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Blood Sweat Tears and Grease => Projects => Enduro / Dirt / Scramblers => Topic started by: advCo on May 20, 2016, 16:05:37

Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 20, 2016, 16:05:37
Yesterday I picked up this basket case of an XL 350 from the next town over. After watching Bruce Brown's On Any Sunday (the original) a few weeks ago, I started to really lean towards finding something to rip on in the woods. I was in no way shape or form looking for a project, but I saw an ad for parts bikes for $100 on craigslist and I couldn't help but check it out. The first bike was the XL, looking like it had been outside for 20+ years (so long that even the tarp that was covering had disintegrated, pieces hanging off all over the bike), no title, for sale as a parts bike. Shot the guy a text, set up a meeting for yesterday after work, and finished up a job a couple hours earlier than expected and headed over to check it out. Naturally, I brought the ramps "just in case."

The bike had been bought by the sellers' father off the lot as a leftover in '74. It was his older brother's bike, but him and his little brother used to 'steal' it and take it for joyrides when they were out. Years later, as they got older and moved away, the XL ended up hanging around, the seller stating that he was probably the last one to ride it, "sometime in the 80s." After checking it out pretty thoroughly and observing no major rot, I offered him $35, he countered at $50, and we loaded it into the back of the truck - which was a bitch since the rear wheel is completely seized. Considering that she's all there except for the seat which had rotted away over the years, I couldn't pass it up.

(http://uploads.tapatalk-cdn.com/20160520/0727a6465fce123586d5f5bfd5f26c00.jpg)

(http://uploads.tapatalk-cdn.com/20160520/c984241d17552140ce94d7c381db4f8a.jpg)

(http://uploads.tapatalk-cdn.com/20160520/047eda0ab9cd1d8792855f06ce47cafe.jpg)

(http://uploads.tapatalk-cdn.com/20160520/e119fe61e1921e1929e692df9de34edf.jpg)

(http://uploads.tapatalk-cdn.com/20160520/632290edc5312462286153bbd68eef23.jpg)


The initial assessment is as follows:

The Good

-Front/rear fenders are in good shape.
-Headlight bucket and gauges intact and useable
-Front and rear rims seem usable
-Front/rear drum brakes
-Tank is rusty as fk, but no majorly rotted areas. Condition TBD after rust removal.
-Frame is usable, surface rust only.
-Engine is all there. May not be seized after all, since the rear wheel was frozen. Also TBD engine condition.
-Keihin Carb included, along with stock airbox and left sidecover.

(http://uploads.tapatalk-cdn.com/20160520/48afcbbf06746b7211ad1794aaa02d55.jpg)

(http://uploads.tapatalk-cdn.com/20160520/0bc1fbac9f5caedc4aa2f66b0e9a20ad.jpg)

The Bad

-Seat pan had completely rotted away
-Forks are in rough shape, lowers seem decent but heavy pitting on uppers
-Rear suspension is trash
-Spokes and rubber is junk, as to be expected
-Muffler had rotted in half from water pooling. Can only hope it didn't reach the head

After a long night, I've gotten all the dangerous rusty bits removed, along with most everything else. Removed a massive rodent nest from the airbox, pulled the carburetor, removed the harness and just about everything else except for the suspension and motor. I'm traveling for the weekend so I've got an ATF/acetone cocktail chilling in the jug for the weekend. When I get back we'll see if she turns. Surprisingly, everything came off pretty easily, and the only screws that were a real pain were the small phillips for the controls on the handlebars.

(http://uploads.tapatalk-cdn.com/20160520/0146cbb59f475a4ca22304aed0730d59.jpg)

(http://uploads.tapatalk-cdn.com/20160520/7fd9fb689a9c426c01f0911513b5e0e3.jpg)

(http://uploads.tapatalk-cdn.com/20160520/d64f0b0da99625b74a04c27da8cce470.jpg)

(http://uploads.tapatalk-cdn.com/20160520/d48ebc5e113f818fcb94cc13c116a8f5.jpg)

(http://uploads.tapatalk-cdn.com/20160520/ffeebceb9f5e55bc2578b64b88b3d998.jpg)

Plan for this project is to restore her very close to stock, while giving it my own aesthetic touch. I will be reusing as many of the OEM parts as possible, media blasting and (hopefully) powdercoating.  There is no title, so I will try to reg in VT when the time comes. Got my hands on a FSM (thanks deviant), and will be indulging in some light reading on the plane to familiarize myself with the world of the single cylinder 4 stroke. Stay tuned for updates.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Nj732port on May 20, 2016, 16:21:27
might wanna try the VT thing before you start spending time and money

I also want to know if it works so I can start buying up all the cheap CL bikes! ;D
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 20, 2016, 16:26:02
might wanna try the VT thing before you start spending time and money

Yeah, I'm going to start looking into it when I get back next week. If not, it'll just be a trail bike until I can get my hands on a titled frame.

PS, its only nicknamed "The Turd" while it looks like a hunk o' shit  ;D
Title: Re: 74 Honda XL 350 - The Turd
Post by: Nj732port on May 20, 2016, 16:48:02
(http://kesterhouse.com/etct/photos/fettle_02.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 20, 2016, 17:22:59
SCIENCE!!
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on May 20, 2016, 20:27:55
Fuck science go chemical

I'm in, I have a sweet spot for the little thump  :-* :-X
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 20, 2016, 23:33:29
It's gonna be a hell of a task, and worth every bit of it.  I love these early XLs. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 21, 2016, 19:03:32
Read through the FSM on the plane yesterday, see if the motor turns when I get back tomorrow. I noticed this hole on the engine and didn't see it/a bolt in the diagrams of the head or engine overall. Located to the right of the exhaust port, looking at the motor from front.

Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 21, 2016, 23:21:13
The screenshot is a 250 head. 

In this pic from Calferacer's thread it shows the hole, as well. I might have something to do with the casting.

(http://4.bp.blogspot.com/-qsxmg9ZF_Ls/UkhlgdmuRtI/AAAAAAAAFb8/gCgmWS2I-Xw/s1600/1975+Honda+XL350+motor.JPG)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 22, 2016, 00:58:39
I thought that might be the case. I'm sure I'll figure it out once I get into that top end.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: CALfeRacer on May 22, 2016, 17:51:42
Oh man, I'm jealous. I miss that 75, I was too quick to sell it and really wish I didn't.
Title: Re: 74 Honda XL 350 - The Turd
Post by: JustinLonghorn on May 23, 2016, 10:12:19
I am in.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 24, 2016, 00:47:10
Back after traveling for the weekend. Finishing up disassembly. Kickstart lever was a sumbitch to get off the spine, ended up splitting it wider with a screwdriver and prying it off. I think I broke the piston free while I was trying to loosen the kicker, so there's that

Drained out some fairly decent looking oil (half of it went on the shop floor). Next time I get out there I'll dig into the top and end check the centrifugal filter.

(http://uploads.tapatalk-cdn.com/20160523/fcd96a3deca4222ea90a8cb722e7df3b.jpg)

Some straight up doo-do out the carbs

(http://uploads.tapatalk-cdn.com/20160523/3f1f16537476fb64c1f4134327eb9f1c.jpg)

Throttle valve/slide is still stuck in there. Got the carb soaking overnight hopefully I can break it free tomorrow. Brass is in good shape, almost looks like it was never messed with.

(http://uploads.tapatalk-cdn.com/20160523/4ce326c893b94163217bd88afdf4b0cd.jpg)

Let's see if we can't eat some rust.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: vandito.cb on May 24, 2016, 01:03:53
the frame doesn't look a tenth as rough as it did when everything was on.

gonna paint or powder?
Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 24, 2016, 01:06:33
It's actually in decent shape overall. I want to powder but this is going to be a pretty low budget build and the list of parts I need to pick up is getting bigger and bigger.

I was thinking of picking up the HF PC gun and a toaster oven for small parts, since I'm keeping a lot of the stock setup.

Gonna have the frame blasted by the guy who did the 360 frame, see what he gives me for a quote to PC on the frame and swinger.


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Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 24, 2016, 22:46:13
Started in on the engine. Exhaust valves have  been stuck open for ?? years. Will definitely need to replace the exhaust valve springs, if not the valves. Exhaust ports are filthy and piston still seized. Cam sprocket is in such a position that I can only access 1 bolt. Tried a few custom 10mm wrenches to free the lower bolt but no luck. I'm thinking my best option is to break a link on the timing chain and let it drop so I can remove the head and access the cylinder.

Any pro tips for this situation?

(http://uploads.tapatalk-cdn.com/20160524/380e28ab15d2e99c51e3d171f6b4e538.jpg)


Rockers, camshaft and upper journals look to be in good shape. No major damage or scoring. That's a win.

(http://uploads.tapatalk-cdn.com/20160524/42c0e21af04e7e4140fac2680f90190f.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on May 24, 2016, 22:55:38
It's toast. If you have a chain breaker pop it and send me the rock box and head  :o
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 24, 2016, 23:11:25
Grind off the end of one pin and push it out.  You can get a master link later. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on May 24, 2016, 23:14:25
Grind off the ends of one pin link and push it out.  You can get a master link later.

Fixed... I have a few master links if you need one later tater
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 24, 2016, 23:16:29
I have a chain breaker...but heard you aren't supposed to reuse pushed out pins?
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on May 24, 2016, 23:19:15
If you are confident in your ability to peen it back on I see no real reason why not but I will likely be scolded haha! I use a fresh chain when possible.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 24, 2016, 23:46:19
I use a fresh chain when possible.
  Same.  I haven't looked into the availability of them for the 350.  I assume it has to cross reference with another motor.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 25, 2016, 19:57:01
If you park your motorcycle outside for 30 years with the exhaust valves open, you're gonna have a bad time.

(http://uploads.tapatalk-cdn.com/20160525/c6359f2d63d674c9c86aeae1ca10034c.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 25, 2016, 20:00:10
I see opportunity  ;)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 25, 2016, 20:02:17
Same. Except I have no idea about engine modding

Besides penetrant and heat, wooden drift and heavy hammer to free the piston?


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 25, 2016, 20:33:41
Same. Except I have no idea about engine modding

Besides penetrant and heat, wooden drift and heavy hammer to free the piston?


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I wouldn't use heat. A nitrogen penetrant might help, too.   It's a thumper, so you might be able to twist the jug back and forth off the piston.  Your praying to the gods of hellfire that the jug isn't pitted beyond all hell to not mod anyway.  That Xlint link I sent ya has the piston kits and megacycle cams.  Some 250 and 350 parts are the same, like valves and hp valve springs.  IMO, these things could use a beef up on low end torque.  I'm doing it with the carb, but a cam is down the line too.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on May 25, 2016, 20:57:50
Yep, not hard to find race parts for the motor. Money makes power  :-[
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 25, 2016, 21:44:41

  It's a thumper, so you might be able to twist the jug back and forth off the piston. 

As in 'rock' it side to side? The studs prevent a twisting motion with the jug.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 25, 2016, 21:47:29
After a high pressure bath.

(http://uploads.tapatalk-cdn.com/20160525/5fce7400a20f39c5089263645435e16c.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 25, 2016, 21:57:32
As in 'rock' it side to side? The studs prevent a twisting motion with the jug.


Sent from my iPhone using DO THE TON (https://siteowners.tapatalk.com/byo/displayAndDownloadByoApp?rid=89466)
Yeah, rocking is a better way to put it.  If you can get it passed the pins, it can be rotated counter and clockwise.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on May 25, 2016, 22:14:01
Last resort chisel the pistion into chunks
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on May 26, 2016, 09:02:14
If you park your motorcycle outside for 30 years with the exhaust valves open, you're gonna have a bad time.

It'd be cool if you could strap the motor to something big and vibrating for a couple weeks, and just stop by to top it off with PB once in a while.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 26, 2016, 17:26:26
The penetrant solution was about 1" lower in the jug than last night, so I decided to take a "whack" at getting the piston out. Used a heavy hammer and a wooden block to pound the piston free. As it neared the bottom of the stroke I used wooden blocks on either side of the cylinder to raise it up.

(http://uploads.tapatalk-cdn.com/20160526/36d2b28d04360a8eae790db316e3a00b.jpg)

Surprisingly the jug doesn't look THAT bad, but I'm not sure if the corrosion at the top would hone out. No major pitting where the piston had seized, either. Will probably try a hone and see how it looks from there.

(http://uploads.tapatalk-cdn.com/20160526/77c3947c4843eebd3de3b4d2bb21cc46.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 26, 2016, 17:30:35
That's great
Title: Re: 74 Honda XL 350 - The Turd
Post by: Habanero52 on May 26, 2016, 17:48:26
Did you get a quote for the frame yet?
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 26, 2016, 20:18:29
Got about .014" of play on the push rod, cause for major concern or just a bit of noise? Didn't see a tolerance for that value in the FSM.

(http://uploads.tapatalk-cdn.com/20160526/7133a9e4c8f633e8edfe8ff6eb3cfb3d.jpg)

Cleaned up the cylinder bore.  Looks like crap in the light, but the walls actually look pretty dang smooth.

(http://uploads.tapatalk-cdn.com/20160526/fbfb042338d2008d721a3fef71f39ece.jpg)

(http://uploads.tapatalk-cdn.com/20160526/efa6184df29e1b957ae6e27a92bb2f52.jpg)

Tank & parts looking pretty good in the vinegar. Turns out it eats aluminum, so the petcock will have to be replaced. Sprung a small hole near one of the forward mounting brackets, but should be easily repairable.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 26, 2016, 21:12:21
For anyone curious about the VT registration process, I spoke with a guy from the VT DMV earlier, and he told me:

Fill out VT Registration form D119 from their website (dmv.vermont.gov), mail it in along with bill of sale and  a check for registration ($44.00) + 6% sales tax (min. $30).

This is what I was told for a motorcycle older than 15 years.
Title: Re: 74 Honda XL 350 - The Turd
Post by: B541Niner on May 26, 2016, 22:17:53
Does the Bill of Sale have to be notarized?
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on May 26, 2016, 22:51:21
Does the Bill of Sale have to be notarized?

Edit: You should call the VT DMV to be sure, but I don't think it does.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 26, 2016, 23:14:43
There was no mention of it and no mention of it in the text of the form either, so I would say no.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 27, 2016, 01:22:57
Spitballin'
Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 27, 2016, 13:11:24
Can anyone give me any references for reputable shops in the New England area (or continental US) to send the head for servicing? I'd gladly support any reputable forum members as well.

I called Dave from XLint to get a quote, they offer bored cyl swap outs for $90 - I may go that route as I need to buy a piston/rings anyways and by the time I buy a hone Id be halfway towards an overbore cylinder anyways.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Habanero52 on May 27, 2016, 14:38:00
I have used DWMS and highly recommend them, Joey is a sponsor of this site and a great human being to work with.
He is in AL.
http://www.dwmsracing.com/
Some of the pictures on the land page are of the work he aha done for me.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 27, 2016, 14:57:56
I'll second Joey.  That shop is awesome, and about the most considerate guys you'll get to touch that motor.  Member Kanticoy just had a head rebuilt by them for his DR build here (http://www.dotheton.com/forum/index.php?topic=69470.msg824939;topicseen#msg824939). 

I'm sending mine to him at some point after I beat the shit of this motor for a little while in it's mostly stock configuration.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Nj732port on May 27, 2016, 15:28:18
you could do some brown with gold flake paint... itll go with the name ;D
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 28, 2016, 02:04:22
Spoke with David from XLint earlier tonight. He knows a thing or two about these motors. Gave me a few pointers on cracking the cases and some things to watch out for including the idler gear losing a tooth.

I can't quite justify the cost of having the top end rebuilt professionally at the moment. Going to really assess the damage tomorrow once i pull the valves out.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 29, 2016, 22:43:38
Pitched a tent in the backyard and started some blasting. I called/went over to the sandblasting shop and no sign of the dude, SO i said f' it and grabbed the cheap 50 lb hopper/blasting gun setup from harbor freight. http://www.harborfreight.com/portable-abrasive-blaster-kit-37025.html (http://www.harborfreight.com/portable-abrasive-blaster-kit-37025.html)

After about 3 hours of use, I will say this thing works pretty damn well.  I ended up cutting the hose from 10-12ft down to about 6' to avoid kinks. The hose is not that great quality so it can easily kink and screw up your media flow. I had the parts on the ground, and I put the hopper up on my welding table at about ~3 feet. Pretty necessary to have the hopper elevated since its siphon fed and not pressurized. Bought a 50 lb bag of aluminum oxide, and I've been able to save about 95+% of the media using the tent method.


Our compressor runs 6.8 CFM at 60 PSI, and I was running the gun at ~80, which seemed to be the best balance between air flow and blasting power.. It seemed to keep up alright, but after a few minutes I would take a break to let my goggles unfog and the air build up. Shake all the shit to the middle of the tent, screen and repeat. Had to run out too many times before I got started, so I only got the swinger and about 50% of the frame done before dark hit. I'll have the complete frame blasted and painted by tomorrow. Not bad turnaround time!
Title: Re: 74 Honda XL 350 - The Turd
Post by: vandito.cb on May 29, 2016, 22:57:12
I'm curious to see how the frame comes out.

the swinger looks good so far.
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on May 30, 2016, 07:59:10
Just found this thread dude.  Looking good and gotcha bookmarked.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 30, 2016, 13:44:41
Getting there. About to head back outside now that the rain's done and finish blasting the frame. Hoping to get all that crap cleaned up, load glass beads into the blaster and get started on the aluminum parts.

Pulled the valves out on Saturday. A quick tap of the hammer and the exhaust valves released themselves. Despite all the junk and carbon, the valves and seats look to be in decent shape. Valve guides are definitely in useable shape. I will check the springs against the FSM specs, but I am planning to do a set of rings, hone, lap the valves and slap it back together and see what happens.

I have done quite a bit of browsing, but have only been able to find rings for overbore cylinders for these particular motors. If I cant find the correct rings, my most reasonable option will be to send out my jug to David at XLint to swap out for a bored cylinder, and pick up a set of rings to match.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 30, 2016, 22:07:44
Finished blasting the frame today. Would not recommend. Took about 8 hours total. But the good news is all the rust was superficial, and I got the frame and swinger primed and painted in gloss black. Had to try out the rustoleum "appliance epoxy" I've been hearing so much about.

(http://uploads.tapatalk-cdn.com/20160531/2bf3d562ef8565463d8d09c3dac9982d.jpg)

I'll give it 4-5 days to hang and dry before moving it since it's niiiiice and humid this time of year.
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on May 30, 2016, 22:48:26
Lookin great!  The epoxy is tough stuff.  I love it.  did my alum fork lowers and headlight bucket.  Years ago...still good.  8)
Im most impressed w its aluminum adhesion.  tiedown ratchet rubbing from Kentucky to Illinois scraped some off...but zero rock chips.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 30, 2016, 23:54:33
Lookin great!  The epoxy is tough stuff.  I love it.  did my alum fork lowers and headlight bucket.  Years ago...still good.  8)
Im most impressed w its aluminum adhesion.  tiedown ratchet rubbing from Kentucky to Illinois scraped some off...but zero rock chips.

I used the VHT Satin black epoxy on damn near everything on the 360. Hasn't let me down yet. Hope this stuff is just as tough.

Window shopping dual sport tires. Came across this *interesting article on tire tread wear.

http://www.w6rec.com/duane/bmw/cupping/index.htm (http://www.w6rec.com/duane/bmw/cupping/index.htm)
Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 31, 2016, 18:35:59
Well, I may have left the tank in vinegar for a bit too long...

(http://uploads.tapatalk-cdn.com/20160531/cbc23d6299795cedf1248e79a026030f.jpg)

That damn crevice between the bottom of the tank and the mounting plate.

(http://uploads.tapatalk-cdn.com/20160531/68e3e0f88cc620f81797576a02582f1d.jpg)

(http://uploads.tapatalk-cdn.com/20160531/2cb9a582d790a1eb8c652d75cd4c5161.jpg)

Probably going to cut this tank up and see if I can't save it, got nothing to lose at this point. Start shopping for a replacement.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Kamn on May 31, 2016, 18:50:01
just braze those holes shut and then seal the tank
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 31, 2016, 20:36:13
What about JB weld  ;D ;D
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on May 31, 2016, 21:40:47
lol not jb weld.  ;)
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on May 31, 2016, 21:42:23
the bottom of my CL100 tank was swiss cheese.  local radiator shop fixed me right up.  I did seal it afterwords w por-15.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 31, 2016, 21:43:02
lol not jb weld.  ;)

Anything but JB weld!

I got a lead on a XL in the area with motor w/"good compression" and chopped frame. If i can pick it up for a lowball it would be cheaper than rebuilding my motor.
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 03, 2016, 12:02:59
Quick update. Been cleaning/painting random parts for reuse. A lot of it is pitted and looks mediocre at best but if i decide to keep this thing that will be for much later down the road.

