JB's 350X Refresh

[HONDA_ATC_FREAK]

I'm very interested to here more on the stator cover plugs from a 400ex i need new ones for my 350x i just about ruined them getting them off for my rebuild.

[jb2wheels]

The 400ex plugs are direct replacements - the small one uses a 6mm hex and the large a 10mm hex.

I bought both caps and both o-rings new from BikeBandit. They weren't particularly cheap.

I'm curious if some of the eBay caps for other engines fit - like for a CRF230? I bet they do.

[HONDA_ATC_FREAK]

what year did you go with for the 400ex caps?

[jb2wheels]

2004 if I recall correctly

[jb2wheels]

A lot of work when I could sneak it in the last few days that you have to look closely at the pictures to see:

- Wire harness installed and all the clamps and stuff. Cleaned all the terminals and switches and painted the labels on the handlebar switches.
- Clutch and throttle cables installed. I'm using an aftermarket clutch lever because I have no parking brake. I don't really like the way it fits - the lever hits the switches before full pull. I might use the stocker instead.
- Rebuilt the carb with a fresh carb kit. I wasn't going to because it was a runner before I tore it down but I'm glad I did. The pilot was plugged, all the gaskets and o-rings were hard and brittle, and the mixture screw was stripped. Carb kit was under $20. Worth the peace of mind
- Carb, vent lines, airbox and all the intake stuff - I had to flip the intake manifold - it was upside down and explains why I had a hard time installing the carb when I first got it. I'm using an UNI air filter in the stock box. I like foam air filters better than pleated paper or K&N style.
- Made my own stainless studs from stainless bolts and installed the exhaust. I bead blasted the whole thing and painted with some hi-temp flat black. Amazingly, I have all the heat shields and the muffler clamp. Nice. I did have to buy the pipe to muffler gasket - it did not have one when I got it.
- Installed the PRM grab bar that arrived yesterday. The stocker was done - bent up and welded/repaired multiple times. I like these Baja Bars because it makes it easier for two people to grab it a throw it in the van.

We're getting close to engine start here. I need to knock out a few things:
- for a start and quick tour around the neighborhood I need to install the chain and gas tank
- blast the stock engine skid plate but I'm leaving it off until I'm sure I sorted the oil leaks
- blast and paint the sprocket cover because I missed it earlier

This things almost done.

[jb2wheels]

IT RUNS!

And it runs pretty good! Started on the 3rd kick. Seems a little cold blooded - I need to fiddle with the carb some.

I was going to make a movie but I pulled the fuel line off and don't have a replacement.

Front and rear fenders, shrouds and headlight came with the trike - including the middle third of the mudflap. The fenders and shrouds all have some plastic welding. The look great from 5 feet away...

Seat cover is an eBay special I installed myself with a Harbor Freight staple gun - air powered and shoots T50 staples uder $20

Tank is a Clarke that came with the 86 I just bought, It got a little wet sanding and scraping and some stickers I had laying around. It also got a cheap replacement petcock.

I rode it around the cul-de-sac some and it's everything I remember the big X being!

The clutch lever seems to work fine.

The punch list is getting shorter:
- stainless bolts or screws for the tank shroud - the stocker ones were too small and I just mounted with some from the screw bucket.
- new fuel line and spring clamps
- find some bolts for the sprocket cover/case save. I think I actually used the correct 6x14 bolts to mount the sprocket so maybe I need to find some shorter ones for the sprocket? I'll know more tomorrow.

[captainweezy]

Looking good

[murfman]

looks great!

[jb2wheels]

Thanks! It looks great but it leaks oil.

I've been chasing leaks on the LH stator cover since I got it. The cover and the case had chain damage. I replaced the cover with the one from the 2nd engine that came with the trike because it had no chain damage. I've been through multiple rounds of gaskets, sealants and filing to clean up the mess. I'll pull the chain and sprocket this weekend and have a closer look. Maybe the output shaft seal is leaking but I think it's the cover/case joint. It drips while parked.

On the RH side, I'm not sure where oil is coming from. Oil filter got a new o-ring and I also replaced the little o-ring on the fiter cover. I have not replaced the cooler line o-rings so that's next.

Not surprised, just disappointed.

[jb2wheels]

I changed the oil cooler line o-rings, then flipped the trike up on its RH side so I could check the leak on the LH side without draining the fresh oil out (I'm a cheap SOB).

First - neither the output shaft nor the shifter seal leak. Dry all around both. Also dry around the chain damage but I have oil down low around the lowest, rear curve of the stator cover. I pulled the stator cover and was able to save the gasket. No obvious damage to either the case or cover. I threw my hands in the air and broke my "no RTV on engines" rule. I put a small bead of hi-temp RTV on both sides of the gasket around the leak area - basically the lower 1/2 from behind the stator all the way back. After it skimmed I put it back together. I left the trike tipped up on it's RH side overnight while the RTV cures.

Of course, this morning there was a little puddle under the leak I still have on the RH side. Looks like it's coming from the oil filter. I changed that o-ring twice but I leave the cooler line attached the whole time. It's sometimes a struggle to manipulate and install. I wonder if I'm pinching it? ID-10-T is the root cause here I think. I'll know more tonight.

[jb2wheels]

I got it dirty this weekend so I guess I can call it "done". Of course, I did not take a camera so all we have is pics from my 3+ year old cell phone:



I pulled the clutch cover and gave that gasket some RTV as well and that seems to have solved most of my oil leaks. I still get a little seepage from the filter housing and now the oil line to the head leaks weeps at the head because I did not change the washers.

I then I hauled it out to Hidden Falls/ near Marble Falls Texas and spent 3 hours on the trails with it.

It pops a bit on decel but otherwise runs great! It starts easy and makes plenty of power. It smoked a bit when I first started it so I will keep an eye on it. I did not go into this engine other than fixin oil leaks and regular maintenance.

Also - is there supposed to be a spring behind the oil filter? Hmmm I don't have one.

[jb2wheels]

After riding for 3 hours last weekend, this Friday I changed the oil and filter and put the spring in behind the filter (I got the spring out of my spare engine).

While the oil was draining I thought it would be a good idea to check bolts. Glad I did - one of the top engine mount bolts was already missing a nut and every engine mount bolt was loose. I put Loctite on everything when I put it together. Amazing. Needless to say, every bolt on the trike got a twist of the wrench.

I went through this with my white 200x last year, too. My son and I were riding at Little Sahara. We stopped at the top of a dune to rest and I noticed it was missing an engine mount bolt. Completely gone. That trike also only had a few hours on it after a rebuild.

Check your nuts. I think I'll add that to my signature...

[atc007]

Great build!!! Thanx for sharing!!