents are such a bummer. Can’t tell you how many air filters they have chewed up on me over the years!
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Had it sandblasted in 2023…
Fast forward to this week, weather has kept us off the job site so we broke out the MIG and got some gussets welded on. https://uploads.tapatalk-cdn.com/20240202/277457a603f12af6eb46f27954f9a5af.jpg
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[sledcrazyinCT]

So my first question since reference pics of gusset locations aren’t on the board anymore, are these in the correct location?
We only tacked in the gussets near the rear seat latch until we test fit the air box. https://uploads.tapatalk-cdn.com/20240202/2b97fda07e677a7e7d77befce7183a75.jpg

[BOB MARLIN]

That's the first '86 I've seen that cracked like that. They seem to hold up much better than the '85.

When I gusseted my '85 I found 12 cracks other than the big crack above my left foot peg.

[sledcrazyinCT]

I have no idea how long a period of time that was cracked. Looking forward to fixing it up. Getting the frame started is my main hurdle.
Managed to chase all the threads in frame and remove a broken foot peg bolt successfully.

I will have to get my forks and shock rebuilt but have most stuff already lined up.

[sjsst41]

Looks great - laying down a nice weld can be extremely satisfying !

[sledcrazyinCT]

https://uploads.tapatalk-cdn.com/20240303/56c2597cbec0b76a4a3e2bc051f5634b.jpg
Prepped the frame for an upgraded rear master cylinder. Now I am looking to buy a set of wicked metal designs foot pegs. Currently sold out, hopefully will go back in stock or someone here would sell their extra stock…


Sent from my iPhone using Tapatalk

[Footy]

I really like the dirt bike style rear master.
I have been thinking about doing the same on my 350X to avoid cooking the plastic reservoir.
If there were any particulars with that mod please let us know.

[HondaRidr]

That's the first '86 I've seen that cracked like that. They seem to hold up much better than the '85.

When I gusseted my '85 I found 12 cracks other than the big crack above my left foot peg.

Did they strengthen the 86 frames?

SledcrazyinCT good choice on the master cylinder with a built in reservoir. I updated the one on my tecate and love it.

[Dirtcrasher]

No, but they had at least 3 versions of the 350X frame where they added a gusset to that left upper frame tube where they snap.

For some reason the seat latch areas seemed to break more on the 85's as wll, it's been a long time I may be forgetting something.

85 had nothing on that verticle frame tube, just the motor mount welded on.

The later serial numbered 86's had a nice wide and long gusset on the backside.

They also changed the upper motor mount bolts from 8mm to 10mm; some claim it's the flexing of the frame that cracks them, I always felt like the suspension was trying to separate the top half of the frame from the bottom. That's where there's only 1 bolt that doesn't join the 2 sides.

I use to wrap them with a piece of DOM tubing and then gusset that, and weld it all into the corner gusset. I made lots of posts about this maybe 15 years ago when I did a bunch of frames.

[BOB MARLIN]

The difference in the 85/86 frames is minimal, but whatever they did it worked.
I never could understand why the 85 frame cracked so much around the seat latch either.

[El Camexican]

I don’t know how I missed this thread, but it is sure nice to see something like this on here. Please keep posting.:beer

[oldskool83]

The seat latch are was nothing more then sheet metal welded right around the grab bar. Here's a thicker better fix I came up with. https://www.ebay.com/itm/126357883127

[BOB MARLIN]

The seat latch are was nothing more then sheet metal welded right around the grab bar. Here's a thicker better fix I came up with. https://www.ebay.com/itm/126357883127

Ironic that's a Solidworks sceenshot. I'm on Solidworks almost 50 hours a week.