Scooted over to a machine shop yesterday. The guy checked the offset on the jug, gave it a quick hone and I was on my way. Looks like the clearance is tight enough that I will be able to run stock rings and call it a day. Score +1.

Just about finished disassembling the carbs. I have never had anything as stuck as the throttle valve in this carburetor. Ended up tying copper wire (didn't have any steel lying around  :-\ ) around the linkage, the other end around the needlenose, and twisting and prying until the fucker popped out. I probably fought with it for at least an hour, broke 3-4 pieces of doubled up copper wire, and it's a wonder I didn't break anything on the carb or my hands. Good news is all the brass looks to be in good shape. I picked up a full NOS carb rebuild kit for $16 on ebay, so can't beat that deal.

(http://uploads.tapatalk-cdn.com/20160603/4b96f88d83808bc034bae1e52a435db1.jpg)

(http://uploads.tapatalk-cdn.com/20160603/79d4561639ca458ec59bd368ca544c2d.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: MILKY on Jun 08, 2016, 09:25:36
this build looks great! would recommend. bookmarked.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 14, 2016, 21:35:12
(http://uploads.tapatalk-cdn.com/20160614/ddc2ededba8bdbdbca87396102373942.jpg)

(http://uploads.tapatalk-cdn.com/20160614/847c40bfd6f61356d0d67945c3231543.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 14, 2016, 22:38:51
this build looks great! would recommend. bookmarked.

Thanks mate it will be a big transformation

(http://uploads.tapatalk-cdn.com/20160614/847c40bfd6f61356d0d67945c3231543.jpg)

Ooooh shiny  :o

They straight??
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 18, 2016, 22:48:17
I guess its time for an update. Split the cases last night, got everything out on the bench and washing all the engine housing parts. The centrifugal filter on this thing is an awful design, and there's no way to pull it out if its stuck (which of course this one was). So naturally I threaded a 10mm bolt in, popped it out, and cracked some kind of sleeve within the crankshaft. Lovely. Looks like it is a sleeve that serves as an oil passage, so I'll pull out the broken pieces, file it down, and make sure all the passages in the crank are clear of debris.

(http://uploads.tapatalk-cdn.com/20160618/226c0e1ad61d06042d5385bec6a13c02.jpg)

All Balls tapered bearings went in the steering stem. Pulled out the old races, froze the new ones and they slid right in. New bearings on stem, greased, polished the top tree and handlebar mounts and we now have a nice, clean, updated steering stem. Progress!

(http://uploads.tapatalk-cdn.com/20160618/7c5c0d99086f774bd282836035c33d9d.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 18, 2016, 23:06:10
Wanna sell the cam?  ::)
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 20, 2016, 13:14:36
I read a few articles about restoring old rubber parts with brake fluid. I'd never heard of it, but all the rubber on this thing was crumbling to bits. I did my best to save all the rubber bits on tear down.

Last night I filled a tub with some DOT3 and let all the rubber soak. Just popped them out and I'm blown away. It puffed them right up, basically filling in any cracks from previous damage, AND they're almost as squishy as new rubber. It didn't really clean up the rust discoloration on the rubber or make any damage go away (obviously) but I'm more than pleased with the results.

(http://uploads.tapatalk-cdn.com/20160620/11987980b8738db66425d2c6b72befb8.jpg)

Side note: a rubber clutch adjuster plug just sold for $60+ shipping at bid on eBay. The only one available, NOS. I have to make some bushings for the shocks and have polyurethane samples in the shop. I may have to start producing those parts aftermarket if the demand is that high
(http://uploads.tapatalk-cdn.com/20160620/5e207a691e103a3f52c1f870101ae2a8.jpg)




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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 20, 2016, 16:04:18
That NOS price is just asking for a smack in the head...

BTW I have an extra mud slinger (oil trap) you can have, just thread the inside of the busted part and pull it that way.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 20, 2016, 16:13:53
That NOS price is just asking for a smack in the head...

BTW I have an extra mud slinger (oil trap) you can have, just thread the inside of the busted part and pull it that way.

Thanks for the offer, but I actually picked up a new one on eBay for dirt cheap the same night that I botched mine. You mean thread the sleeve inside the crank to pull out the broken fragments? Or am I misunderstanding that.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 20, 2016, 16:24:43
Yeah, just run a tap in that wont mar the crank and then run a bolt in to get the trash out

The shaft has a spring ball on it, you can get it out

(http://images.cmsnl.com/img/partslists/honda-xl350-1976-usa-oil-pumpoil-filter_bighu0042e5207_df2a.gif)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 20, 2016, 16:45:36
I'm not seeing it in that diagram. That whole sleeve in the crankshaft comes out? I wouldn't want to change the balance on the crank by removing weight. The photo from above is looking into the crankshaft underneath the centrifugal filter

(http://uploads.tapatalk-cdn.com/20160620/279c3a986ca298b9a540b5a9b143f2f3.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 20, 2016, 16:53:11
Oh so you broke the threads off?
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 20, 2016, 16:54:56
Okay well I have a whole crank you can have but the rod is out of tolerance
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 20, 2016, 16:56:08
I tapped and threaded a bolt into the filter to pop it out. When it hit the crank below, it cracked that sleeve inside the crank. In this photo you are looking down the inside of the crank, underneath gears 2 & 5 shown in the diagram you posted.
(http://uploads.tapatalk-cdn.com/20160620/49d8bc419d7a8c37857dc18fe3bf0495.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jun 20, 2016, 17:01:49
I'm not sure the demand is as high as the supply is low on those plugs. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 20, 2016, 17:11:48
(http://uploads.tapatalk-cdn.com/20160620/afe74b5cb04a3f02a3526280059fac84.jpg)

Yeah looks like you broke of the threaded shaft


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 20, 2016, 17:13:36
The cup is pressed on so a trip to the freezer will help


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 20, 2016, 17:45:08


Yeah looks like you broke of the threaded shaft


You're confusing the shit outta me right now lol. The threads for the lock nut that hold the cup in place are fine. See below,  the nut is threaded on to the crankshaft w/out the cup in place. You can see the crack piece inside.

(http://uploads.tapatalk-cdn.com/20160620/2533c3761cf6d6b9e6e9ba80d0829275.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 20, 2016, 18:05:33
You're confusing the shit outta me right now lol. The threads for the lock nut that hold the cup in place are fine. See below,  the nut is threaded on to the crankshaft w/out the cup in place. You can see the crack piece inside.

(http://uploads.tapatalk-cdn.com/20160620/2533c3761cf6d6b9e6e9ba80d0829275.jpg)


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Haha! me too... I went out and looked, the tube your looking at has a steel ball at the end plugging it off from the crank end... I can't see where its serviceable but I think your fine if you clean it up
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 20, 2016, 18:07:58
Look at the opposite end, you will see a ball, I am pretty sure that rod pushes the ball against a stop and never moves or only under extreme pressure as i cant move it at all. Clean up the end thats all buggered and run it
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 23, 2016, 14:52:16
We have registration. Thanks VT for not giving a shit who registers a vehicle in your state! Luckily the plate made it here, since the numbnuts who put it in the envelope forgot to seal the thing, so the plate was just chillin in there.

(http://uploads.tapatalk-cdn.com/20160623/14b2707389bd599c665dc5cafeabc99d.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 23, 2016, 19:24:17
What all did you provide please


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 23, 2016, 20:22:22

What all did you provide please

Page 2 of this thread I posted everything I sent in. You have to go by NADA value on sales tax though may want to call them to confirm how much the tax is going to be, they sent mine back once because the amount was wrong.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 23, 2016, 21:21:12
Just seen the tag on my phone. What tax rate?


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 23, 2016, 21:22:38
6% nvrmind


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Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Jun 23, 2016, 22:24:05
That brake fluid trick is cool. Congrats on the VT tag, too.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 23, 2016, 22:28:56
Nice selection of parts:

http://stores.ebay.com/MotoSmart-Used-Motorcycle-Parts/_i.html?LH_TitleDesc=1&rt=nc&_nkw=XL350&_sid=999149681&_trksid=p4634.c0.m14.l1513&_pgn=1
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 23, 2016, 23:06:57
That brake fluid trick is cool. Congrats on the VT tag, too.

Thanks. Was easier than I expected. I even cleaned up the dust covers for the clutch/front brake with it. Works great.



Nice selection of parts:

http://stores.ebay.com/MotoSmart-Used-Motorcycle-Parts/_i.html?LH_TitleDesc=1&rt=nc&_nkw=XL350&_sid=999149681&_trksid=p4634.c0.m14.l1513&_pgn=1

Yep I got a few parts cheap from them and they do best offer on a bunch of stuff  8)

So the spokes I ordered on eBay (that came from Thailand, great) are wrong for the front wheel. They sent a set for a disc brake model and I have a drum. So half of my spokes are the wrong length. There goes my "deadline" of July 4th weekend  :o Hopefully I don't end up losing a shitload of money on that. Fuckin' eBay.

(http://uploads.tapatalk-cdn.com/20160623/fd845893544d60eefa8ed6c110518503.jpg)

Dual sport knobbies, tubes, and rim strips all arrived today. Looks like I'll be waiting a while to rebuild that front wheel..good thing there's an engine to rebuild.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 24, 2016, 23:01:31
Picked up 2 part 85a urethane and poured some bushings tonight.  Thanks deviant for the shocks.

I am going to try and post a quick little video on the process I used after they set up and once I know they work

(http://uploads.tapatalk-cdn.com/20160624/c6ff7fd92e1bda4813e1a7aa4e267fe9.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jun 25, 2016, 00:18:15
I love Smooth-on.  Consider Polytek too.  I go back and forth between the two, depending on what I'm getting.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 25, 2016, 07:08:52

I love Smooth-on.  Consider Polytek too.  I go back and forth between the two, depending on what I'm getting.

Seemed to work pretty nicely. Interested to see how it sets up.

Btw this stuff in general is awesome, I see a lot of use in my future.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 25, 2016, 07:13:21
That is a great little trick I hadn't seen before, any way you could add in the bushing while wet or jig it up with a bushing and pour it?
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 25, 2016, 08:00:17

That is a great little trick I hadn't seen before, any way you could add in the bushing while wet or jig it up with a bushing and pour it?

Yep I was going to make 3D printed mock ups and use for molds but I figured this would be faster just going to drill holes in the center and slap them on for a quick fix. Depending how they feel I may make some improved ones later.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 25, 2016, 08:02:22
Nice!
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jun 25, 2016, 09:31:02
Now simmer them in a pot of Rit dye and make them a cool color.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jun 25, 2016, 09:34:14
Seemed to work pretty nicely. Interested to see how it sets up.

Btw this stuff in general is awesome, I see a lot of use in my future.


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They also sell plastics.  Been using Smooth-On and Polytek this side of 15 years.  Wonderful companies, both of them. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Jun 25, 2016, 10:19:29
Rad where is that stuff sold?  I need new shock bushings
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 25, 2016, 10:26:45

Rad where is that stuff sold?  I need new shock bushings

I found it locally here: http://www.reynoldsam.com/


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 25, 2016, 10:27:43

Now simmer them in a pot of Rit dye and make them a cool color.

I was wondering about that. They told me about their pigment but said I'd be fighting the white and it would just end up gray if I used black pigment. I'll give it a shot. Simmer on low in a pot?



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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jun 25, 2016, 11:49:40
I was wondering about that. They told me about their pigment but said I'd be fighting the white and it would just end up gray if I used black pigment. I'll give it a shot. Simmer on low in a pot?



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Yep. I know it works on skateboard wheels.  Not sure if there's something different in the composition that would make theirs not take to the dye just as well.  You have to boil the Rit dye first then bring it down to a simmer.  You can melt the urethane, so you'll have to work with temp, time and keep it stirring.  Should only take a few minutes. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 25, 2016, 19:20:19
Just came back from a ride on the 360 and large package was waiting at the front door.

New forks. Need rebuilt but the stanchions are immaculate, even the caps will polish up nice. Not bad at all for under $100 shipped.

(http://uploads.tapatalk-cdn.com/20160625/65ce603db51152653dea45ac5f502d30.jpg)

(http://uploads.tapatalk-cdn.com/20160625/f5ed5f69b6a36d660ad350e76009a375.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 25, 2016, 19:33:14
Bushings came out sweet. Popped right out thanks to the mold release. Going to let them fully cure (48 hours) then make some holes and then I should have some functioning suspension on this beast.

(http://uploads.tapatalk-cdn.com/20160625/aff61d24de7e9cf49811798a4eeb31fd.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jun 25, 2016, 19:42:41
I don't understand why you didn't cast them with your shafts already in place.  You can form oil clay around it, put a dowel of any material through and cast it in exactly the right shape. You can also make a mold, cast plaster positives, then make molds off the plaster positives.  There's really lots of ways to do it. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 25, 2016, 20:13:24
The shocks on the XL have bolts for both top in bottom, I suppose I could have made a jig to hold them perpendicular and perfectly in the center. I have tons of the stuff left so if this method doesn't work I will retry it that way.

I plan to eventually 3D print a positive, cast a negative mold and then cast the poly in that, since I would like the bushings to protrude at least 1/8" on either side. But that's down the road, these will do for now.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 25, 2016, 20:24:14
Also I'm a noob at casting


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Habanero52 on Jun 27, 2016, 11:24:16
That is great idea.
Are there much hardness differences between the 2 part 85a urethane and the Polytek?
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 27, 2016, 11:45:15
That is great idea.
Are there much hardness differences between the 2 part 85a urethane and the Polytek?

Polytek is just another brand of urethanes. The number "85a" refers to the hardness of the material on a scale called "shore durometer" which signifies a class "a" plastic and a hardness rating of 1-100. So if you wanted a harder bushing, you could go with a higher numbered durometer mix.

The supply company I purchased the material from sent me about 10 samples from the A range, and I chose the 85a which was the second hardest mix because I wanted the bushings to be solid enough where they would not reform but still have a bit of give.

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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jun 27, 2016, 11:48:57
That said, I think much harder to 90% would get to the point of solid and not what we want in a shock bushing, I look forward to the results after some ride time. Deterioration is always a concern with this "stuff" lol.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 27, 2016, 12:11:21
That said, I think much harder to 90% would get to the point of solid and not what we want in a shock bushing, I look forward to the results after some ride time. Deterioration is always a concern with this "stuff" lol.

Yep it will be a good experiment. 85a is one of the harder urethanes used for skateboard/longboard wheels that are meant to hold up to sliding on pavement, so I think I will get some time out of them. I don't plan on being nice to this bike, either.  ;D
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jun 27, 2016, 14:26:12
Looks great. I'm curious how much better the harder bushing is. Most that come with shocks are around 65a.    With skateboards, you can go from 65 to 91 on truck bushings.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Habanero52 on Jun 27, 2016, 15:06:59
That said, I think much harder to 90% would get to the point of solid and not what we want in a shock bushing, I look forward to the results after some ride time. Deterioration is always a concern with this "stuff" lol.
Thanks.
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 03, 2016, 15:05:42
Lots of bead blasting. Didn't go crazy on the engine parts since everything is gonna get painted. Just got the grime and corrosion off.

(http://uploads.tapatalk-cdn.com/20160703/1d4c75d82f83dd84ed4454651710755b.jpg)

Clutch mechanism housing super corroded. Don't think the sliding surfaces are damaged though so should be good to go. Hoping I can save the needle bearing since they are no longer available.

(http://uploads.tapatalk-cdn.com/20160703/1d24ce541f0a8461e03b4cd229128992.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: spurlock on Jul 03, 2016, 17:33:17
Hi there, it looks like the part of your left side case that holds the short lifter rod is toast, and probably the hole that holds the lower end of the actuating lever as well. That is common on these magnesium cases. Below is a shot of the hole on my case, which was not nearly as eroded as yours:
(http://i1228.photobucket.com/albums/ee457/billspurlock/Bills%20photos/XL250/IMG_8209s_zps6z2n4z6k.jpg)

I did an epoxy and brass bushing repair on mine, pictured below. I believe Dave at XLint offers this service. I wrote up the full details on the first page of a post on another forum here: http://bayarearidersforum.com/forums/showthread.php?t=491468 (http://bayarearidersforum.com/forums/showthread.php?t=491468).

Anyway, here are a couple of photos of the repair:
(http://i1228.photobucket.com/albums/ee457/billspurlock/Bills%20photos/XL250/DSC00871_zpsikfzuvw3.jpg)

(http://i1228.photobucket.com/albums/ee457/billspurlock/Bills%20photos/XL250/DSC00898_zps2lvqf1j4.jpg)

Hope this helps,

-Bill
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 04, 2016, 11:00:50
Thanks Bill. Some great info on your build there. Nice looking bike! I have many of the same issues on this one so your techniques will be helpful.

Looks like you're right about the clutch mechanism housing. I spoke with Dave at XLint and got a quote to repair the surfaces in there but it's a bit out of the budget for this build at the moment.

I will look into your method and may try that route, provided I can find someone or somewhere to machine some bushings. I will see how bad the damage is to the lower seat when I manage to pull the actuator out.

Where did you source the needle bearing?


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Title: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 06, 2016, 20:01:16
Got a line on a LH case cover, I don't think mine is really worth the time and cost of rebuilding.

(http://uploads.tapatalk-cdn.com/20160706/2764e14f685ab4970429d7f62a003812.jpg)

Transmission gears, gearshift mechanism and crank cleaned and reinstalled into the cases. New main shaft and countershaft seals. Closed 'em up.

(http://uploads.tapatalk-cdn.com/20160706/844716731b5da6ac1f926baacfa2f0fd.jpg)


Found a chipped tooth on the idler gear which I'm not surprised about. Wondering if I should just clean it up and run it or try to find a good used one.

(http://uploads.tapatalk-cdn.com/20160706/e899d740135a3a92801e247e96b6aaf3.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 06, 2016, 20:37:52
Got a line on a LH case cover, I don't think mine is really worth the time and cost of rebuilding.
This is how it usually goes with these things.  Magnesium sucks for durability.  A spare motor is always a good idea, and a collection of spare covers is required.  I have about 2.5 XL250 and 175 motors when it's all counted.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 06, 2016, 20:43:17
This is how it usually goes with these things.  Magnesium sucks for durability.  A spare motor is always a good idea, and a collection of spare covers is required.  I have about 2.5 XL250 and 175 motors when it's all counted.

I'm seeing that. If i ever have the chance to get a decent spare motor I will for sure.

What was the benefit for the use of magnesium? I notice that its a bit lighter but barely enough to make a difference.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jul 08, 2016, 15:24:53
The one I have is worse

(http://uploads.tapatalk-cdn.com/20160708/fcb35d261c8711dafe0f561c6e013460.jpg)
(http://uploads.tapatalk-cdn.com/20160708/a1cd6c17e63f8fc0bf64b41ea9caf782.jpg)
(http://uploads.tapatalk-cdn.com/20160708/dc235171f0fb13d8de1907dc600eb555.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Mr.E on Jul 08, 2016, 15:51:40
I'm seeing that. If i ever have the chance to get a decent spare motor I will for sure.

What was the benefit for the use of magnesium? I notice that its a bit lighter but barely enough to make a difference.

a lot of MX bikes used magnesium back then because of the weight (mostly cost) savings.  longevity of the motors wasnt as much a concern as it was for heavier bikes that had a foreseeable future.  MX bikes were basically expected to last a few years and a few rebuilds, and then go to scrap for a new one.  I did have reasonable sucess TIG welding the magnesium covers on my elsinore, but it was doing much the same thing.  And I'm also keeping an eye out for a spare motor at some point for mine for the same reasons.  CB750 or XS650 cases on the other hand, practically last forever.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 10, 2016, 23:10:14
So what happened this weekend. Seized rings removed, grooves cleaned, new rings gapped and installed. Went to install the jug with a POS piston ring compressor and tore the gasket. Got to cut a new gasket now.
(http://uploads.tapatalk-cdn.com/20160710/39d1731e3e2f5af6c82d3fd0168f1607.jpg)
(http://uploads.tapatalk-cdn.com/20160710/98ee165cae6e5caade3df0e8562561c8.jpg)

eBay forks cleaned and dismantled. One of the lower springs was a bit out of spec so I swapped it for a better one from the original forks. Polished up the lowers real quick, popped in new sealed and threw em in.
(http://uploads.tapatalk-cdn.com/20160710/4212d7220dff21a4ada1fd757ae2021e.jpg)

Front wheel laced up and trued, as good as I could get it for something that had been abused. Spokes fit like garbage. After getting a new set with the "right" length, I laced and replaced this thing about 5 times. The 2 part hub is a pain in the ass. The eBay spokes are hardly to spec, as the length from the bend to the flange is longer than stock. I think they are all seated, but we'll see what happens after a couple miles. Threw everything together real quick.
(http://uploads.tapatalk-cdn.com/20160710/2a779a08f062862cf2fe14d231c5365f.jpg)

Rear wheel bearings been on back order for over a month now. Gotta find a new source and cancel that order. Holding me up from having a roller.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Mr.E on Jul 10, 2016, 23:41:31
Heres the big one

http://www.ebay.com/itm/Honda-OEM-Bearing-96140-63040-96140-63040-10-/361381130216?hash=item5423fe6fe8:g:bJwAAOSw3ydV6du7&vxp=mtr

Heres the small one

http://www.ebay.com/itm/91061-KS6-831-91102-VA4-013-96120-62040-10-96140-62040-10-601B6204UU-BEARING-204-/370878711577?hash=item565a180719:g:G0UAAMXQxKxSDkLY

I like to look up the old honda numbers, then plug those into ebay.  lots of time you will find someone else has already cross referenced bearings and gone straight to mfg like the NMD one there.  NMD is one of several bearing makers that supplies "oem" bearings to companies.  Plus, pretty sure my elsinore uses the same ones ;)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 11, 2016, 00:13:37
I like to look up the old honda numbers, then plug those into ebay.  lots of time you will find someone else has already cross referenced bearings and gone straight to mfg like the NMD one there.  NMD is one of several bearing makers that supplies "oem" bearings to companies.  Plus, pretty sure my elsinore uses the same ones ;)

Sweet. Good looks. I usually just go to all balls and get their part numbers. I do that with everything else though. Love those parts fiche diagrams.

