Let the games begin! (1986 350X project)

[J!m]

The parts list shows an o-ring for the tappet adjustment covers so those will be replaced with all the other gaskets and o-rings.

Any areas requiring sealant will get either aviation form a gasket or Hondabond.

[J!m]

And yes I have access to a large mill welder and grinders.

I work in thermal spray so I basically paint with metal. Well, I did. Now I’m the engineering manager. Respectable n stuff.

[J!m]

Well, I didn’t get the motor out.

But I did get the carb off, and that will be in its way to Curtis in the morning. Bowl is full of rust but otherwise seems okay. Timing is poor as well so I’ll get back a good carb.

Exhaust next- if anyone needs a DG exhaust, let me know.

[J!m]

Blasted up the header today. It’s going to need a lot of paint to look decent. We’ll see I guess… flat paint rather than semi-gloss may help hide some of it.

Tape pulled the clear off the front hub so had a set back there. I’ll do the black first I guess.

Blasted and painted the clamp and cover for the thumb throttle. Need to do some cosmetic work on the cable too.

[J!m]

Well, an update. Photos are becoming a PITA so until further notice, there won't be any unfortunately.

Ordered more bolts n stuff. Front hub is all better- new bearings (all balls Taiwan stuff) but I'm awaiting the next delivery which will have Honda seals. I think I pressed the bearings in fully, as opposed to what rolled into the garage... I thought the spacer was short, but after I pressed the new bearings in the spacer is tight. I guess that's the difference between using a and using a press to install bearings...

Oh, and those '86 brake disc bolts? Yeah. I thought the order was screwed up. Diagram shows bolts, but studs arrived (with the correct part number). So, I had to order the three U-nuts anyway... Red locktite on those new studs, so once the nuts come along with the seals (same package) the hub is really done.

Header is looking good too. A few coats of silver high heat paint sanded back and then several of black, sanded back. I think one more will do it well enough.

Discovered the "Collar, engine hanger" (50130-HA5-000) was replaced with a stack of 1/2-13 nuts or something. NLA but replacements have been made... but stainless, so I may remake these in aluminum as original, if anyone is interested, as I'll probably only do one run of them. And the M10 x 235 flange bolt is also NLA but there is a Kawasaki flange bolt available that is M10 x 238 I'll probably grab and try. I suspect everyone uses the same bolt makers in Japan, but it'll look better than the (7/16" I guess?) bolt in there now.

Ordered the correct toolbox today as well. A bit rough but I'm good at turd polishing now.

Engine is just about ready to come out. Top end will come off to discover source of the smoke and then I may split the case to replace the left side with chain rash and JB Weld. God only knows what I'll find inside, but if nothing else, the screen will get a bath. New timing chain any bearings I feel need it (possibly all of them) and every seal and o-ring.

Lower triple tree cleaned and polished up (needs more polish) and a replacement HONDA emblem found on eBay. Pretty sure it is a repop but it looks better than my original one anyway.

Carb is with Curtiss (but no reply that he actually received it yet- is that normal?) and seat is with Tammy.

FOR SALE UPDATE:

Full DG aluminum muffler (steel head pipe) exhaust Looks good- I didn't note any significant dents or damage. (did find a hangar has been cut off my frame however...)
Unknown (but nice) rear wheels and tires
12/85 dated front wheel (200X I'm pretty sure) in nice shape
"Pro Taper" bars (whatever) that came off this that are straight with "Honda" logo pad
85 lower center case (complete gears etc) no side covers and the top end I'm hanging onto until I see what I have on the 86 motor. (I posted the serial earlier in this thread) The jug and piston are right on size and may go into the 86 if needed. Also, the head and rocker cover which I believe was not scored in the cam journals but I can check/send photos if anyone is interested. I want to use as much 86 hardware as possible.

Rear grab bar. It's a wide aluminum one. Not sure of maker but if I figure that out, I'll post.

I still need stuff as I work my way rearward, so please let me know if you're up for trading too.

Merry Christmas!

[J!m]

I have a nice heat shield now. I never knew they were chrome under the paint…

In other news, how the heck do I remove this muffler insert? I got the screws out (not easy) and have the clean out cover removed. I’ve used heat, penetrating oil and coarse language and it’s not moving. I know they can be bought new still, but there’s nothing wrong with mine. I just want access for inspection and cleaning.

[Red Rider]

Most likely just being held in by carbon build up. No advice on how to get it out, but a few more expletives couldn't hurt.

[J!m]

I'm all out of expletives and patience.

I'll be cleaning it, replacing the hardware and calling it a day.

Well, I'll glass bead the whole thing now that I cooked and scratched the paint, but otherwise, yeah. Done.

[Red Rider]

I hear ya. l never disassembled my stock silencer, but I assume the center core is removable, with all of the packing wrapped around it, once those 2 screws are removed. You could possibly hook a slide to that vertical rod, in the center of the core, and coax it out that way? You would definitely be risking deforming the rod and core though, if it doesn’t want to budge.

[J!m]

I thought of making a hook that fits the rod but is just small enough to fit inside the pipe. You’d rotate it under the rod and then thread it so a disc could cover the end and you pull it out slowly.

But that seems a bit much for one muffler insert…

[J!m]

Been busy spending money… more fasteners and bits from Partzilla; new front Pro Vector from Serwa, along with their grab handle, and new fork boots. Then yesterday the repro brake hose guide and helmet hook for the top triple. This should give me everything to get the forks together, since I bought a headlight assembly as well. Mine was “customized” with a pair of fog lights I guess the same size as original, but bolted through the plastic surround at the bottom. Too bad because the plastic wasn’t horrible… if anyone wants to run crazy bright bulbs (I think they are standard H1 bulbs) let me know!

[J!m]

New Serwa front tire and grab handle are in! Getting the tire mounted shortly.

Found one fork is leaking at the seal so I ordered new Honda parts to reseal and also replace the drain plugs and their washers which were also weeping a bit.

Rebuilt front master also on the way along with a proper 86 sprocket guard. I have a very nice 85 guard if anyone needs it now.

Engine still isn’t out but I’m hopeful it will be this weekend. No word back on my carb restoration. It’s been over a month if anyone has spoken with him in the last month. I understand it’s the holidays but it’s been a long time with zero comms- not even “I have it” although it has been shown to be delivered… I don’t really want to buy another carb!