I'll draw up those bushings eventually. Taking a step back from the motor for a couple days to put out some little fires here and there.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 12, 2016, 22:15:22
Any ideas? This thing is stuuuuuuuck. I can spin it back and forth with some effort, but the arm pin snapped so now I got no lever.

(http://uploads.tapatalk-cdn.com/20160712/86286df7cd047a155140d8eabf3d6a07.jpg)
(http://uploads.tapatalk-cdn.com/20160712/0bb3a314e6bb54cb8e117f387d07ac8a.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 12, 2016, 22:46:24
THis should look familiar...

http://www.bayarearidersforum.com/forums/showthread.php?t=491468
Title: Re: 74 Honda XL 350 - The Turd
Post by: spurlock on Jul 12, 2016, 22:58:57
Any ideas? This thing is stuuuuuuuck. I can spin it back and forth with some effort, but the arm pin snapped so now I got no lever.

Most likely it is the needle bearing at the top of the shaft that is rusted/seized to the shaft. One option is to use a torch - carefully - to heat the bearing area and use a hammer and punch against the flared part of the shaft in the first photo to try to drive the shaft upwards. Second option would be to weld a threaded stud to the broken end of the shaft, then use a collar and nut to pull it out. You need a new left side case, shaft, bearing and seal. Wil; not be easy to find though.

-Bill
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 16, 2016, 12:16:17
Headed up to NH for some camping this weekend, stopped off to pick up 60 lobsters and a few bushels of clams for my buddy and there was a cycle salvage yard nearby, figured I'd take a quick stop.

(http://uploads.tapatalk-cdn.com/20160716/2de348e999da92f700b8d6764784e73d.jpg)

And that's just the first floor. I could've spent all day in there. Picked up a muffler off a Yamaha enduro and a decent shape seat off a Kawi that should fit.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Jul 16, 2016, 18:55:32
Where in NH is the salvage yard?
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 17, 2016, 18:54:06

Where in NH is the salvage yard?
It was actually in Fitchburg, MA pretty close to the NH line. Sky Cycle Salvage. So much good stuff, I could've hunted through there all day.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 17, 2016, 18:58:05
(http://uploads.tapatalk-cdn.com/20160717/362b83d9572c4628a59bdd5d4f7246f4.jpg)

Seat and silencer, think the silencer is off a KDX, should do the trick. May have to modify the seat pan a bit to fit but it's close to the stock shape on the XL.

Buddy put on a legit clam bake.

(http://uploads.tapatalk-cdn.com/20160717/47066f1ad26cfabef5d95f8edc367840.jpg)

All in all pretty successful weekend.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Jul 17, 2016, 19:36:11
Wow! That looks amazing.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Jul 18, 2016, 08:46:13
Nice score on the parts and nice cooking! That looks like a tasty pile of seafood!
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jul 18, 2016, 09:45:13
Yeah me next to that with a stick of butter would be like a preview of heaven
Title: Re: 74 Honda XL 350 - The Turd
Post by: Habanero52 on Jul 18, 2016, 11:27:27
Now I am hungry!!!! Yum.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 18, 2016, 22:44:12
Another frustrating spoke ordeal. Started lacing up the rear wheel and the hub isn't even close to being centered on the rim, and like a noob I tore all the spokes off without measuring the hub offset. These shitty spokes are really starting to grind my gears. You can see below the difference in the elbow bend between the new spokes and the old.

(http://uploads.tapatalk-cdn.com/20160718/eee07f6855c9a3eca2d995db1953becf.jpg)

The outers seem to be causing the majority of the problem, everything looks close to centered with the inners only installed. There is a slight inward angle on the bend of the original outers, where the new spokes are at 90*. My first solution is to try and slightly bend the new spokes to get a closer match to the originals, but before I go ruining anything I thought I'd get a second opinion.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Mr.E on Jul 19, 2016, 00:01:26
I've not been overly impressed with mine either. They are on there, and the wheel is mostly true, but it was pure hell. Not buying the Thai spokes ever again. I'll go back to buchannon or piece a stock set together. I haven't complained to the Thai company yet, kinda out of time before my big ride.
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 19, 2016, 00:57:07
I've not been overly impressed with mine either. They are on there, and the wheel is mostly true, but it was pure hell. Not buying the Thai spokes ever again. I'll go back to buchannon or piece a stock set together. I haven't complained to the Thai company yet, kinda out of time before my big ride.

Yeah I'm with you on that. I was able to get the front wheel together by combining the two sets of spokes they sent me (after the initial screw up with the drum hub). It's pretty terrible, no quality control. They just guess on the spoke dimensions and send you the right length. Not sure what I'm going to do on this one.

Btw I ended up buying a "new" left side cover, it should be much more suitable for repair than the original one but I may try and refurbish them both if one goes well.

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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jul 19, 2016, 10:41:01
To pointer
(http://uploads.tapatalk-cdn.com/20160719/33da730481c1adc1ba304eaa37b0677d.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 19, 2016, 13:02:31
Sucks you guys are having such issues with the spokes.  I got mine installed and trued in about an hour.  No issues whatsoever.  They aren't perfect, but they work fine.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 19, 2016, 19:32:04
Started over from scratch again. Pretty sure I've gotten off to the right start with the inners and the offset is just about at 10.5mm but these last set of outers are just so far away. The spokes don't sit in the grooves from the old spokes due to the angle of the elbow, and it seems like the difference is adding up by the time I get to the second set of outers.

(http://uploads.tapatalk-cdn.com/20160719/c84f064a70102d3f8ded9ddfbd3c8f4f.jpg)
(http://uploads.tapatalk-cdn.com/20160719/3dfbb5c8c39fd7e5a1c5b2dea5966dfa.jpg)

Am I missing something obvious?


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 19, 2016, 19:45:16
I lace up one side at a time.  If the hub is offset, like for a speedo gear, I do that side first because you can lay it flat on the table.  Then, when done, I flip it over and do the other side with the rim up on blocks.  I only turn the nipples a few screws each- maybe 5 finger turns at the most.  If you keep them all equal, it's easier to true later.  If you tighten one side down too much, you can make it so the other side won't thread on.  For 36 hole, 2 cross wheels, your spokes should have 3 holes in-between.  You also have to get the other side (inside or outside) started on the right hole, or they won't work.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 19, 2016, 19:47:12
Looking at that last pic, you need to put the rim up on something.  The hub should be centered, or have it's proper offset.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 19, 2016, 19:52:54
Looking at that last pic, you need to put the rim up on something.  The hub should be centered, or have it's proper offset.

That's the issue I'm having. I generally lace all the inners first, both sides. In this case, everything lines up until that point. When I start installing the outers, they begin to pull the rim too far to that particular side, so that when I start lacing the last set of outers, it's way off.

If i pick the rim straight up as it is, the angle of the spokes don't change, it looks the same as in the pic even when rim is blocked up.   ???
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 19, 2016, 20:35:39
(http://uploads.tapatalk-cdn.com/20160719/5dad9c8e4a04a80044a4a5c7d17a5b65.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jul 19, 2016, 21:30:47
I bought that case and an idler gear from the same seller for $9 shipped, it's for a 250 so I will check it out to see if it's the same.

(http://i.ebayimg.com/images/g/0f0AAOSwPe1T3jNH/s-l1600.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 20, 2016, 00:45:31

I bought that case and an idler gear from the same seller for $9 shipped, it's for a 250 so I will check it out to see if it's the same.

(http://i.ebayimg.com/images/g/0f0AAOSwPe1T3jNH/s-l1600.jpg)

Cool let me know if you don't need.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 20, 2016, 00:50:00
This is as far as I got. Based on my photos and knowledge of lacing wheels, the configuration of the spokes should be correct. I had to bend the outers into place and tap them with a rubber mallet to get them to seat.
Old:
(http://uploads.tapatalk-cdn.com/20160719/ba896e7d55a7c2081add850849d79cbf.jpg)
New:
(http://uploads.tapatalk-cdn.com/20160719/26b9cbe06d8556cb1cb1c6c41f1fa621.jpg)

Here's where I'm at now....
(http://uploads.tapatalk-cdn.com/20160719/eb804386dc310da1f505ac3a56114c2b.jpg)

...but what the f**k? The spokes all the way around appear to be about 1cm too long. Been a long day I could just be botching this job at this point.

(http://uploads.tapatalk-cdn.com/20160719/3440d693921c49d343a6a08bc0902ee0.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 21, 2016, 01:47:48
Had to start jumping around now that I'm waiting on the rear wheel. Carb cleaned and reassembled, all new rubber and a new float valve and seat. Not sure where the needle was set so I went right in the middle and see how it runs.

(http://uploads.tapatalk-cdn.com/20160720/34a457084c33766406d3400c34d03804.jpg)
(http://uploads.tapatalk-cdn.com/20160720/1baaf6cf0efc69e4626d70c120a05321.jpg)
(http://uploads.tapatalk-cdn.com/20160720/1fd1190f1777ba3f5f5bcf2cb3406965.jpg)

One thing I noticed, and it's gotten better since cleaned, but the choke butterfly doesn't close all the way. It hangs up on the carb body walls on the left and right side.

(http://uploads.tapatalk-cdn.com/20160720/cafeb4ef81a5cf9dd474d34902b45b23.jpg)



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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 21, 2016, 07:46:22
Oh well, chunk it in the trash and get an FCR from an RMZ 250.  Just a casualty of war, man.  In 78, Keihin started making a single pumper version of the PD carb for their dirt bikes and dual sports.  It's basically the #2 carb on a CB750.  Just an FYI ;)

If you do keep this'n, pull that cover off the diaphragm on the side and plug the hole up.  It's an air cutoff, whose sole purpose is to reduce afterburn.  It has zero effect on performance and is just another piece to maintain.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jul 21, 2016, 08:31:13
Loose the screws on the choke, close it and see if it lines up then re tighten while closed
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 22, 2016, 01:29:42
You mean the air-cut valve? I'd be interested in swapping out carbs maybe but I'll give this one a shot first, mess with that choke plate if it's a hard start.

Boring stuff today, fixed the kickstand, bead blasted some stuff, got 1/2 controls rebuilt. Mostly trying to make some room on the floor/bench by getting rid of some little easy.



 (http://uploads.tapatalk-cdn.com/20160721/e2d7648511d511be8a9c40e2ef5359b9.jpg)

(http://uploads.tapatalk-cdn.com/20160721/662f7ccb0b46eda87c7630d8277a08ad.jpg)

And that project reminded me why I hate flux core welding,  being all lazy and not switching out the wire, ha.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 22, 2016, 08:20:57
Yeah, Honda put out a race tech bulletin in the 80s about cutting off the air cut valve. It has no performance benefit, good or bad, except when it gets a hole.  Then you have a vacuum leak.  It's such an active diaphragm that it's prone to failure.  The repops are not well made and tend to fold, and a fold becomes a hole.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 22, 2016, 12:03:07

Yeah, Honda put out a race tech bulletin in the 80s about cutting off the air cut valve. It has no performance benefit, good or bad, except when it gets a hole.  Then you have a vacuum leak.  It's such an active diaphragm that it's prone to failure.  The repops are not well made and tend to fold, and a fold becomes a hole.

Interesting. The manual states it's purpose is to "prevent backfiring upon rapid deceleration." The diaphragm wasn't in the best of shape when I reinstalled. I think I'll just stick a bolt in the fuel line attached to it and call it a day, that should do the trick eh?


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 22, 2016, 12:20:42
No fuel line going there. It's all air.  Backfiring is exactly why they started using them.  It's not bad backfiring at all, just emissions shit.  The race tech bulletin calls for a ball bearing in the hole, but a piece of rubber works just as well, if not better.  All the info is here... http://www.motorcycleproject.com/text/aircut_valve_more.html and here... http://www.motorcycleproject.com/text/keihin_idle_circuits_white_paper.swf

I absolutely love the PD carbs.  Once you get passed the hell it can be to clean them, their performance is great especially with the accelerator pump.  Thumpers really like that extra juice to get going.  On my '73 250 motor, I'm running a pumper PD carb from an '81 250r.  Otherwise, seriously look at an FCR.  A lot of 2000s 2 stroke come with them, so they show up on eBay for pretty cheap.  One for an RMZ 250 is the perfect carb for an XL350 motor.  Mostly, you'll have to take the TPS crap off and add an idler screw, but no biggie.  I'll take that to get an FCR for $100 any day. 

Here's a bit on how to install and FCR on an old DR.  http://www.mxrob.com/FCR_Install.htm
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jul 22, 2016, 12:28:22
Nice!
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 22, 2016, 12:43:43
Sweet...FCR seems like a good bang for your buck mod for down the road. Bookmarking that page. As for the air cut valve, I have some 3/16 line running from it just for looks basically. I was saying to plug the end of that to restrict all airflow to the air cut valve, but from your photo there and there article it seems that plugging one of the two small openings is the best way to workaround the valve, so the diaphragm itself still operates.
(http://uploads.tapatalk-cdn.com/20160722/fb6657a0d4efba56039a72c47b1fdc28.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 22, 2016, 12:57:53
Diaphragm doesn't operate when you plug that hole.  It acts on vacuum, so in a way it's similar to the diaphragm on a cv carb just serves a different function.  When you do the mod, you can remove the diaphragm altogether but as the article points out it will act as a seal so you might as well keep it in there. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 22, 2016, 13:12:45
What I'm wondering is if I can cut off airflow completely to the valve by essentially blocking the brass nipple that feeds the vacuum to the valve? Or do I need to just block one of the two holes inside the valve. It's tough to tell what's going on in that photo you posted, there's not much context.

(http://uploads.tapatalk-cdn.com/20160722/e827a05f6a346244a5092d09023d8ccf.jpg)

It looks like the 'mod' involves plugging that lower hole. But there is one up top as well that feeds directly into the intake end of the carb bore.
Title: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 22, 2016, 13:58:19
You're plugging the hole with the o ring for the mod, but in the carb side.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jul 22, 2016, 23:16:31
So I got the 1975 XL250 clutch cover and was elated that it has been upgraded with a needle bearing and seal. The whole cover is very nice but the chain wadded up and took a chunk... The good thing is the chunk is intact an I can weld it back. The idler gear is also a match, I need to check runout but it seems the same just some speed holes.
(http://uploads.tapatalk-cdn.com/20160722/0328c205f5f8101f37937c358d43dbc6.jpg)
(http://uploads.tapatalk-cdn.com/20160722/75bfdeff1b06c741f94b0dad5ad6198b.jpg)
(http://uploads.tapatalk-cdn.com/20160722/b5c5e0ec9a73f4386c31ec4b7e0e4e99.jpg)


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Title: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jul 22, 2016, 23:17:09
Still needs further cleaning, I did test fit it to a 350 case and it fit perfect!


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 23, 2016, 10:52:28

Still needs further cleaning, I did test fit it to a 350 case and it fit perfect!

Sweet! Nice buy on that case btw looks like a good one


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 24, 2016, 15:17:34
Speaking of which, turns out the one I bought a couple weeks ago is not as good as I initially thought, and is basically scrap. The hardware on the other hand, is in good shape.

(http://uploads.tapatalk-cdn.com/20160724/578a861d1ea255f3ccd762d72878cc55.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jul 24, 2016, 15:42:39
Try a 250 search, you may have better luck. The idler is a no go tho as it's too thick.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 24, 2016, 17:21:32
I have a 250 cover, I believe.
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Jul 24, 2016, 17:35:04
what the heck causes those covers to do that?
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 24, 2016, 18:02:29
what the heck causes those covers to do that?
Water.  Magnesium disintegrates when exposed to water, or condensation, for long periods of time.
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Jul 24, 2016, 18:04:40
Water.  Magnesium disintegrates when exposed to water, or condensation, for long periods of time.
I didnt know that.  assumed they were aluminum.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 25, 2016, 11:56:56
Yeah magnesium, great idea.

Got a call from the machine shop this morning, and one of the exhaust valves is bent. Any of you guys have an extra stock 250/350 valve around?


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 25, 2016, 12:24:43
Yeah magnesium, great idea.

Got a call from the machine shop this morning, and one of the exhaust valves is bent. Any of you guys have an extra stock 250/350 valve around?


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Yes
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 25, 2016, 12:34:34

Yes

My hero. PM sent.

The suck part about it is that I'm moving on Friday, so I'm going to have to move without the head, have the machining finished and then have it picked up and shipped to me. Oh well.

\_(ツ)_/


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 25, 2016, 15:00:07
Progress is pretty much at a halt for now. Most of the parts are in boxes ready to get shipped. I tossed on the front sprocket I got in, which has bolt holes for both the 250 and 350 plate I believe. The plate I have won't work, since the bolt holes line up with spaces instead of the teeth like I need.

(http://uploads.tapatalk-cdn.com/20160725/7a84ef054ce3a9ed4990842d9515ad3d.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 25, 2016, 15:20:04
Progress is pretty much at a halt for now. Most of the parts are in boxes ready to get shipped. I tossed on the front sprocket I got in, which has bolt holes for both the 250 and 350 plate I believe. The plate I have won't work, since the bolt holes line up with spaces instead of the teeth like I need.

(http://uploads.tapatalk-cdn.com/20160725/7a84ef054ce3a9ed4990842d9515ad3d.jpg)


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You have to rotate the lock plate in the groove on the countershaft.  You have the right part.
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 25, 2016, 16:10:36
Oh wow, that's right. I'm slow. Been a while. Is this spacing legit, though?

(http://uploads.tapatalk-cdn.com/20160725/68513991824f1a2204e5aa4077c98546.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Jul 25, 2016, 16:15:39
Put the chain on and see but it looks ok to me.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 26, 2016, 13:38:24
So after completely botching the braze job on the tank last week (I was using the wrong rod), I picked up some fluxed bronze brazing rod and picked up where I left off. I had tried to flow the bronze into the back seam to seal up the swiss cheese, but basically just ended up with a giant mess of unused flux, and a hole blown through where I tried to use the MIG (don't do it).

I couldn't get in there to clean it out, so I formulated a new plan. Cut off the tank mount to expose the damaged area, clean it up to get a proper weld, and then braze the tank mount back into position. Easy, right?

(http://uploads.tapatalk-cdn.com/20160726/3f9e9df89360beef854b7b787cc027ea.jpg)

Swiss cheese. Real cheesy.

(http://uploads.tapatalk-cdn.com/20160726/7489efbd1948aa54215131f48e5196df.jpg)

(http://uploads.tapatalk-cdn.com/20160726/816ab6bfd1ff7e57f7a21a4426ce6b48.jpg)

Brazed up. This plan works much better, since I can actually see what I'm doing. I will let the tank cool naturally, spray some soapy water on the seam and blow into it with the shop vac to see if were sealed up.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Jul 26, 2016, 13:47:19
Looks like you got it, test will tell but that looks ok in pics.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 26, 2016, 21:50:06
Nope, one pinhole left and I ran out of acetylene.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jul 31, 2016, 20:38:26
Tanks aren't that hard to find, but hope you can get back init soon  :o
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 05, 2016, 12:45:31
Not much to update. Move from MA -> TX complete without too many problems. New shop waiting to be set up.

(http://uploads.tapatalk-cdn.com/20160805/0f8ef109a0ecd776afa68ba625b9a6e8.jpg)
(http://uploads.tapatalk-cdn.com/20160805/17f5a6833c8bd8951ae60a6f8d842910.jpg)
(http://uploads.tapatalk-cdn.com/20160805/0204216ee26c036ae4ff84184cca873c.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Aug 05, 2016, 12:59:07
Nice! turn the kennel into a chicken coup the smell is dreamy  :-[
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 05, 2016, 13:07:10

Nice! turn the kennel into a chicken coup the smell is dreamy  :-[

Hah yep that's the plan I think it was a coop at one point we may get a few to help out with the lawn maintenance


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Aug 05, 2016, 13:09:45
Nothing like fresh eggs that you don't have to worry about salmonella or even refrigeration. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Aug 05, 2016, 13:27:27
Valves and head
(http://uploads.tapatalk-cdn.com/20160805/63c2e61b2c9d6c04e1138a7e90cfbbab.jpg)

Ran em on the soft wheel look good by eye no grind on tips
(http://uploads.tapatalk-cdn.com/20160805/5e9dac27930a4d49299304e879133f1e.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Aug 05, 2016, 13:32:27
Seeing that pic makes me wonder about an XL350 cam in an XL 250.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Aug 05, 2016, 13:37:16

Seeing that pic makes me wonder about an XL350 cam in an XL 250.

250 cam higher lift pretty sure


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 05, 2016, 14:54:14
Sweet, look good you can keep the springs n keepers I'll get ya paypal'd


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Aug 05, 2016, 17:04:22
They went with, toss what you don't use I have no use, but the height is in spec on em  ;)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 05, 2016, 18:19:23
Thanks man maybe I'll get this thing moving this year


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 09, 2016, 18:21:20
Ran em on the soft wheel look good by eye no grind on tips

Just heard from machinist they're both bent   :'( :'( The hunt continues

Found some NOS on eBay, may just go that route I'm about had it with these valves at this point, engine been open too long.

Other news, third times a charm with the spokes. New set is in should get to lace up the rear wheel this weekend and have a roller.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Aug 09, 2016, 18:44:44
Hell! they sat in the seat nice and the carbon had no marks, I guess i could have run a dial indicator on them.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Mr.E on Aug 10, 2016, 11:55:04
Just heard from machinist they're both bent   :'( :'( The hunt continues

Found some NOS on eBay, may just go that route I'm about had it with these valves at this point, engine been open too long.

Other news, third times a charm with the spokes. New set is in should get to lace up the rear wheel this weekend and have a roller.

I gave up and took my wheels to the Honda shop locally. Old guy there had them fixed pretty quick and then asked why I couldn't do it.  I'd be happy if I don't touch a front xl/cr wheel again.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 10, 2016, 12:05:27
I gave up and took my wheels to the Honda shop locally. Old guy there had them fixed pretty quick and then asked why I couldn't do it.  I'd be happy if I don't touch a front xl/cr wheel again.

Does the Elsy have the front hub with the bolt on plate for the long spokes? I had a hell of a time with that thing. Finally got it laced it up and the holes were off a space  ;D
Title: Re: 74 Honda XL 350 - The Turd
Post by: Mr.E on Aug 10, 2016, 12:39:43
Does the Elsy have the front hub with the bolt on plate for the long spokes? I had a hell of a time with that thing. Finally got it laced it up and the holes were off a space  ;D

exactly that.  I did too, twice. So i gave up and took it to the local shop
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 14, 2016, 02:37:00
New spokes laced up. They look reasonable...but still need to be seated. One of the nipples found its way onto the deck of the trailer during the move. I picked it up and stuffed it in my pocket, but I have no idea where it ended up. Tore apart the truck and toolbox to no avail. Going to see if I can scrounge one from the CB but not sure if I kept any of the old spokes.

(http://uploads.tapatalk-cdn.com/20160813/e385f92b9d314ea87c7b7b3b53b5a344.jpg)

A decent looking tank came up on eBay, so I pulled the trigger. I'll get the original tank sealed up eventually but hopefully I can toss this one on in the meantime.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Aug 14, 2016, 08:43:34
A/C?

Seems like a lot of exposed threads but they look fine, not SS Buchanan's Foien but fine  ;D
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 14, 2016, 13:33:19

A/C?

Seems like a lot of exposed threads but they look fine, not SS Buchanan's Foien but fine  ;D

Nope not yet. Ran up and down all day Friday but no luck. We borrowed a bit window unit to cool the house for now.

I only have them twisted on 3-4 turns in the pic they should seat fine once I get em all tightened. The old spokes stuck out 1.5cm all the way around bottomed out on the threads, I'll keep em around though got a full set of random length spokes now.


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Title: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 18, 2016, 18:54:48
(http://uploads.tapatalk-cdn.com/20160818/3efd7ee798726ffbd2431cc93fbfee67.jpg)

The elusive nipple! Started working out in the shop out back and it turned up, knew that little bastard was somewhere.

Head is finally buttoned up at the machine shop. Only problem is its 2,000 miles away back in MA. Flying back this weekend to take care of some loose ends so I'll pack it up and ship it back, finally get this motor back together.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 18, 2016, 23:08:06
(http://uploads.tapatalk-cdn.com/20160818/be59fb4059219afa7b90bb1cd9ded6f3.jpg)

So the back hoop is trash, nice big dent in it. Gonna true it up as best I can for now and throw the rubber on it...this thing ain't going on the highway anyways. If I keep it I'll have to buy a new set.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Aug 18, 2016, 23:10:40
They make washers too.  Not sure if you need them or not, but I know on my GL rims they have washers.
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 18, 2016, 23:29:13
They make washers too.  Not sure if you need them or not, but I know on my GL rims they have washers.

Naw I think these are good without, they didn't have washers originally either. The spokes suck but I'm gonna tap the dent in a bit with a mallet to straighten it out a bit and get it as close as I can.

These rims have been abused. Looks like an S

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Title: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 19, 2016, 14:40:26
I snagged this decent looking tank off he 'bay a couple weeks ago, since I don't have the time right now with the new house to keep messing with the original tank. It came in today, and looks really solid. No scaling on the inside, the seam at the back looks good. A quick etch and seal and this thing will be on and ready. The paint isn't bad, there are a couple of significant dents so I'll see if I can't pop them out from the inside before I seal it. Not going to worry about a new coat of paint right now, maybe down the road.

(http://uploads.tapatalk-cdn.com/20160819/81210929b6ec4f2559f000983fa790e2.jpg)
(http://uploads.tapatalk-cdn.com/20160819/e6255bc1be89abe697f2b25d3bd52213.jpg)

I know Kamn will be disappointed I didn't seal up the original tank, but I do plan on finishing up that one when I have some more free time

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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Aug 19, 2016, 17:23:56
(http://uploads.tapatalk-cdn.com/20160819/9e80f1a6d1dac53d11b564cc2ff4c477.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Aug 19, 2016, 17:25:08
Just JB that for a smooth surface and your golden


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Kamn on Aug 19, 2016, 17:29:11
Not disappointed at all man
And glad to see that you got a decent tank to finish this bad boy up
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 20, 2016, 14:57:37

Just JB that for a smooth surface and your golden

How's the sliding surfaces look, still need brass bushings fit?


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 20, 2016, 14:58:42
Head all buttoned up, over a month later. Looks all good. Once I get it back to TX the top end will be ready to get all buttoned up.
(http://uploads.tapatalk-cdn.com/20160820/6eed7124b6e5d7a07e91bf04cf65c731.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Aug 20, 2016, 18:37:02
(http://www.dotheton.com/gallery/11494-200816163635.png)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 25, 2016, 23:22:53
Look, a roller!

(http://uploads.tapatalk-cdn.com/20160825/7e4217b06ed67925353233094245811d.jpg)

Tank looks halfway decent. I tried to pop out the big honkin' dent on the right hand side. It popped a bit but tough to get leverage way down there.

(http://uploads.tapatalk-cdn.com/20160825/a122bee83967c801aec913c4cd7ed15c.jpg)

But the other side looks good anyways.

(http://uploads.tapatalk-cdn.com/20160825/338d64e0725e9dd41390bad0827d0461.jpg)



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Title: Re: 74 Honda XL 350 - The Turd
Post by: JustinLonghorn on Aug 26, 2016, 07:30:50
Huzzah!
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Aug 26, 2016, 08:25:03
Nice Job.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Kamn on Aug 26, 2016, 08:42:32
I see wheelies in your future
Title: Re: 74 Honda XL 350 - The Turd
Post by: Mr.E on Aug 26, 2016, 12:26:20
Looking great. And, there was a XL250 Motorsport on the Vintage 1000 ride last week that was unstoppable.  It took everything in stride and was one of the few bikes on the trip that didnt need a thing.  If yours ends up anything like the 250, you're in for a lot of fun in the future.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 31, 2016, 01:35:36
Thanks gentlemen, and E I can only hope this old girl turns out to be as reliable as that 250.

Had a fun time reinstalling the valve springs and keepers. Ended up making a adapter for a clamp out of PVC to get the keepers in, the valve spring clamp I bought was not helpful. If anyone has a better tool for reinstalling valves, let me know.

New seals:
(http://uploads.tapatalk-cdn.com/20160830/c09de3b397f1d67475a4a0a48b3b3777.jpg)

Springs installed (the right way) and keepers:
(http://uploads.tapatalk-cdn.com/20160830/6237f827582e7e0888b1f8140a1725f8.jpg)

Started to install the camshaft and realized I ordered every other oil seal except the camshaft seal. Doh! They were going for $18+ on the bay, but I found one for $6 shipped coming from somewhere in Texas. Sweet! Hopefully I'll have it before the weekend, set the cam timing and get the top end sealed up.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Aug 31, 2016, 09:13:20
If you have a drill press you can make a jig to rest the head on and use a custom notched and ground hole saw 5/8 - 1in dia chucked up key is to have a locking throw

This or an arbor press works with a digital baking scale for testing spring rate works too
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 31, 2016, 10:25:38

If you have a drill press you can make a jig to rest the head on and use a custom notched and ground hole saw 5/8 - 1in dia chucked up key is to have a locking throw

This or an arbor press works with a digital baking scale for testing spring rate works too

Ah yeah drill press woulda worked I don't have a locking throw but could rig something up I will try that next time.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 06, 2016, 13:44:09
After quite the wrestling match I was able to get the motor bolted up last night.

(http://uploads.tapatalk-cdn.com/20160906/2580529b9052f4b53d5b428ce9f224da.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: JustinLonghorn on Sep 07, 2016, 07:31:27
Huzzah!
Title: Re: 74 Honda XL 350 - The Turd
Post by: Kamn on Sep 07, 2016, 08:25:42
its coming together......keep the pics coming
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 08, 2016, 02:07:28
Been trying to do a little bit each day to keep the ball rolling. A new kickstart idler gear with all its teeth went in, new clutch springs from Barnett, torqued the clutch and oil filter nut down. Gotta pick up some more engine paint/primer tomorrow and shoot the right and left case covers. Engine should be all together soon. XB hooked me up with a good shape left case, third ones a charm. Still showing some pitting because magnesium, so I tossed some JB weld on as filler and cleaned it up. This isn't going to be some trailer queen show bike so it doesn't have to be perfect, just hide the curse a bit and seal up that mag from any and all future moisture

(http://uploads.tapatalk-cdn.com/20160907/4ba80091355cb0261e6224579ecb3d9c.jpg)

(http://uploads.tapatalk-cdn.com/20160907/a6c8763265d8e9a41d20f562fe9951dd.jpg)

(http://uploads.tapatalk-cdn.com/20160907/13e988a5fc01454ccf3cc482a6f40952.jpg)

(http://uploads.tapatalk-cdn.com/20160907/cf2a3cf2340771d51309c8bbbd8518fd.jpg)

Started to clean up the advancer and points plate assembly. On the CB, you could twist the cam and the weights would spring out, I'm not sure if this type is the same. But the cam won't budge off the backer plate so I'm guessing it's all seized on there.

(http://uploads.tapatalk-cdn.com/20160907/dbc3ae1b8834d4c53448196f3c981237.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Sep 08, 2016, 14:26:55

Did you get the slinger slingin!

(http://uploads.tapatalk-cdn.com/20160908/c2de82d464cba16d2c1bc43495a3de03.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 08, 2016, 14:32:53

Did you get the slinger slingin!

Not yet froze it a couple times yesterday had to pick up some PB got it soaking now, got some paint stuff to do while it works it magic


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Sep 08, 2016, 14:46:43
It will free up, likely just nasty old grease, you don't have to take it all apart just get the cam off and clean it use just a touch of moly grease going back

(http://uploads.tapatalk-cdn.com/20160908/144b733a0bb25b0713480b0f5e23cf13.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 13, 2016, 01:42:03
Been putting out little fires here and there. Got the advancer polished up and reassembled. I found that one of the posts had 3 little thrust washers below the circlip and one had 2, possibly to make up for discrepancies in mfg? Tough to see in the photo though but it's there.

Put it all back together and greased, there's no slop on the hinges for the weights so I guess I've got it right.

(http://uploads.tapatalk-cdn.com/20160912/92c2b8dbbd884a2e3f0cac3ae49f84b3.jpg)
(http://uploads.tapatalk-cdn.com/20160912/da466a2f6022583219384ca54fb6d9f1.jpg)

Points plate assembled and everything back in place. Using an aftermarket Denso breaker point, I've heard they're not the best but the stock one is shot. I found some OEM ones on eBay for short money I may pick up in case this one sucks. New heat shrink, etc etc. Not timed yet...

(http://uploads.tapatalk-cdn.com/20160912/56577daeb6ae438124dea73035fe3cad.jpg)

Got the fenders painted up and riveted back together. Ended up using some silver paint left over from a job, came out pretty decent considering what I started with.
(http://uploads.tapatalk-cdn.com/20160912/b4d0f4470fc97accae6fd6b4b87e2426.jpg)
(http://uploads.tapatalk-cdn.com/20160912/28fa90f840591966bebef7d85fa98d14.jpg)

FINALLY got a left case cover that I can use. Had to JB weld some pitting on the outside. Had a cleaned up needle bearing and actuator from another case ready to go so fit everything together with some grease and a new dust seal and were in business.

(http://uploads.tapatalk-cdn.com/20160912/5ed2a77dfab399f5bc42dae2950ded85.jpg)

Blocked the air-cut valve on the carby. Pretty sure I've got this right. The documentation on this mod has pics with pretty poor context so I'm not 100%. I cut out a piece of fuel line with a punch, may be a tad thick so if I'm idling high on startup I know where to look. Anyone whose done this mod care to check my 'work'?

(http://uploads.tapatalk-cdn.com/20160912/e758a7723081ab40af2637d4c71e6df0.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 13, 2016, 19:16:47
Got my hands on a FMF power core 4 pretty beat up an a nice shape muffler off a YZ or something. Top muffler is a KDX I bought originally at the salvage yard but it's giant and I don't think I can make it work with the suspension.

The YZ muffler looks the best I may try and fit that, gotta get the back tire in place then mock it up.

(http://uploads.tapatalk-cdn.com/20160913/11dfbf12bf512558af3413aa8b795c65.jpg)




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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Sep 13, 2016, 19:23:58
Nice! they come apart easy, clean up nice and the cans are likely the diameter so interchangeable parts
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Sep 13, 2016, 21:29:26

Blocked the air-cut valve on the carby. Pretty sure I've got this right. The documentation on this mod has pics with pretty poor context so I'm not 100%. I cut out a piece of fuel line with a punch, may be a tad thick so if I'm idling high on startup I know where to look. Anyone whose done this mod care to check my 'work'?

(http://uploads.tapatalk-cdn.com/20160912/e758a7723081ab40af2637d4c71e6df0.jpg)


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  That's right, playa.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 14, 2016, 22:54:38
Sweeeeet.

(http://uploads.tapatalk-cdn.com/20160914/a91227064e78d6481658ffb603df91fa.jpg)

Bolted the shocks up with some new flange bolts from McMaster. Turns out M10x1.25 is pretty uncommon size/pitch. Tossed the wheels back on for good this time. Hooked up the front brake - I'm pretty unimpressed with the fitment of the cable, seems like the jacket is about 1/8" too long so I have basically zero room to adjust. But I don't feel like trimming it so I'll just have to wait until the shoes seat in and the cable stretches a little bit.

Next on the list is to fit the airbox and finish cleaning/re wrap the harness.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: JustinLonghorn on Sep 15, 2016, 06:57:47
BRAAAAAAPPPPPPPPPPP
Title: Re: 74 Honda XL 350 - The Turd
Post by: Nj732port on Sep 15, 2016, 08:21:59
this thing has come a looooong way from what you started with! looks great 8)
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Sep 15, 2016, 08:57:18
Comin on great Adco. the punch list is near.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Sep 15, 2016, 09:01:52
Fer real, dude.  The bizness.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Sep 15, 2016, 09:04:40
Nice job, almost a new bike now.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 15, 2016, 10:31:45
Thanks fellas. I was going to start making a punch list last night but it was getting too long to call it a punch list so I'll wait til next week :D


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 16, 2016, 01:00:42
Sprayed the plastic covers in satin black. I think I'll put some vinyl on there...I wanted to hand paint on em but I don't have any striping paint and well, I have a vinyl cutter.
(http://uploads.tapatalk-cdn.com/20160915/85f2d657abbaeb0159f1661a1af6663b.jpg)

Started work on the electrical. Lashed up the coil using some m6 nuts as spacers. Had to ream the holes on the coil to mount it, spacing was about 2mm off for the factory mount
(http://uploads.tapatalk-cdn.com/20160915/af4ead09d45124ac9146ee9aff616ecd.jpg)

Taped up the harness using some wiring loom self adhering tape. Stuff is great and no sticky mess if I have to pull it apart for any reason. I soldered in a nice weather proof blade fuse holder, soldered on the connections for the new R/R (thanks Matt), and ended up running a new hot wire to the ignition cuz the one that was there was all burnt up. Great part about the loom tape is you can add wires after you've already wrapped it, just wrap it some more!

(http://uploads.tapatalk-cdn.com/20160915/7b5b31e288b6621cdc60dbb55d4ecdaf.jpg)

Gotta put some sleeves on the rest of the connections, I bought some 1/8" vinyl tube I'm going to make a tool out of some crappy pliers to crimp it over the connectors. More on that later.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Sep 16, 2016, 08:32:45
Everything looks beautiful. Great job with the harness.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 16, 2016, 17:22:10
Thanks man!

So this being a pretty budget build, I'm cleaning up all the old connectors. I hate cleaning the housing for the female ends, so I make new ones with vinyl tube. I made a quick video to demonstrate "the process"

(http://uploads.tapatalk-cdn.com/20160916/ccf788d06719b368b80472d66efa7f7a.jpg)





Title: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 16, 2016, 19:31:07
Video below /end sarcasm. Enjoy!

http://youtu.be/dmaQO-qVj7I

Also thanks tune.
Title: Re: 74 Honda XL 350 - The Turd
Post by: stroker crazy on Sep 16, 2016, 21:51:59
Video below …

It looks like Ichiban Moto has a competitor!

Crazy
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 16, 2016, 22:16:13
It looks like Ichiban Moto has a competitor!

Crazy

I can't compete, I don't have badass hand made tools like Ichiban does. Or badass stickers.


Just tell it like it is

Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Sep 17, 2016, 20:07:59
So this being a pretty budget build, I'm cleaning up all the old connectors. I hate cleaning the housing for the female ends, so I make new ones with vinyl tube. I made a quick video to demonstrate "the process"

This is great- I plan to do the same with my failing connectors. Thanks for posting the video!
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 17, 2016, 20:43:50

This is great- I plan to do the same with my failing connectors. Thanks for posting the video!

No problem! Hope it helps. I use different size vinyl tubing for the male connectors and for the 3-way female connectors as well. Some of them have to be crimped on multiple sides but as long as you bond it to the wire jacket you're set


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 17, 2016, 23:24:06
Had to paint trim and doors in the house today, so that was...fun. Got a few hours in the shop so I decided to clean up the workbenches and organize my projects.

Made a punch list. And a parts list. Mostly no lights for the moment I'll address that after Barber. Let me know if I missed anything.

(http://uploads.tapatalk-cdn.com/20160917/aaf8f9d1410d014d541dca8288690640.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 18, 2016, 22:49:54
Lashed up new R/R in the factory spot, locks into the factory slot as well. It protrudes a bit further but still clears the airbox no problem. Put a couple flat washers behind the unit to allow some airflow.

(http://uploads.tapatalk-cdn.com/20160918/f1c65f24d02ef67d55110fb2bf040c3e.jpg)
(http://uploads.tapatalk-cdn.com/20160918/12f626c29e1959b491dfc6df863a9d9e.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Sep 18, 2016, 23:20:06
Looks good, maybe drill some speed holes in the back for even more air airflow!
Title: Re: 74 Honda XL 350 - The Turd
Post by: mitchn06 on Sep 22, 2016, 10:11:49
Is that a 6V Reg/Rec?


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Hurco550 on Sep 22, 2016, 10:18:25
Had to paint trim and doors in the house today, so that was...fun. Got a few hours in the shop so I decided to clean up the workbenches and organize my projects.

Made a punch list. And a parts list. Mostly no lights for the moment I'll address that after Barber. Let me know if I missed anything.

(http://uploads.tapatalk-cdn.com/20160917/aaf8f9d1410d014d541dca8288690640.jpg)


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I have one of these lists for barber for the interceptor. Problem is, evertime I cross  something off I think of a new thing to add haha
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Sep 22, 2016, 10:21:31
Ha, I had one of those lists for the GL to be done for my Cabot trail ride, it worked, but again like Hurco, you seem to cross off 2 things and a new thing back for a bit.
Title: Re: 74 Honda XL 350 - The Turd
Post by: mitchn06 on Sep 22, 2016, 10:25:44
Making lists indicates wisdom, adding to them indicates creativity and confirmed brain function.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 22, 2016, 12:00:49
Is that a 6V Reg/Rec?

Yes, it is. Got it from Sparck (Sonrier).

I have one of these lists for barber for the interceptor. Problem is, evertime I cross  something off I think of a new thing to add haha

Yep I have added a couple things that I forgot but for the most part been crossing stuff off  8)
Title: Re: 74 Honda XL 350 - The Turd
Post by: mitchn06 on Sep 22, 2016, 12:39:53
Cool, is it the "step up converter?


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 22, 2016, 12:44:00
Cool, is it the "step up converter?

Just a standard R/R that combines the separate regulator and rectifier from the original harness. I was going to swap to a 12v system but I had already purchased a battery and the R/R so I'm going to stick to the 6v for now. I can always use a step up to 12v to run the lights, if necessary.
Title: Re: 74 Honda XL 350 - The Turd
Post by: mitchn06 on Sep 22, 2016, 12:46:35
Just a standard R/R that combines the separate regulator and rectifier from the original harness. I was going to swap to a 12v system but I had already purchased a battery and the R/R so I'm going to stick to the 6v for now. I can always use a step up to 12v to run the lights, if necessary.
Ok, in my state, only lights required are headlight and tail/brake light. But finding a decent 6v aftermarket headlight is difficult. Was going to go full LED. So 12v would be good, but still doable with 6V, but not as easy. And current draw as we all know is significantly less with LEDs.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 22, 2016, 14:54:05
Ok, in my state, only lights required are headlight and tail/brake light. But finding a decent 6v aftermarket headlight is difficult. Was going to go full LED. So 12v would be good, but still doable with 6V, but not as easy. And current draw as we all know is significantly less with LEDs.

Yep Sparck sells a step up converter. I am going through the same issue with headlights so I may end up going that route, and keeping the rest of the lights at 6v. If you happen to find a good 6v headlight, let me know.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 22, 2016, 16:32:26
Here's a quick mockup of how I may mount the muffler, this is using the stock mounting hardware and the YZ muffler. The quality on this one seems much better than the FMF but using the mounting point is going to pose a problem, and I'm not set up to weld aluminum or TI which I believe the inlet pipe is made of.

(http://uploads.tapatalk-cdn.com/20160922/f6bde643863ea65b2715545b631d3dbe.jpg)
(http://uploads.tapatalk-cdn.com/20160922/6863c43effe28ce2526babcd751ba0b0.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 22, 2016, 16:36:54
The FMF. I think it's gonna be this one, the moveable mounting bracket will make my life easier.

(http://uploads.tapatalk-cdn.com/20160922/9b16c307e00889380d57fcf7d16a5e75.jpg)
(http://uploads.tapatalk-cdn.com/20160922/5204b51311a5e0e0dc96e9346f65dbeb.jpg)
(http://uploads.tapatalk-cdn.com/20160922/c7259fd3dfb36462958efb31bb197bf9.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Nj732port on Sep 23, 2016, 12:17:16
couldn't you remove the permanent bracket and make a nice moveable one for the can u like?
or make up a new frame to can piece
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 23, 2016, 13:08:20

couldn't you remove the permanent bracket and make a nice moveable one for the can u like?
or make up a new frame to can piece

Yeah, I could but I'm not set up to weld aluminum so I'm kinda out of luck there.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: canyoncarver on Sep 23, 2016, 17:10:53
Nice "patina" on the exhaust hangar. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 24, 2016, 14:19:16

Nice "patina" on the exhaust hangar.

Thanks. I thought that was a nice touch, a hint to the past of the bike hah!

Set the cam chain tension and valves last night. Someday I'll get the proper tool for doing these valves. Started to set the timing, but the eBay special ignition switch I got isn't working. The wires may need to be switched around, I gotta check the continuity between the leads.

I bypassed the ignition switch but started blowing fuses, so I called it a night.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 25, 2016, 16:42:12
Fun little project that got me to finally set up my welder in the shop. The stock footpegs once had rubber on them to give something substantial to stand on, but all of that was gone and I was left with some skinny daggers. This wouldn't do.

(http://uploads.tapatalk-cdn.com/20160925/6db8e542ff88f008af0c1b9aa50a2302.jpg)

So I swapped out the plug on the welder to match the outlet in the shop, and set out to weld (on a terrible welding surface). I cut a piece of 3/8" steel rod I had lying around into 4 equal-ish pieces, and welded fore and aft on each peg.

(http://uploads.tapatalk-cdn.com/20160925/bd2b6ba458ba3dcf393c3fd7843a083c.jpg)

Cut some grooves with the angle grinder and smoothed them out as much as I cared to.

(http://uploads.tapatalk-cdn.com/20160925/be22644dc7225d0a13075b201e2dea5a.jpg)

Black epoxy.

(http://uploads.tapatalk-cdn.com/20160925/78da01ad2b07df0225e44e83d8df9fb6.jpg)

Dipped in clear plasti-dip and cut and peeled the excess around the mounting area. Looks good to me, just need to get the right mounting hardware.

(http://uploads.tapatalk-cdn.com/20160925/d0c754988eb7ff252ba2a7fe1f3a6d97.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Sep 25, 2016, 16:57:48
(http://cdn.shopify.com/s/files/1/0208/5734/products/fp001_1024x1024.jpeg?v=1455110377)

 ;)

Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 25, 2016, 17:13:02

;)

#builtnotbought


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Title: Re: 74 Honda XL 350 - The Turd
Post by: mitchn06 on Sep 25, 2016, 23:23:37
Nice pegs, is that the stock shift lever? Mine is all messed up, was looking for an aftermarket one with similar bend. Got any ideas? Probably a moose one or the likes.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Sep 25, 2016, 23:28:18
#builtnotbought


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I can tell  ::)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 26, 2016, 00:11:46

Nice pegs, is that the stock shift lever? Mine is all messed up, was looking for an aftermarket one with similar bend. Got any ideas? Probably a moose one or the likes.

Stock shifter. There are some used ones available on eBay. Looks like most of the moose/aftermarket ones are for the mid 80s XL250/350


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 30, 2016, 16:04:13
Last load of parts coming in. Big thanks to Mr. E for spinning me up some sweet brass tach/speedo plugs and the missing link for the rear brakes.

(http://uploads.tapatalk-cdn.com/20160930/16112d54aa2be22c7deee3c2129cdbae.jpg)

An XL seat pan with a crappy cover and o-ring chain from eBay, and air cleaner unit from cxman.

(http://uploads.tapatalk-cdn.com/20160930/84718c60f76d61f961334f385ecff881.jpg)

Will be buttoning some things up this weekend for sure. Just waiting on some mandrel bends and exhaust parts and she'll be running.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Sep 30, 2016, 16:34:43
yours is prettier

but mine is running i have a vm36 mikuni on it and it pulls real nice i just have a minor nuisance oil leak on the left cover to deal with

its dripping on to the exhaust

but after 18 years in boxes it runs again
 
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 30, 2016, 17:40:29

yours is prettier

but mine is running i have a vm36 mikuni on it and it pulls real nice i just have a minor nuisance oil leak on the left cover to deal with

its dripping on to the exhaust

but after 18 years in boxes it runs again
 

Sweet! I'm interested in doing the VM36 swap down the road, I will be in touch for sure.

Those left covers are a pain in the ass, I went through 2 junk ones  before I found a good one


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 30, 2016, 21:10:09
(http://uploads.tapatalk-cdn.com/20160930/d250eca1ce94dc5606221044e1964b7b.jpg)

Soon.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: el barto on Oct 01, 2016, 06:47:48
Dang that shop looks great
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Oct 01, 2016, 08:39:06
Last load of parts coming in. Big thanks to Mr. E for spinning me up some sweet brass tach/speedo plugs and the missing link for the rear brakes.

(http://uploads.tapatalk-cdn.com/20160930/16112d54aa2be22c7deee3c2129cdbae.jpg)

An XL seat pan with a crappy cover and o-ring chain from eBay, and air cleaner unit from cxman.

(http://uploads.tapatalk-cdn.com/20160930/84718c60f76d61f961334f385ecff881.jpg)

Will be buttoning some things up this weekend for sure. Just waiting on some mandrel bends and exhaust parts and she'll be running.


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Brass kicks ass... I once got a little box from Mr. E... I keep my private jets init 
Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Oct 01, 2016, 09:35:06
must be a big box most private jets i have flown are pretty big
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Oct 01, 2016, 09:39:20
must be a big box most private jets i have flown are pretty big

Only ever flown private "jet" twice... My "private jets" are factory fuel distribution ports  :-[
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Oct 01, 2016, 21:24:19
Nice, shes really coming along and looking good bud.
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 16, 2016, 19:03:37
Tackled the header and muffler situation this weekend. Kamn spun me up a header spigot to start off with (thank you sir). Shortened up the inlet on the YZ muffler, I couldn't use the FMF it was just too beat up. Tacked everything up, reconfigured the section behind the footpeg about 10 times, and then sealed everything up.

(http://uploads.tapatalk-cdn.com/20161016/fcdbdc779e7da527a54db106873cd296.jpg)

(http://uploads.tapatalk-cdn.com/20161016/ca498226e5e6fcb5bfc6f0674c01ebb4.jpg)

(http://uploads.tapatalk-cdn.com/20161016/d1d464d3bac253bb86b99d8acd642fa6.jpg)

Made a new hanger with some 3/16" rod and 1/8" steel.

(http://uploads.tapatalk-cdn.com/20161016/57973254b25f0035cda97be4589e5b15.jpg)

(http://uploads.tapatalk-cdn.com/20161016/d8c67f294be70840d4200d6c99aebc3f.jpg)

Had to keep the muffler low since I'm going to be fitting boxes. May have to relocate the top support later.

The pipe behind the footpeg clears my boot with a couple inches to spare, but ill probably be moving around a bit on the pegs so I decided to throw together a mini heat shield to protect my boot just in case.
I had a piece of aluminum lying around from another project. Drilled some speed holes, shaped it, and then welded a couple of tabs with nuts welded underneath to the header. Should do the trick.

(http://uploads.tapatalk-cdn.com/20161016/1dea327b668891dea683c969fb3d783b.jpg)

(http://uploads.tapatalk-cdn.com/20161016/68226da00b067739ef2bc00af28277d3.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Oct 17, 2016, 20:21:40
Looks cool.  A bit surprised you didnt go w a high pipe, though.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 17, 2016, 20:32:36

Looks cool.  A bit surprised you didnt go w a high pipe, though.

I thought about it. The 350 originally comes with a low header and upswept muffler, so I decided to keep the stock position for the header and mount the muffler lower. Next step is to build a luggage carrier off the back and some pannier mounts - I am going to run a 40mm ammo can on each side for panniers, and I think the high pipe would've been a pain to lash up with the boxes.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Oct 17, 2016, 20:36:50
I think I have one of your side covers, if you don't already own them.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 17, 2016, 20:41:22
I think I have one of your side covers, if you don't already own them.

Thanks. I have them, they're sitting in my office waiting for me to decide what graphics to put on them.  ;D
Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Oct 17, 2016, 21:44:25
xl410 is what i need for mine
Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Oct 17, 2016, 21:46:54
i need a package rack for mine but this is a little rude

http://www.ebay.com/itm/NOS-Honda-XL-600-R-XL-350-R-XL-250-R-New-Rear-Luggage-Rack-Assembly-1983-1987-/191753525109?hash=item2ca5669775:g:Q3YAAOSwo6lWMQfo&vxp=mtr

Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 17, 2016, 21:54:37

i need a package rack for mine but this is a little rude

http://www.ebay.com/itm/NOS-Honda-XL-600-R-XL-350-R-XL-250-R-New-Rear-Luggage-Rack-Assembly-1983-1987-/191753525109?hash=item2ca5669775:g:Q3YAAOSwo6lWMQfo&vxp=mtr

Yikes that is steep, I like the design though...
I am going to make something similar with 1/2" conduit most likely but I would like 3/8" diameter better.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 19, 2016, 01:20:46
Crossing things off the list. Rear brake linkage and pedal set up, thanks again to Mr. E for the fancy titanium retainer.

(http://uploads.tapatalk-cdn.com/20161019/0a1a5d98bc6eb5cc24e2a238ddbf7bfe.jpg)

Chain fit up and tensioner reassembled.

(http://uploads.tapatalk-cdn.com/20161019/5df501c5f84ba13ffa3ab6842fc58262.jpg)

Found a scrap of ABS I had from the 360 and took to fixing the chain guard. Traced and cut a chunk of scrap, cleaned and smoothed the broken edges, and welded away with the soldering gun. Surprisingly easy to do and probably stronger than before. Doesn't look perfect but it'll do the trick.

(http://uploads.tapatalk-cdn.com/20161019/0f13f89defc7111bcf83ab4a8caf02c2.jpg)

(http://uploads.tapatalk-cdn.com/20161019/c7539e3c4b5cdbd5e22ff381244188f2.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 19, 2016, 04:18:30
Went to install the eBay petcock and it didn't come with a mesh screen. I broke open a plastic in line filter to steal the mesh.

(http://uploads.tapatalk-cdn.com/20161019/9d8353b85de4594455a1334fac31e95a.jpg)

Cut it with tin snips and drilled a tiny hole, there's that.

(http://uploads.tapatalk-cdn.com/20161019/db87ac6f1a5d3da6097a4e4d93e37eaf.jpg)

The tank is clean inside but since I don't like to run in line filters I like the idea of having one line of defense between the tank and carb.
Tank is installed and fuel line routed. I'll need to grab the correct size socket for the spark plug, it's pretty hard to access.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Oct 19, 2016, 08:25:23
yup i just pull the tank off then can get at mine
Title: Re: 74 Honda XL 350 - The Turd
Post by: el barto on Oct 19, 2016, 14:15:03
Loving your diy solutions, especially the heat shield. 8)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 21, 2016, 13:34:34

Loving your diy solutions, especially the heat shield. 8)

Thanks mate. Just using what I got lying around the shop on this build.

I swapped out the bars for a straight set I picked up on the cheap at Barber. They are a bit lower and seem to be a bit more comfortable. Still undecided on the headlight situation, I want to make a fairing outta some sheet metal.

(http://uploads.tapatalk-cdn.com/20161021/9fb312e1e7aa352f2db4c9025c849ca2.jpg)

Going to gas her up for the first start later today.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Oct 21, 2016, 13:37:20
Good luck, it should be fine. try not to pull to many wheelies LOL.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 22, 2016, 18:08:31
First start, success!

https://vimeo.com/188452440 (https://vimeo.com/188452440)

I managed to mess with the clutch enough to get it working, and took it for a quick run around the block. Running kinda rough at 1/4 throttle but wakes right up above that.

Gotta go around and make sure everything's tight before another ride. Almost lost the muffler on the way back LOL.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: HerrDeacon on Oct 22, 2016, 18:43:06
Excellent, always nice to hear the first start up.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Oct 22, 2016, 18:45:26
Racin hair scrambles tomorrow?  :o
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 22, 2016, 21:50:02
Quick vid of the first ride. Front wheel surprised me a little bit there :D . This thing is a blast. I parked it after a ride and found a pretty good oil leak near the clutch pushrod. I'll lean it over on the side and pull the cover off tomorrow and see what's going on.

I think I need to add a hanger for the header near the footpeg, seems to be vibrating a bit too much for my liking.

https://youtu.be/jx7VXSkpuQA


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Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Oct 23, 2016, 08:15:06
that is awesome
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Oct 23, 2016, 10:08:39
Quick vid of the first ride. Front wheel surprised me a little bit there :D . This thing is a blast. I parked it after a ride and found a pretty good oil leak near the clutch pushrod. I'll lean it over on the side and pull the cover off tomorrow and see what's going on.

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Awesome.  Pretty sure these things are exactly like the 250, which means there's a big seal for the push rod that requires you to split the case to replace.  PAIN. IN. THE. ASS.  I luckily still have the rubber plug for mine, along with the plug for the cam chain adjuster, so I'll be able to get by.  Those plugs can be hard to find.
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 23, 2016, 13:12:28
that is awesome

Awesome.  Pretty sure these things are exactly like the 250, which means there's a big seal for the push rod that requires you to split the case to replace.  PAIN. IN. THE. ASS.  I luckily still have the rubber plug for mine, along with the plug for the cam chain adjuster, so I'll be able to get by.  Those plugs can be hard to find.

Thanks fellas. And yup, they are the same. I replaced the pushrod seal and all the other oil seals when I had the engine torn down so there's no way that should be leaking. There may have been a weak spot in the mating surface between the left hand case and the main crankcases, but iirc the LH cover I ended up with had a good mating surface.

I have the cam chain tensioner plug in good shape, but the clutch adjuster cover is shot. I'm going to make a few using an old LH case and that poly I used for the shock bushings.




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Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Oct 23, 2016, 20:31:16
i may have aclutch adjuster cover if you are stuck

also have a look and make sure its not the magnesium case rot thru from teh inside near one of the screw holes
Title: Re: 74 Honda XL 350 - The Turd
Post by: el barto on Oct 24, 2016, 12:51:31
Quick vid of the first ride. Front wheel surprised me a little bit there :D . This thing is a blast. I parked it after a ride and found a pretty good oil leak near the clutch pushrod. I'll lean it over on the side and pull the cover off tomorrow and see what's going on.

I think I need to add a hanger for the header near the footpeg, seems to be vibrating a bit too much for my liking.

https://youtu.be/jx7VXSkpuQA


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Yeehaw
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 25, 2016, 16:06:07
Hard starting today. Pulled the plug and it was for sure carbon fouled. Cleaned it off and got her fired up, but decided to drop the needle one slot since the plug was showing rich. After that she fired right up 2-3 kicks.

Trying to troubleshoot the situation, it idles nice and smooth but runs like shit at 1/4 throttle. Seems to be missing a lot at low RPMs but once I get to around 1/2 throttle it pulls pretty well. Going to try and borrow a timing light tomorrow and get that dialed in to rule it out.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 25, 2016, 17:39:43
Laid the bike on its side and pulled the stator cover off. The oil seal is dry as a bone. The culprit seems to be the rubber grommet that seals the stator wires where they pass by the clutch actuator. It seems to be a common problem spot. It looks like a depression had been made from being compressed for so many years, accompanied by a bit of shrinkage. Cleaned everything up and hit it with some Hondabond, should be good to go.

(http://uploads.tapatalk-cdn.com/20161025/e55bc4c7d2ac644b633aba21cc3d7adf.jpg)

(http://uploads.tapatalk-cdn.com/20161025/00e5206bda4504d81dfc92055e04c744.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: xb33bsa on Oct 25, 2016, 19:23:23
Laid the bike on its side and pulled the stator cover off. The oil seal is dry as a bone. The culprit seems to be the rubber grommet that seals the stator wires where they pass by the clutch actuator. It seems to be a common problem spot. It looks like a depression had been made from being compressed for so many years, accompanied by a bit of shrinkage. Cleaned everything up and hit it with some Hondabond, should be good to go.

(http://uploads.tapatalk-cdn.com/20161025/e55bc4c7d2ac644b633aba21cc3d7adf.jpg)

(http://uploads.tapatalk-cdn.com/20161025/00e5206bda4504d81dfc92055e04c744.jpg)


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bitchen totally dude you could build a motoe track in the nayboors yard eh ?
is that case a familiar piece ? great that you got bike running and its not knocking or clanking always a big relief in my book
the runninng issues do you have an foam element wrapped on the wire cage ?
new honda or at least japan made points and condenser ?
the advancer working smoothly ?
and yes timing light must be used to set it correctly while running
a spare stator cover with a window is titty la ritty for this
definately need a hanger, like just aft of footpeg
a can support strap should only be relied to steady the weight of the can you need something to stop the sideways vibration
Title: Re: 74 Honda XL 350 - The Turd
Post by: xb33bsa on Oct 25, 2016, 19:32:20
new sparkplug cap or at least remove the resistor in the stock unit ,i have seen them fully corroded inside, looking new outside
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 25, 2016, 19:56:38
bitchen totally dude you could build a motoe track in the nayboors yard eh ?
is that case a familiar piece ? great that you got bike running and its not knocking or clanking always a big relief in my book
the runninng issues do you have an foam element wrapped on the wire cage ?
new honda or at least japan made points and condenser ?
the advancer working smoothly ?
and yes timing light must be used to set it correctly while running
a spare stator cover with a window is titty la ritty for this
definately need a hanger, like just aft of footpeg
a can support strap should only be relied to steady the weight of the can you need something to stop the sideways vibration

Yup thats the case. No foam element just yet and the cover still off the airbox, haven't gotten around to sticking it back on. New Japan made points and condenser, advancer was disassembled and greased up good. New NGK plug cap on there as well.

I'll weld on a hanger once I get this other stuff straightened out before any real riding.
Title: Re: 74 Honda XL 350 - The Turd
Post by: xb33bsa on Oct 26, 2016, 05:27:30
the sputtering is a lean condition not rich ,lean misfire creates a sooty plug
needle clip does not effect starting
try wrapping duct tape around that screen to see what happens if the air is slightly restricted
leave it about half covered the open parts at the rear
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Oct 26, 2016, 22:28:08
Taped up the air filter cage. Should help for now, got some filter foam coming early next week. Fires up pretty easy now, after I spent about an hour kicking it over with the stator unplugged wondering what was wrong, LOL. Good news is that rubber grommet isn't leaking anymore.

Put a timing light on it, got it dialed in to fire right on F at idle, but at 4k nowhere close to the advance marks. I don't trust the timing light I was using so I'm going to check it with another light before I take the advancer apart.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Nov 01, 2016, 23:47:01
(http://uploads.tapatalk-cdn.com/20161102/01e736112d868c07f652c4c5a18ff4c0.jpg)

(http://uploads.tapatalk-cdn.com/20161102/e21a8d49009f9b57e4cc4fed59bbdeef.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: B541Niner on Nov 02, 2016, 07:24:50
Saweet!
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Nov 02, 2016, 08:22:53
nice.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Nov 02, 2016, 08:54:29
Nice work mang!
Title: Re: 74 Honda XL 350 - The Turd
Post by: el barto on Nov 02, 2016, 10:48:41
Clean!
Title: Re: 74 Honda XL 350 - The Turd
Post by: xb33bsa on Nov 03, 2016, 02:59:08
that is nice work,i  like the bold lettering
you will need to look at the advancer something is keeping it from full.
nothing with the timing light  it is literally impossible for it to give you a wrong reading, if it works, if it is flashing, its good,thats all
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Nov 03, 2016, 14:15:40
Thanks fellas.

@xb - My issue was with the light itself. It was not flashing on each fire of the plug and was making it difficult to read.

When setting timing with a light, it is my understanding that at base timing the advance on the light should be set to 0 degrees. Then, when checking timing @ full advance, the advance on the light must be set to the correct advance angle put forth by the manual (which in this case is 8.5 degrees)
Title: Re: 74 Honda XL 350 - The Turd
Post by: xb33bsa on Nov 03, 2016, 15:16:16
Thanks fellas.

@xb - My issue was with the light itself. It was not flashing on each fire of the plug and was making it difficult to read.

When setting timing with a light, it is my understanding that at base timing the advance on the light should be set to 0 degrees. Then, when checking timing @ full advance, the advance on the light must be set to the correct advance angle put forth by the manual (which in this case is 8.5 degrees)
no no double g dam no  :-\ >:( ;D
 its been a while but that is not how to use that function  just use it and leave it on zero like it was a timing light with no extra functions
pretty sure you tricked yourself into playing chicken with yourself and lost
tough to do but i do it often
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Nov 07, 2016, 21:13:39
Got it. I will put the light back on and do it the right way later this week. After getting the FA50 running and finishing up crank seals on the RD it's time to get back to business on this thing.

I made a couple of paper templates and cut/glued some UNI foam to make a filter element. I used hot glue to hold everything together, and cut the pieces a bit small so it would be a snug fit.

(http://uploads.tapatalk-cdn.com/20161108/ec702e49f4148f0bad11e847f0ecf0d7.jpg)

(http://uploads.tapatalk-cdn.com/20161108/e7633fac1edc20fb96d3526e3d3a839b.jpg)

Slapped a coat of silver on the headlight bucket. Patching some holes on the ring and mending up some rotted spots on the headlight and ring. I'm using the stuff that came with the bike for now and will probably end up grabbing a new bulb down the road. 


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Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Nov 08, 2016, 07:06:54
i bought a few of these they have the 6 volt bulb and fit well

http://www.ebay.com/itm/NEW-CHROME-SIDE-MOUNT-5-3-4-6V-HEADLIGHT-ASSEMBLY-HARLEY-DAVIDSON-CUSTOMS-/401114275220?hash=item5d64461d94:g:dXYAAOSwZAtXJgf-&vxp=mtr
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Dec 08, 2016, 00:46:29
I cleaned up the stock bucket and I'm going to use it for now until I'm ready to upgrade. Can someone explain the purpose of the 10w 3.61 ohm resistor in the wiring diagram?

(http://uploads.tapatalk-cdn.com/20161208/e7541ed24cffca23e501426b42572521.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: spurlock on Dec 08, 2016, 01:05:21
I cleaned up the stock bucket and I'm going to use it for now until I'm ready to upgrade. Can someone explain the purpose of the 10w 3.61 ohm resistor in the wiring diagram?

(http://uploads.tapatalk-cdn.com/20161208/e7541ed24cffca23e501426b42572521.jpg)

The resistor is to compensate for the difference between high and low beam headlight power. The lighting coil puts out 35 watts which matches the 35W high beam draw. The low beam filament is only 25W so the resistor in the low beam circuit burns off the excess 10 watts. Without the resistor the low beam filament gets incinerated quickly.The stock resistors are scarce and hard to come by. Not sure where to find a generic that will handle the power and heat.

-Bill
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Dec 08, 2016, 01:07:14
The resistor is to compensate for the difference between high and low beam headlight power. The lighting coil puts out 35 watts which matches the 35W high beam draw. The low beam filament is only 25W so the resistor in the low beam circuit burns off the excess 10 watts. Without the resistor the low beam filament gets incinerated quickly.The stock resistors are scarce and hard to come by. Not sure where to find a generic that will handle the power and heat.

-Bill


Thanks for the info Bill. I figured it was something of the sort. I believe I still have the stock resistor, I wonder if there is any way to ensure it is working properly.

Do you recall where and how the resistor is mounted? It was so long ago that I disassembles the headlight bucket. I noticed from the parts fiche there is a metal bracket used to mount the resistor as well.

Title: 74 Honda XL 350 - The Turd
Post by: advCo on Dec 21, 2016, 13:47:27
Been a while since I've made any real progress but here's a small update. I cleaned up the gauges, replaced a couple bulbs and reinstalled them. Put on a set of KTM brush guards I grabbed at Barber for a few bucks and some repop stock mirrors.

(http://uploads.tapatalk-cdn.com/20161221/be38f7d3e5b2c288ec0a9c1d1e7647dc.jpg)

(http://uploads.tapatalk-cdn.com/20161221/475b34df0e938b79393ba63b484570d5.jpg)

(http://uploads.tapatalk-cdn.com/20161221/1e2b7d56cbf1b28bcdcf8504ee972ba3.jpg)

Started to bend up the luggage rack. I like the initial shape. I'll bend up a cleaner version, add some cross members and weld some stays on it so it's removable as well.

(http://uploads.tapatalk-cdn.com/20161221/567f28993868c635fe83acf6567d7e47.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Dec 21, 2016, 19:57:48
Bent up another luggage rack and got it fitted up. Next is to fit supports for the panniers.

(http://uploads.tapatalk-cdn.com/20161221/856830f6a776282272d71e4f0aa4fdfc.jpg)

(http://uploads.tapatalk-cdn.com/20161221/528e0aaa0dafb5903523ad7b95f61b36.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: HerrDeacon on Dec 22, 2016, 05:10:00
Wow, that looks great, looks factory. I'd like to eventually make one for my XL, what size tubing did you use?
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Dec 22, 2016, 08:36:04
Nice Job Nick, that looks store bought LOL, maybe better!
Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Dec 22, 2016, 09:15:42
when will mine arrive ???

Title: Re: 74 Honda XL 350 - The Turd
Post by: Kamn on Dec 22, 2016, 09:33:04
Nick, that luggage rack is looking great
Title: Re: 74 Honda XL 350 - The Turd
Post by: JustinLonghorn on Dec 22, 2016, 10:04:37
I am a fan.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Dec 22, 2016, 10:10:54
Thanks gents. I'm pretty happy with how its coming so far.

Wow, that looks great, looks factory. I'd like to eventually make one for my XL, what size tubing did you use?

I used 1/2" galvanized conduit and a home depot conduit bender (which will be going back to the store after this is finished  ;D), the rack will have cost a total of about $6 in materials.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Dec 22, 2016, 10:12:44
Man, I hope you wear a respirator when you weld that shit up.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Dec 22, 2016, 10:14:03
Man, I hope you wear a respirator when you weld that shit up.

Yeah i'm going to flap wheel the coating off with a respirator on before I weld it up.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Dec 22, 2016, 10:18:23
Yeah i'm going to flap wheel the coating off with a respirator on before I weld it up.
You still need to weld it with a respirator on.  You're not likely to get it all off.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Dec 22, 2016, 10:25:49
You still need to weld it with a respirator on.  You're not likely to get it all off.

Roger that.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Dec 22, 2016, 10:59:57
Roger that.
I'm over cautious with that stuff.  It's because I love ya.   :-*
Title: Re: 74 Honda XL 350 - The Turd
Post by: Kamn on Dec 22, 2016, 11:05:49
Get a room then ;)
Title: Re: 74 Honda XL 350 - The Turd
Post by: xb33bsa on Dec 25, 2016, 00:42:42
that rack looks bitchen
you can get extreme good quality easy bending cr steel non plated tubing at your hydraulics supply
its for hard line take a look at any backhoe,steel tubing everywhere 1/4"-1" sizes ,common stuff
fuk that galvi ,tha' nasty shit
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Dec 25, 2016, 10:00:25
Got Milk  ::)
Title: Re: 74 Honda XL 350 - The Turd
Post by: canyoncarver on Dec 26, 2016, 14:26:38
You have a nice rack sweetie.
Title: Re: 74 Honda XL 350 - The Turd
Post by: datadavid on Dec 27, 2016, 10:55:47
I'm over cautious with that stuff.  It's because I love ya.   :-*
Zink poisoning is not that bad, a bit of fever and shakes, milk helps against the nausea😀
Title: Re: 74 Honda XL 350 - The Turd
Post by: xb33bsa on Dec 27, 2016, 11:24:14
Zink poisoning is not that bad, a bit of fever and shakes, milk helps against the nausea😀
you loco go mow a lawn
Title: Re: 74 Honda XL 350 - The Turd
Post by: datadavid on Dec 28, 2016, 03:25:26
you loco go mow a lawn
I mexicant do that all lawns are frozen up here in ultima thule. Going back to the 316 ss and the 12" #20 crap. 😕😕
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Dec 28, 2016, 09:19:13
you know when yer gettin a high dose of zink pollution, it tastes horrid.

Mowing frozen turf could both sharpen the blade and clean the mower deck.... no?
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Dec 28, 2016, 23:01:33
Anyways...

Got the rack and pannier supports welded up. Pretty easy to avoid weld smoke to begin with and with a fan and respirator no harm done. The welds look like shit but this thing is stout.  After this weekend I'll clean it up and hit it with a coat of paint.

I'm debating whether to weld flanges w/threads onto the ammo boxes to mount them or bolt through. My only concern is keeping moisture out if I go with a bolt through. Plan for is to flush mount the stock flashers from the 360 onto the rear of the boxes. I may try and rig up a small indicator for the side of the boxes as well for more visibility. Thoughts?

(http://uploads.tapatalk-cdn.com/20161229/5419449d27492a4cbf1fbb85a7f890d6.jpg)

(http://uploads.tapatalk-cdn.com/20161229/92d9cb07c2e3bda8c5509745e66faef3.jpg)

Welded a 1/8" plate over the giant hole where the indicators used to go. I'll drill through and use a beefy nut and bolt to support the weight.

(http://uploads.tapatalk-cdn.com/20161229/85d67d9341ed501ebb543d7e3c2dd785.jpg)

3D printed some spacers to take up the non-threaded area on the flasher studs.

(http://uploads.tapatalk-cdn.com/20161229/87eda881d603068091a94a35e1973a4d.jpg)

(http://uploads.tapatalk-cdn.com/20161229/561c41baf84f60ac537f37aa7794d522.jpg)

These knurled inserts on the hand guards are a bit too small for the inside of the 7/8 bars. I need a quick fix to get them to snug up. Maybe some JB weld to get a bit more girth?

(http://uploads.tapatalk-cdn.com/20161229/8735669e97abca34e9e8189fec5fc4a7.jpg)




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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jan 15, 2017, 19:41:43
Finally got a chance to get in the shop this weekend. Got the wiring mostly hooked up, signals and headlight installed. New throttle cable set up.

(https://uploads.tapatalk-cdn.com/20170115/2b5e7349e88a4d3537fb9bbfa3f92b8d.jpg)

Welded a little piece on the kickstand so I can get my boot on it when the muffler is installed.

(https://uploads.tapatalk-cdn.com/20170115/b6a8d88e9a236e308d7e096f8a46367b.jpg)

And an exhaust hanger that uses the footpeg mounting bolt. Pipe is solid now. I need to find somewhere to order a larger copper gasket for the exhaust, the one I have moves all over the place when reinstalling the pipes and judging from the exhaust marks on the head, isn't sealing 100%

(https://uploads.tapatalk-cdn.com/20170115/a1a592741891a22c2fa01abc451ee2e3.jpg)

Someday I'll clean up the booger welds and paint the header.
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Jan 15, 2017, 19:48:21
She just gets better and better.  Good work bro.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jan 15, 2017, 20:45:41
Thanks Eric.

I was able to reuse the old spring and rear stop switch from the 360 to replace the junk one. I wedged a flathead between the spring coils and then pulled it to stretch it about 1.5" to fit.

(https://uploads.tapatalk-cdn.com/20170116/e0921e9f2cfef7dbc17babdccb5e905a.jpg)

Replaced the front switch with a new Honda switch and the brake lights are up and running.
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Jan 18, 2017, 00:21:05
Wow, you've come a long way with this bike! The rack looks good. Are the panniers going to be 40mm cans? I'm eager to see how you mount them.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jan 18, 2017, 03:10:16
Wow, you've come a long way with this bike! The rack looks good. Are the panniers going to be 40mm cans? I'm eager to see how you mount them.

Thanks! Yep, I bought a set of 40mm cans that I'm going to use for now. I've been researching a few different ways to mount them, and I think I have a good strategy in mind that will allow me to quickly disconnect them from the inside. I want to add locks to each side, so they will effectively be locked closed and mounted all with one lock.

My one concern is being waterproof, however. I can always use a dry bag if I need to. Should be able to get to that over the weekend.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Feb 14, 2017, 15:58:41
Thanks to irk for reproducing these unobtainium clutch adjuster plugs. Fits like a glove.

(https://uploads.tapatalk-cdn.com/20170214/0a66817f6686f7e1e7f1e9a4a0da8d66.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Feb 14, 2017, 17:17:28
Yisss
Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Feb 14, 2017, 17:44:05
ok since it has the arrow where to "set" it?
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Feb 14, 2017, 17:53:27
Pretty sure the arrow points up.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Feb 14, 2017, 18:03:16
Installed the NOS choke cable and bracket assembly I picked up from xb a while ago for $18.

(https://uploads.tapatalk-cdn.com/20170214/e09b984fb42cdc264c540fee71ed7223.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Feb 14, 2017, 21:26:19
The arrow points to the highest point on the cap, so it points forward.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Feb 15, 2017, 19:05:21
Been sitting on these ammo cans for way too long, so I decided to tackle the mounting today. First I bent up a piece of steel for the bottom, so I can slide them into place. I spaced it out 1/4" to allow for more clearance up top. Just tacked up for now.

(https://uploads.tapatalk-cdn.com/20170215/542b0fe16c71acb362af9637387bceff.jpg)

I wanted to do quick release fasteners up top, but I had a bunch of these 3/8" threaded inserts from another job, so I decided to go with them to get it done.

(https://uploads.tapatalk-cdn.com/20170215/a69a73d6bbbcd31bed4d37ea4d4faeb2.jpg)

(https://uploads.tapatalk-cdn.com/20170215/ac7502613f00063c0b927789975efdc7.jpg)

(https://uploads.tapatalk-cdn.com/20170215/baa608cd8af0a056955afaadbb4232da.jpg)

(https://uploads.tapatalk-cdn.com/20170215/a7ab10debd275df20ed1706f3904fa6c.jpg)

Pretty happy with the outcome, and once I add locks to the ammo boxes I will be able to lock them on and the bolts will only be accessible from the inside. I'll do the other side and then weld everything up for real.

Next step is to mount directionals. I am thinking of using the matching signals and mounting them on the back, or just getting some small flush mount LED ones.
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Feb 15, 2017, 20:40:07
That looks awesome! I used carriage bolts to secure my cans to the rack on my CL, keeping the nuts inside the cans for security just like you did. Don't want anyone to walk off with my hoagie while I'm in the arcade chipping away at the high score on Donkey Kong. It'd be cool to have a quick-release setup but I think you were smart to skip premature optimization in favor of just getting it done. You're already halfway there if you decide you need more flexibility later.

This guy's locking hardware worked great for me, in case you don't plan to DIY: https://www.amazon.com/gp/product/B018EYU5HQ
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Feb 15, 2017, 20:48:47

This guy's locking hardware worked great for me, in case you don't plan to DIY: https://www.amazon.com/gp/product/B018EYU5HQ

Those are pretty handy. Do you use a padlock type lock for your panniers? I'm worried that something like that will rattle around while I'm riding and drive me crazy...
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Feb 15, 2017, 20:58:49
Yes. I got a slightly-longer style padlock and cut strips of MTB tube to slide over the bodies to quiet rattling when I ride around with them attached, but usually I leave them off when I'm in motion. I picked them up at the hardware store so I don't have a link I can share, but I'm pretty sure they're Masterlocks. If you want I'll look for a product number tomorrow. They work very well.

(http://i.imgur.com/xkG8BuZ.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Feb 15, 2017, 21:06:12
I also sandwiched PVC blocks between my cans and their mounting points to dampen vibration and protect the vintage chrome on the rack. I have no idea if it makes things better or worse but it seemed like a cool idea at the time. My cans don't buzz or rattle so I'm keeping them.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Feb 15, 2017, 21:06:39
Yes. I got a slightly-longer style padlock and cut strips of MTB tube to slide over the bodies to quiet rattling when I ride around with them attached, but usually I leave them off when I'm in motion. I picked them up at the hardware store so I don't have a link I can share, but I'm pretty sure they're Masterlocks. If you want I'll look for a product number tomorrow. They work very well.

Ahh that's a great idea. I may even glue a piece of neoprene under the lock.

Are your lids completely removable? I am going to weld the front latch in place so it acts more like a hinge, and maybe put some small pistons in to keep them up while their open.
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Feb 15, 2017, 21:19:17
Are your lids completely removable?

Yes. At first I thought this would be a cool feature- in theory I could carry objects in the panniers that were much larger than the panniers themselves (much like when shopping for large furniture or lumber with a two-seater convertible). But the first time I tried it my cargo ejected pretty much immediately. I knew I shouldn't have sold that convertible.

I am going to weld the front latch in place so it acts more like a hinge, and maybe put some small pistons in to keep them up while their open.

Gas struts would be wicked! My lids flip open 180-degrees and stop, so when open they serve as a nice tool/parts table, tea and cookie tray, etc. Pretty convenient. The less convenient bit is that they often detach on their own if you're not careful. I've been meaning to insert a little bolt through the can to the side of the hinge to prevent this. It'll be easy and will completely solve the problem, I just haven't gotten around to it.

Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Feb 15, 2017, 21:21:27
Are your signals going on the taillight bracket or on the panniers?
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Feb 15, 2017, 21:38:18
If you go with that lock setup and they rattle you could maybe also open up the holes a bit and heat shrink the tops of the lock hoops where they make contact. I ultimately decided it's unnecessary despite the awesome speed and vibration of the 100cc host machine.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Feb 16, 2017, 02:48:17
Are your signals going on the taillight bracket or on the panniers?

I'm still working this out. Now that I have one pannier mounted, I can mock up how I want to run the signals. I'm thinking I will probably mount the 360 signals to the rear of the panniers or the taillight bracket, and use a small flush mounted signal on the side of each pannier. Now that I'm typing it out, attaching the signals to the frame or taillight bracket might be a better idea in case I want to remove the panniers and luggage rack at any point down the road...

How are yours mounted, got any pics?
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Feb 16, 2017, 08:45:54
Lookin good mang!

Isit legal now?
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Feb 16, 2017, 10:30:24
If I were you I'd mount the signals on the taillight bracket. I haven't noticed any ill effects from doing so, and in my case I like that it looks factory. The CL arrangement is slightly complicated by the stays on the Triple-A rack, which tie into the taillight bracket, and the CL signal stems, which have an offset locating bolt. For our XL's it'll be a little simpler.

(http://i.imgur.com/13N4TX9.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Feb 16, 2017, 15:16:21
I had to shorten the old signals from the 360 to fit between the taillight and the panniers. Chopped a couple inches off and rewelded them together. I removed the original rubber mount bracket and will use the locator pin and one bolt to hold them on. Had to remove some material from the rear facing edge of the mount to account for the curved surface of the taillight bracket.

Original on left, modified on right.

(https://uploads.tapatalk-cdn.com/20170216/aebb8889ac02e26b5ccaae28e03d586f.jpg)

Here it is mounted up. Going to do the second one and put a coat of black epoxy on them since the chrome is junk.

(https://uploads.tapatalk-cdn.com/20170216/4d8874dbfdaa18bfb1dc42a99ffa8415.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Feb 16, 2017, 15:29:05
nice job, looks great Nick.
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Feb 16, 2017, 15:35:20
Right on.
Title: Re: 74 Honda XL 350 - The Turd
Post by: canyoncarver on Feb 21, 2017, 12:43:47
Looks great man, I like those signals tucked in tight too.  Those cans will hold a ton of stuff. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Feb 22, 2017, 12:53:28
Thanks guys. Here they are painted up and mounted. Pretty happy with the fitment. Just need to find some 6v single filament bulbs.

(https://uploads.tapatalk-cdn.com/20170222/c110fccdc33040e155056cbbe97c110a.jpg)

(https://uploads.tapatalk-cdn.com/20170222/8f6516dc7a2dd29596bfd78b39c12d66.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Feb 22, 2017, 13:07:02
I think Matt(Sonrier) has a doohicky that can take your 6V and convert to 12V for LEDS etc.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Feb 22, 2017, 13:07:44
also scooter supply places have more 6V bulb choices than motorcycle ones.
Title: 74 Honda XL 350 - The Turd
Post by: sealedwithakay on Feb 22, 2017, 13:10:05
that [moto]ass tho


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Feb 22, 2017, 13:11:39
Nick. 35 bucks from Spark moto and you can run all your signals and stop tail as 12V. way easier to find bulbs that way.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Feb 22, 2017, 13:17:37
Thanks. Pops has a bunch of 6v single and double filament bulbs from the Beetle 12v conversion so he's gonna send those my way. I'll probably convert to a full 12v system down the road.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: HerrDeacon on Feb 22, 2017, 13:21:33
Nick. 35 bucks from Spark moto and you can run all your signals and stop tail as 12V. way easier to find bulbs that way.

Thanks for mentioning this, I never knew something like this existed and it will be perfect for my XL. Thanks!
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Feb 23, 2017, 11:02:52
Lookin all Hipster N shit  :o
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Mar 20, 2017, 12:10:43
Not much to update..finishing up some woodworking projects before I move this back into the shop and finish mounting the panniers.

Been messing with electrical a wee bit. Most everything is working except for the neutral light, turn signal dummy light (works with right side signals and not the left) and horn.

Thinking I may just do a 12v conversion now and call it a day.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: firebane on Mar 20, 2017, 15:42:46
Not to dismiss Sonreir and his products but you could also look at a Reg/Rec unit from a Honda Cub 90 with part # SH570-12 which will do 6v to 12v as well.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Mar 20, 2017, 17:14:10
Not to dismiss Sonreir and his products but you could also look at a Reg/Rec unit from a Honda Cub 90 with part # SH570-12 which will do 6v to 12v as well.


Thanks. I will look into that.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Mar 20, 2017, 17:15:57
Here's a pic of the coffee table I've been working on while I've been paying no attention to the XL. Dry fitting the tabletop and panels. Today trimming top to size and adding 1/4" strip border around the edges.

(https://uploads.tapatalk-cdn.com/20170320/8200cfca245dd9bace56b7e888afbfc7.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: Rider52 on Mar 22, 2017, 15:11:05
Great job on the coffee table!
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Mar 22, 2017, 15:25:50
Thanks! Here is a better pic from today after I added the edging.

(https://uploads.tapatalk-cdn.com/20170322/8b08273876aa3222b233814f1ad13e06.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Mar 22, 2017, 16:17:17
Pretty. Is there a bottom shelf, too? It's hard to tell from the pictures.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Mar 22, 2017, 17:21:01
Pretty. Is there a bottom shelf, too? It's hard to tell from the pictures.

There is. Its suspended underneath. Its tough to get a decent angle on it, the shop is pretty cramped, but i'll have some good photos of it once its all buttoned up.
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Mar 23, 2017, 06:05:06
that is gorgeous bud.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Mar 29, 2017, 19:19:16
that is gorgeous bud.


Thanks man, I'm gonna be assembling the finished piece tomorrow, I'll be sure to post some pics.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Mar 29, 2017, 19:24:35
Small update but I'm trying to gain some steam and get this thing buttoned up within the next few weeks. I have a couple new projects brewing, so it's time to wrap this build up and put 'er on the road.

All the original cable stay brackets were ruined by rust, so I pulled out the tin snips and worked some sheet metal.

(https://uploads.tapatalk-cdn.com/20170329/bb3ac765ea46b91d7f25234406cc4eaa.jpg)
(https://uploads.tapatalk-cdn.com/20170329/dc94ba048b05d59d30f272ab91cf4cd8.jpg)

Here they are installed.

(https://uploads.tapatalk-cdn.com/20170329/771917d117a459038f033b7ac9046832.jpg)
(https://uploads.tapatalk-cdn.com/20170329/d38c49a15fc697277f0c53860cba94bb.jpg)
(https://uploads.tapatalk-cdn.com/20170329/435ce4ce14ce54451848886b9d802520.jpg)

And one for the speedo cable since that was junk as well

(https://uploads.tapatalk-cdn.com/20170329/52e7bd96428193ffd4510f824962dfd3.jpg)

Title: Re: 74 Honda XL 350 - The Turd
Post by: firebane on Mar 29, 2017, 19:38:52
Such a small detail but looks so good and done well.
Title: Re: 74 Honda XL 350 - The Turd
Post by: HerrDeacon on Mar 29, 2017, 20:18:53
Nicely done, they look great.
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 02, 2017, 13:43:28
Yesterday's project was to mount up the KTM barkbusters I snagged at the Barber swap meet for a few bucks. They were made for 1" thick walled bars and the bars i have are 7/8".  So I modeled and 3D printed some spacers for the bar clamps to take up the space there, and welded 8mm nuts inside the bars since the aluminum expanding inserts were too small to get a tight fit.

(https://uploads.tapatalk-cdn.com/20170402/9b71aa84764426a259c1d988ebb00769.jpg)

(https://uploads.tapatalk-cdn.com/20170402/614ae5d682db03802eca1435694049de.jpg)

(https://uploads.tapatalk-cdn.com/20170402/d98dd69d690be5ff53f193651d81bc73.jpg)

Stuck an 8mm bolt in the drill and locked the cut-off aluminum spacers in there. Spun them down with a file and some paper to get rid of the nasty gouge marks. It's a redneck lathe but worked a treat.

(https://uploads.tapatalk-cdn.com/20170402/5e2356a3fd970fc8e97d4d7b7efc6bf4.jpg)

And here we are all installed.

(https://uploads.tapatalk-cdn.com/20170402/641ccf3776c3ee3dc4ea2682aea1f47e.jpg)

Fun little project. Would have been way less time consuming to order a pair that bolted right up but what's the fun in that.

The beveled spacers that go into the ends are all busted up. I'm going to model them and have them 3D  printed in aluminum, since I don't have a lathe. Works the same, but the turnaround time is a few weeks so that's the only downside.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Apr 02, 2017, 14:37:51
Cast them yourself in aluminum.  It's not that hard, since it melts at such a low temp. You can melt it with a torch, or even charcoal.  Cast your model, reproduce in wax, cast the wax, melt wax out, pour aluminum.  Easy peasy.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 02, 2017, 14:39:36
Cast them yourself in aluminum.  It's not that hard, since it melts at such a low temp. You can melt it with a torch, or even charcoal.

I need to get some casting sand, I have a solder pot that might melt aluminum..have to check the specs.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Apr 02, 2017, 14:40:13
I need to get some casting sand, I have a solder pot that might melt aluminum..have to check the specs.
You can melt aluminum in a steel can.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Apr 02, 2017, 14:41:07
You don't need casting sand, which is basically bentonite and silica sand.  You can do it in silica/plaster molds.
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Apr 02, 2017, 17:21:49
It's a redneck lathe but worked a treat.

(https://uploads.tapatalk-cdn.com/20170402/5e2356a3fd970fc8e97d4d7b7efc6bf4.jpg)

Youre a man after my own heart.  Thats the same sort of shit I have to pull all the time cause I dont own any "real" tools.

Also, if you play w molten aluminum, babbitt, lead, etc.  Be absolutely cautious WATER (rain drop, sweat, etc) CAN NOT accidentally enter the mix. Molten aluminum and water is VERY VERY EXPLOSIVE.  Splatters of molten aluminum on your hands, face or eyes.

Well, that would just hurt like a mother fucker.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 04, 2017, 14:01:19
Didn't like the little nub I welded onto the kickstand a while back, so I hacked it off and made a new one out of steel rod. Looks much better now, and will be real easy to reach the kickstand once the muffler is installed

(https://uploads.tapatalk-cdn.com/20170404/29f11ae215abbd052da56cab9eb104f6.jpg)
(https://uploads.tapatalk-cdn.com/20170404/189dde98f460515356c463f16b4a327c.jpg)

Had to trim back the skid plate to fit by the header.
(https://uploads.tapatalk-cdn.com/20170404/27a988e82ed82016e76f42a8a7f631a5.jpg)
(https://uploads.tapatalk-cdn.com/20170404/851b12d246e047c9e7a5e1e28dc38304.jpg)

Drilled some speed holes in the stainless RR bracket for ventilation, and got the new Sparck Moto 12v RR installed. Just have to get it wired up. 12v bulbs are on the way and the battery will be installed today.

(https://uploads.tapatalk-cdn.com/20170404/d411d322ad02d914ca509916882cbea9.jpg)

Panniers are mounted, luggage rack is being painted. Have to sort a few details out on the panniers like a hinge and locks.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Apr 04, 2017, 14:04:59
Looks good Nick, getting close to done now!
Title: Re: 74 Honda XL 350 - The Turd
Post by: JustinLonghorn on Apr 04, 2017, 14:16:07
You've got some riding to do.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 04, 2017, 20:57:36
It's getting there fellas. Starting to feel good.

Today's issue to sort was the panniers. I disliked having to unlatch the front and back to open the boxes, so I hacked the latch off the front end to make space for a hinge. I used a piece of 3/16" rod filed to a point as a drift to open up the end so I could slide some 1/4" rod in and weld it to the box.

Left is welded up with a hinge, right side is untouched.

(https://uploads.tapatalk-cdn.com/20170404/e041dd904b08fe5e11df7c982dd28ffd.jpg)

Inside the box, still needs to be cleaned up
(https://uploads.tapatalk-cdn.com/20170404/35c25677908ff33c80b97ce5a752cd80.jpg)

I was going to buy some aluminum or stainless drawer pulls to use as tie down points on the panniers, but after I cut the old handles off I realized they were perfect for what I need. Trimmed them down and welded them on.

(https://uploads.tapatalk-cdn.com/20170404/d1e718e69eb28dd89bc403d4e2171267.jpg)

Quick vid of the hinge action. Works well enough for me.

https://youtu.be/zZS4sRfSCm4

These are getting close to paint!



Title: Re: 74 Honda XL 350 - The Turd
Post by: redwillissuperman on Apr 04, 2017, 21:40:36
Actually, if it's PLA, you can pack it and then melt it out. Check out YouTube for PLA casting.
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Apr 04, 2017, 22:13:30
Cool. The double latch would have driven me nuts, too. Nice work on the hinge!

If you didn't already mount the panniers, here are my unsolicited tips: first, try to angle them slightly so stuff tends to slide forward- that way it's easy to keep heavy stuff toward the front. Also, if you're adding a rack/platform in-between them, keep the boxes a half inch or so higher. That way, anything you strap down has that lip on each side to help keep it in place.

Finally, I don't know if you care or if you already plan to do this, but I've found you can grind off those spot welds pretty easily if you're patient. In other words, you could also delete the now-redundant latch plates from the fronts of the panniers (under your new hinges).

The recycled anchor points were a good call, too! I'm looking forward to seeing everything painted.
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 04, 2017, 22:41:39
Cool. The double latch would have driven me nuts, too. Nice work on the hinge!

If you didn't already mount the panniers, here are my unsolicited tips: first, try to angle them slightly so stuff tends to slide forward- that way it's easy to keep heavy stuff toward the front. Also, if you're adding a rack/platform in-between them, keep the boxes a half inch or so higher. That way, anything you strap down has that lip on each side to help keep it in place.

I actually did mount them angled forward a bit so they would line up with the luggage rack. Good to hear that I accidentally did that part right. I've never had a bike with bags or panniers before, so I'm guessing on a lot of this stuff.

 I ended up making the top of the boxes flush with the rack, since I am going to add passenger pegs so I can ride 2-up. If they were any higher, the corners of the panniers were diggin into my girlfriends legs, so I tried to tuck them out of the way a bit.

Finally, I don't know if you care or if you already plan to do this, but I've found you can grind off those spot welds pretty easily if you're patient. In other words, you could also delete the now-redundant latch plates from the fronts of the panniers (under your new hinges).

I actually thought about that, I had luck with a pry bar pulling up the spot welds on the side. I'm going to leave the latch plates, I kinda like the look of it, breaks up the plane.
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Apr 04, 2017, 22:50:19
Design criterion number one: comfortable girlfriend! All other design criteria can be disregarded.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 06, 2017, 13:54:54
More fun with the hot glue gun...

(https://uploads.tapatalk-cdn.com/20170406/42bbded4bca803bb476c1f937bd03a58.jpg)

(https://uploads.tapatalk-cdn.com/20170406/f523975265838a8bde70d455c2c08c5f.jpg)

And more recycled tie down points because why not?
(https://uploads.tapatalk-cdn.com/20170406/e53b19f44be4ccb80598899d193f3058.jpg)

Finally got this sucker in paint.
(https://uploads.tapatalk-cdn.com/20170406/c3e26559297510a9ca5356492c340a50.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Apr 06, 2017, 13:58:40
Great stuff. That rack looks fantastic.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Apr 06, 2017, 14:09:02
Nice job, that looks awesome
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 06, 2017, 14:15:24
Thanks guys. It was an awful pain in the ass. I probably have 75 hours in the rack alone. I won't do it again without a pipe notcher.

I ran out of gas on the welder and I've been trying to use up the rest of this spool of flux core before I go get the bottle filled...hence the splatter everywhere..hate the stuff.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Kamn on Apr 06, 2017, 14:26:59
Looking great Nick
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 06, 2017, 15:20:22
So I made up this little doohickey from the lock handles I cut off the boxes. I want to mount it on the front either to strap my phone or a map to (above headlight), or a tool roll (below headlight).

I think the above light placement would be more practical and it would be cool to bungee my phone to, but I think it looks better below. Might look better up top if I cut it down.

What's the general consensus?

(https://uploads.tapatalk-cdn.com/20170406/8d518c4b84823c9b1634f48cfbfde3c5.jpg)

(https://uploads.tapatalk-cdn.com/20170406/c7bd0177e081d7cdc16ff62e2a891a06.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Kamn on Apr 06, 2017, 15:21:23
MEH
not working up there for me
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 06, 2017, 15:24:20
MEH
not working up there for me

Yeah I think below is the winner..just have to figure out how to mount it, maybe hang it from the headlight ears?

I'm probably going to change the headlight later anyways to be honest with an 80s enduro maybe square headlight.




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Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on Apr 06, 2017, 15:29:20
below for sure. neat idea.
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Apr 06, 2017, 15:32:02
Would you mount the phone more-or-less flat on the plate? If so, I don't think you'd be able to see the screen well in the sun at that angle. A DIY RAM-style mount on the bars might be better.

I like your creativity!
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Apr 06, 2017, 15:45:04
I loooooove the Ram mounts.  I run them on all of my bikes.  Some, the phone replaces the speedo and there are apps that combine GPS mapping with a speedo.  They aren't overly priced for what you get and the durability.  Also a tank bag is a better place for your map, IMO.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 06, 2017, 19:44:33
Luggage rack installed. Glad to be done with that project.

(https://uploads.tapatalk-cdn.com/20170406/95759792a61bac946f3b3a2152a4a0a0.jpg)

(https://uploads.tapatalk-cdn.com/20170406/76e084c6e285413afd63d998d20c47af.jpg)

Popped on my Bernie Sanders, looks like I can ride on the road once I get the lights sorted.

(https://uploads.tapatalk-cdn.com/20170406/2541ef5a4fe114a878b21017cea20224.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Apr 06, 2017, 22:43:45
That came out awesome bud!
Title: Re: 74 Honda XL 350 - The Turd
Post by: canyoncarver on Apr 07, 2017, 14:09:52
(with a straight face) "Nice rack Nick". 
Title: Re: 74 Honda XL 350 - The Turd
Post by: ncologerojr on Apr 07, 2017, 17:02:41
Good job on the rack. I like it.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 07, 2017, 19:09:56
Thanks fellas. I'm quite happy with it so far. I managed to leave some metal shavings inside which is pretty annoying LOL.

Modified the battery box to fit the new 12v battery snugly. Welded up a couple pieces of steel and used a big rubber grommet I had lying around.

(https://uploads.tapatalk-cdn.com/20170407/1538c386f5576367a5176bd6af531289.jpg)

Finally got the 12v RR hooked up and the battery wired in. I ran new positive and negative leads to the battery to clean up the wiring, and relocated the fuse to the right side of the battery box.

(https://uploads.tapatalk-cdn.com/20170407/4eb9ea36a286c4f7eedac7e5d04adae2.jpg)

Waiting on some bulbs and the 12v conversion should be complete.
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 08, 2017, 12:28:48
I sorted out some electrical issues yesterday. I had the headlight lead and black wire from the stator crossed somehow. The last time I left the old battery hooked up overnight it was dead the next day. So I got everything straightened out, left everything hooked up and we're still sitting at 13.00v today.

Pulled the header off last night to get to the kickstand. It's so worn out that the bike leans about 4-5" further than it should, and it's been bothering me since day 1 so I figure what better time than now to get that sorted out. I'll be drilling for a bushing and possibly replacing the bolt...

The exhaust is going to change a bit, was debating high pipes but I don't think I'm going that route now. I want to tighten up the section along the downtube and widen the radius behind the footpegs since my boots get hung up on it now. Pics to come tomorrow.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 13, 2017, 18:44:32
Here's a fun one. I got these sweet LED bulbs from Sparck Moto at the beginning of the week. Swapped the rears out fine, then I remembered the OEM front signals on the 360 use a dual filament bulb. Since I'm not using them as running lights, I decided to convert the sockets from dual to single filament.

 (https://uploads.tapatalk-cdn.com/20170413/883a3d8d25cef6cf6535a209c6695261.jpg)

To do the conversion, I clipped the wire to one of the leads as close as I could. Then drilled out the center of the little plate and filed it to relocate the main lead to the center. Stuck a piece of duct tape to the front to keep the solder clean, and epoxied in place.

Eliminated the ground strap and soldered the previously-clipped wire (now a ground) to the socket. Had to file down the pin slots since the original bulbs had offset lock pins.

(https://uploads.tapatalk-cdn.com/20170413/e057c561d4490a125102fa8cf68a2702.jpg)

Takes a bit of finagling to get the spring and plate back into place. Back together, fits like a glove.

(https://uploads.tapatalk-cdn.com/20170413/c929a0624b33da423d57209dc5803db6.jpg)

Caught a pic. Man these things are BRIGHT!!

(https://uploads.tapatalk-cdn.com/20170413/3427c6e13164c47540b90aac80ace0cf.jpg)


Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Apr 13, 2017, 20:47:48
(http://www.dotheton.com/gallery/11494-200816163635.png)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 23, 2017, 22:15:43
Been doing a whole lot of work but not much to update. I ended up cutting the header apart since the angle on the downward piece was just not right and it bothered me every time I looked at it. Was able to tuck this one in nicely and can still get the LH cover off with it on. I swapped the can I had on there for a beat up old FMF powercore 4, it's lighter and looks a bit better than the old. It will surely need a baffle.

(https://uploads.tapatalk-cdn.com/20170424/2838c49e042fcfc17ba1b0b977d7100b.jpg)

(https://uploads.tapatalk-cdn.com/20170424/df935c1d701623763bc12be0c9927651.jpg)

The kickstand had also been driving me crazy, the bolt and hole were so badly worn I had about 3-4 inches of slop at the foot of the kickstand. Mr. E was able to turn the shoulder on the bolt down and whip up a slip fit bushing to get this thing tightened up.

(https://uploads.tapatalk-cdn.com/20170424/5a49b5ac1d177835c2ae76f99eed0347.jpg)

(https://uploads.tapatalk-cdn.com/20170424/d84a1755631261454ba717ddff54c42b.jpg)

Down to a handful of items on the punch list. Getting closer now.

Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Apr 23, 2017, 22:20:20
Shes looking good dude.   8)
Title: Re: 74 Honda XL 350 - The Turd
Post by: JSJamboree on Apr 26, 2017, 14:03:08
Just catching up on your build, super pumped about that rear rack and that price point seems nice.  I might have to try something like that on the MT
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 26, 2017, 23:29:31
Thanks. The rack was cheap but conduit is garbage to weld. I would do a different design and use plates on the outside edges and steel rod for the actual rack if I did it again.

In other news I picked up a rusty '78 XL350 today for $25. Motor was apart but it turns over and the cam journals look good. I will definitely be stealing the LH cover for the '74, as it looks to be in mint condition (from the outside anyways) and the one on there is leaking. I'll snap some more pics of it tomorrow. I may try and slap it back together and see if I can't get it running for shits and giggles.

(https://uploads.tapatalk-cdn.com/20170427/6010ae65e8f44bc3a3bd4167ed588591.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Apr 28, 2017, 19:26:23
Panniers painted and mounted. All that's left is to hook up the lights.

(https://uploads.tapatalk-cdn.com/20170428/59be67851a9a567443d2c802e5750277.jpg)

(https://uploads.tapatalk-cdn.com/20170428/725f9696e39a5397efbaf442e650ce4f.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: clem on Apr 28, 2017, 22:18:16
Those are nice looking. Time for an adventure ride.

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Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on Apr 29, 2017, 09:35:45
Nice work- the panniers and rack look great. Have you taken the bike for a spin yet?
Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 03, 2017, 22:56:26
Thanks guys. Peach - I had the bike out around the neighborhood in October before Barber. I'm currently swapping out a few good bits from the parts motor I picked up to hopefully fix an oil leak and sloppy shift lever. Once I get it back together I should be able to fire it up. Will need to make a baffle for the 'new' can as well.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 05, 2017, 14:59:49
Trying to get this thing running again, I haven't had it going since the 12v conversion. I went back through and adjusted the cam chain and valves. Went to set the timing again, and it looks like the points are grounding out somewhere...

I've been using the multimeter on continuity w/the beep, and setting the timing to the beep and the T mark. But, right now it's just showing that the points are grounding out when it's both open and closed... maybe a short somewhere?


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Title: Re: 74 Honda XL 350 - The Turd
Post by: mitchn06 on May 05, 2017, 15:20:21
My guess is that the points could not handle the extra current from the 12v conversion. Might have to keep the ignition system on 6v and run the lighting stator windings on 12v. Just my thoughts. I've been silently following you through your build as I'm doing a 72 xl250 and would like to do the 12v conversion also.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on May 05, 2017, 15:31:07
Do these points have the little fiber washers to isolate the screws? sometimes those break and short. Also if the o ring for the wire that gets connected to the point arch gets turned it can touch and ground against the base plate. See the pic and how the wire is positioned so it is up away from the base plate. I fought the same issue on my wing only to finally notice when I replaced the points I had let one of the wires touch and ground on the plate.
(http://www.dotheton.com/gallery/1732-050517133312.jpeg)
Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 05, 2017, 15:34:03
Well, on this bike the lighting circuit is run through a 12v RR, but the ignition and headlight circuit runs directly from the stator, so the ignition system is still running on 6v.

These points do have the fiber washers, and they are set up to insulate correctly as I had the bike running quite nicely before and have not touched the points since. I will double check when I get back to the shop.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on May 05, 2017, 15:47:22
Check the wire connection I circled as well. It can short/ground even if it is slightly off the plate. put shrink wrap on mine over the exposed solder joint as well.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 05, 2017, 17:07:39
Will do. I'm usually pretty good about checking that, I had the same issue with the 360.

I should mention that while I am having this issue, I still have spark. So that's weird.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on May 06, 2017, 06:56:49
6v or 12v don't matter with points.  If you got a gap. Then yes There's a
Short to ground
Somewhere.  When using meter to ring points be sure to unplug them from the coil.  As the meter can read through backwards through coils ground .  This means it don't matter if you can see points gap.  It will still ring.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Maritime on May 06, 2017, 10:18:09
+1 I was about to ask after you said you had spark if you unplugged the coil before trying with a meter.
Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 06, 2017, 15:59:41
HA. That's right, I knew I was missing something. The points werent grounding out, I just forgot the lead needs to be disconnected.

Got too many bikes and they're all different. Last one I did I had to rotate the stator plate to set the timing


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Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 10, 2017, 20:44:24
Ok so got the static timing set, but ran into something strange. I had pulled the plug the other day to check for spark after Trying to start it a few times. Popped the plug back in and kicked it over, now there's little/no compression being built up. Like I can kick it over by hand. With the gauge it's reading 60 psi, which is way low.

I haven't done anything to the motor since I had it running aside from set the cam chain, re-adjust valves (all of which are in spec).

Reads 60psi with a few squirts of oil in the cylinder, which points to the valves. With the tappet covers off, I can visually confirm that all valves are opening and closing as they should. Ideas?


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 10, 2017, 21:18:44
Have you had the valve seats recut? 

Have you dropped oil into the plug hole to see if compression rises?
Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 10, 2017, 21:22:08
Have you had the valve seats recut? 

Have you dropped oil into the plug hole to see if compression rises?

Yep. I had all the valve seats cut at a machine shop, replaced 1 valve that was bent, new valve stem seals.

And yes to oil in cylinder, it did not effect compression reading.

I mean, I had to put all my weight into it to kick this thing over before. It's worth noting that I didn't hear anything break or any noises when it happened.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 10, 2017, 21:31:55
I'd be inclined to pull the head an recheck the seals on the valves. Sounds like you're losing compression in the head.  I doubt you've blown a head gasket that bad.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 10, 2017, 21:36:16
Dumb question, but you are checking compression with the throttle open, right?
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 10, 2017, 21:59:10
Lol. I wasn't. Brain fart.

It's reading ~100 psi cold, and same reading with a few squirts of oil. I had the cylinder measured and honed and put in new rings, haven't gone enough miles to get them broken in and seated quite yet (under 10 miles since rebuild)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 10, 2017, 22:18:07
Haha.  All gravy, baby.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 10, 2017, 22:24:42
This thing should start. I'm gonna pull the carb tomorrow and make sure it's not gummed up from sitting, even though I drained it


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Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on May 11, 2017, 08:56:16
do a leakdown test dont tear it apart till you know what the issue is
Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on May 11, 2017, 08:59:02
if you have the stock carb and it was colder the last time

they are a pin in the ass when it gets warmer you have to lean the mixture out to get them to start

or at least that is what i had to do on mine

key off one -2 kicks with the choke on

then key on 3/4 choke dont touch the throttle and  kick it a few times it should go

or just give it a little squirt of ether get it going and re set the mixture

Title: Re: 74 Honda XL 350 - The Turd
Post by: JustinLonghorn on May 11, 2017, 09:48:54
That poor old yellow light.

(http://www.dotheton.com/avs/avatar_102736_1492572301.png)
Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 11, 2017, 22:05:47
Cleaned some gunk outta the carb and tossed it back on, no luck. It doesn't even sound like it wants to start.

I did swap out the stator with the '78 model when I put that LH side cover on. Pretty certain nothing changed there between 74-78 but I may try swapping that back to the old one to eliminate one variable.

Looks like I'm gonna have to find a leakdown tester.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 11, 2017, 22:11:41
Cleaned some gunk outta the carb and tossed it back on, no luck. It doesn't even sound like it wants to start.

I did swap out the stator with the '78 model when I put that LH side cover on. Pretty certain nothing changed there between 74-78 but I may try swapping that back to the old one to eliminate one variable.

Looks like I'm gonna have to find a leakdown tester.


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Hold on.  You don't need a leak down tester.  You said you have compression.  Anything above 90 will run.  Do you have spark?
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 11, 2017, 22:14:10
Hold on.  You don't need a leak down tester.  You said you have compression.  Anything above 90 will run.  Do you have spark?

That's what I thought. Still doesn't explain why it's so easy to kick over now.

I do have spark. And fuel now.
Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on May 12, 2017, 07:42:47
when in doubt check it out
Title: Re: 74 Honda XL 350 - The Turd
Post by: redwillissuperman on May 12, 2017, 09:26:21
When in doubt, add gas ⛽️....

If you spray carb cleaner down the throat or use a syringe to squirt fuel in, it should cough and run if spark is present. If it doesn't, then it's ignition.
Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 20, 2017, 21:05:42
I swapped the original stator back onto the bike. Double and triple checked the valves and timing, gave her a few big huffs of ether and she fired right up.

Took a maiden voyage around the block. The tach stopped working about halfway around and the new can is way too loud, but I made it back with no issues.

Planning to make a baffle this week and I got a repop seat cover to throw on. The paint is staying for now. I will to repaint the tank and fenders later, when I get my paint gear back from my rents place in MA.

Here's a shot after the test ride

(https://uploads.tapatalk-cdn.com/20170521/dd9c220068674cf7641eac22ca56dfc8.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: JSJamboree on May 20, 2017, 23:46:16
lookin good, we need an MT250 XL350 faceoff
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on May 21, 2017, 00:13:19
Winner!  8)
Title: Re: 74 Honda XL 350 - The Turd
Post by: iatethepeach on May 21, 2017, 09:23:13
Right on! Not having to push the bike home on its maiden 'round-the-block voyage is a nice morale boost. I think I had to do that three times in a row with my CL.

Watch out for the front end getting light over bumps when you have the panniers loaded up; they sit pretty far back. If there's any room to slide them forward, I would.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Brodie on May 21, 2017, 09:30:01
Gotta love the old XLs. Makes me want to rip into mine...
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 22, 2017, 21:09:19
Thanks guys. I'm pretty happy with it so far.

Peach - I hadn't though of that. I can't really move the boxes the way I have em mounted currently without a bunch of cutting and welding. I'll have to do my best to keep the weight forward. Long term plan is to upgrade to larger aluminum boxes in the future anyways, so I will revisit that later.

Took her out again yesterday without changing anything. Did great on the road and even got a taste of some dirt/sand for a bit.

I did have two stalls, both when I pulled in the clutch to downshift/slow for a stop sign. Pretty sure I just need to play with the mixture and get the idle ironed out and that should take care of it. I'll do that and put the timing light on it sometime this week.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 23, 2017, 16:07:37
Attempting to dial it in today.

I set static timing w/multimeter and it was dead on. When I put the strobe on it, it's advanced quite a bit from the 'F' mark this setting at idle. The closer I get it to F at idle(retarding the timing), the worse it runs. At 4K the advance marks are nowhere to be seen. I was careful reassembling the advancer after cleaning it up, but that could be causing an issue.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 23, 2017, 17:29:02
Where do you have your idle set? By "closer I get to F at idle" where is the mark in relation to the F mark- to the left or to the right of it? 
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on May 23, 2017, 18:38:03
When static timing, points "open" at F mark correct?

May or may not be a silly question to ask.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 23, 2017, 18:49:16
When static timing, points "open" at F mark correct?

May or may not be a silly question to ask.

Yup.
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on May 23, 2017, 18:58:57
Yup.

Ok just had to ask.  Ya know.  ::)
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 23, 2017, 19:02:27
You're not answering my questions.  :-\  At what RPM are you setting your idle with a gun?  Is there preload on your advancer springs at idle or at rest? If you're springs are stretched, which happens when they get old, you can lose up to 10 degrees or so of advance, which is 1/3 of your total advance. 
Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 23, 2017, 19:02:54
So, with the timing light on and bike idling, this is where the points plate is when the F mark lines up with the index mark.

(https://uploads.tapatalk-cdn.com/20170523/f513ac8ef5feabadfa6ee974b5fa6b7a.jpg)

For reference, when I set static timing the hash mark on the points plate was pretty close to lining up with the mark on the head.

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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 23, 2017, 19:03:41
So, with the timing light on and bike idling, this is where the points plate is when the F mark lines up with the index mark.

(https://uploads.tapatalk-cdn.com/20170523/f513ac8ef5feabadfa6ee974b5fa6b7a.jpg)


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That's retarded not advanced.  As you move toward the timing mark (right) you're advancing it.
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on May 23, 2017, 19:06:04
Gap is spec?
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 23, 2017, 19:07:32
Right. If I said advanced that's my bad, it's retarded. I'm setting idle timing @ 1200 RPM.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on May 23, 2017, 19:08:49
Re-check static. Advancer is mechanically locked to the cam w a pin or key or something?  So, it cant slip on cam.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 23, 2017, 19:10:58
That's way too retarded on the timing.  If anything, you should be slightly on the other side of the mark. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 23, 2017, 19:25:55
Re-check static. Advancer is mechanically locked to the cam w a pin or key or something?  So, it cant slip on cam.

Yep the points plate and advancer is almost identical to my 360 just with one less point. Gap is smack in the middle of spec.

I know its too retarded. But that is what the timing light is telling me. Which is why I think that something's up.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on May 23, 2017, 19:29:47
The advance setting on the timing light should be at Zero, yes?


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 23, 2017, 19:35:49
Check your advancer springs.  There should be pre-load on them.  If they're stretched, you're losing advance and thus bogging and losing power.  It can also cause hard starts and rough idle. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on May 23, 2017, 20:08:01
The advance setting on the timing light should be at Zero, yes?

Sorry I cant answer this.  My timing light doesnt have that feature.  Its older than you are.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Hurco550 on May 23, 2017, 20:38:30
forget all this "ignition" crap, cut your losses and drop a diesel klr lump in it and call it done.



your welcome
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on May 23, 2017, 21:21:48
Convert it to electronic ignition.
Title: Re: 74 Honda XL 350 - The Turd
Post by: JSJamboree on May 24, 2017, 01:07:02
Buy an old two stroke so you just don't deal with timing chains, valves, or advancers.


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Title: 74 Honda XL 350 - The Turd
Post by: advCo on May 24, 2017, 09:29:44
Check your advancer springs.  There should be pre-load on them.  If they're stretched, you're losing advance and thus bogging and losing power.  It can also cause hard starts and rough idle.

I'm thinking this may be where my problem lies. I'll pull the advancer out of the parts motor bin and compare.

If I grab the advancer lobe on the cam with my fingers and try to rotate it there is some slop there.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 02, 2017, 15:59:48
https://youtu.be/osk6puKlml0

There's not enough tension from the springs. I don't think they're sold as an individual part, though.

I took the advancer off the parts motor, it's a different design with different springs. Seized, going to rebuild and try swapping it on.

(https://uploads.tapatalk-cdn.com/20170602/c91dde64f97b636133b2ce9866f66fca.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jun 02, 2017, 16:55:27
I've gotten away with removing a coil- basically cutting off the pigtail and pulling one coil to become the pigtail to replace it.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 02, 2017, 18:04:08
I've gotten away with removing a coil- basically cutting off the pigtail and pulling one coil to become the pigtail to replace it.

Nice, I will give that a shot and see if it helps.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Brodie on Jun 03, 2017, 18:28:40
That is what most fitters at my work do when a spring starts to go.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jun 05, 2017, 16:24:04
Alright so I removed a coil and that took out a lot of the slack from the advancer. It's much stiffer now, hopefully not too stiff. Going to re set the static timing and see where the light reads this week.

Made a baffle out of some 3/4 pipe and what was left of a reducer I had lying around.

(https://uploads.tapatalk-cdn.com/20170605/35eb82451e0ebb88b71b66bc21143056.jpg)

Wrapped in some fiberglass packing.

(https://uploads.tapatalk-cdn.com/20170605/235d79087ce6f2092d2e1b31f7fe9116.jpg)

It's still pretty damn loud. I may end up going down to 1/2" on the inner tube.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 03, 2017, 18:20:36
Lost interest in this thing for a few weeks. Last time I had it out it stalled a few times while riding and now it doesn't want to start.

SO, went back through and adjusted the cam chain, valves and timing again. The valves were pretty tight after a couple heat cycles, so I adjusted all four. I talked with a guy who has had a bunch of these old XLs and he recommended to set the valves to .003" and .005" as opposed to the FSM stated .002" and .003", so I gave that a shot. Still doesn't want to start, even w/a squirt of ether.

Maybe if it cools off later I will try and set them back to factory spec and try again.
Title: Re: 74 Honda XL 350 - The Turd
Post by: Tune-A-Fishİ on Jul 04, 2017, 10:15:09
Don't sound like valve clearance issues seems more ignition to me, I run valves a tad loose on old motors without starting problems


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 04, 2017, 11:35:33
I agree.  I'd check coils and points.  Coils could be fried, or the points could be burned up or just cruddy.  If you're running a resistor cap, check the coils with and without the cap on the wire.  I'd make sure all connections are sound with a meter. 
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 04, 2017, 11:43:50
Roger that. I was thinking the same as well after no firing with starting fluid. The points are good, I just checked the timing yesterday. Could definitely be coil and/or condenser. I'll check the kill switch(es) to make sure those aren't screwing me up either.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jul 04, 2017, 13:23:43
Don't get discouraged.  Once you sort through the bugs it'll be good for a while.  These things are so easy to hotrod and the aftermarket is plentiful.  You can go big bore, hot cams, FCR- all of it.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 31, 2017, 16:20:47
I think I found the cause for the stalling: The repop fuel cap I put on isn't venting correctly. It looks like it has a small vent hole, but it's not doing it's job. Im thinking drill and tap the cover to install a MX style breather tube?

(https://uploads.tapatalk-cdn.com/20170731/d47575568fd7fcc0bac0705ed2b9450d.jpg)

I picked up this VM34 at mid-o for a few bucks. The stock carb is 36mm so I'd have to make up a spacer. Wondering if it's worth it or find a vm36? The stock Keihin is just a pain in the ass.

(https://uploads.tapatalk-cdn.com/20170731/01acac5ff5031eda4a14c8e6817b6298.jpg)

Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Jul 31, 2017, 16:32:19
if you are driving in town the 34 will be better off the line than the 36 but slightly less top end but only a WFO

i have

3.0 slide

37.5 pilot (may be a bit rich for you)

main jet 240

6dh4 needle 2 nd groove down from top

q2  needle jet

no air correct
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jul 31, 2017, 17:40:17
I think I will fit the 34 after I get it dialed in and see how I like it..

Still hard to start. Compression is at 150. Spark is good. Timing has been set. I just cleaned the carb before I tried to start it up. Nothing.

Getting tired of kicking this thing might have to put a decomp in lol


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 06, 2017, 20:16:39
So I pulled the carb again today and REEEEEALLY cleaned it. Tossed it back on w/the fuel bottle and got nothing after 4-5 kicks. Pulled the plug and it's dry as a bone. Sprayed a shot of starter fluid and it fired right up. Not sure what's going on with the carburetor but something fishy is up.

Once she's running it's like a bat outta hell. This thing is a torque monster. Brought it around the neighborhood for about 15 minutes with no issues whatsoever.

Stalling issue is most definitely fixed. I ran around with the fuel cap just resting on there to see if that did the trick and it surely did. Got some fuel on my legs but at least I got to ride it. I think I'll put a brass barb and breather tube on the cap.

Going to let it cool down and see if it wants to start back up in a bit.


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Title: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 06, 2017, 22:11:23
The plug after today's ride. Looks like a faulty needle and seat may have leaked some fuel into the crankcase. I'm lucky it didn't hydrolock if it did happen. I had to take quite a bit out of the crankcase, like almost 1L, but It didn't really smell of fuel. Shrug.  Going to change the oil before I run it again.

Time to start piecing together that Mikuni and put the Keihin in the trash.

(https://uploads.tapatalk-cdn.com/20170807/c10153237b73672e813fb81878741b8e.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 08, 2017, 19:32:31
Got the correct amount of oil in there after a change or five... (a long story for another day)

Threw in a new plug and the old girl starts right up first kick every time.

My method is 1 kick with main switch off to prime. Turn switch on and one good kick and she fires right up. Seems to be running really well. I need to do something to quiet this exhaust so I can go down and get this thing inspected. Maybe rebuild the baffle with 1/2" pipe instead of 3/4"?

Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Aug 08, 2017, 20:57:24
(http://www.dotheton.com/gallery/11494-200816163635.png)
Title: Re: 74 Honda XL 350 - The Turd
Post by: mitchn06 on Aug 09, 2017, 00:38:53
Glad to hear you are getting it sorted my friend!


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Title: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 09, 2017, 13:18:39
I've noticed while tuning the stock Keihin that the mixture screw does not cause the motor to stall or bog when screwed in all the way. It is on the engine side, so therefore it is a fuel screw if I am not mistaken. In this case, turning the screw IN should lean out the mixture. In this case, it would appear that the idle circuit is too rich, so a smaller pilot jet would be the solution?

The fastest idle speed is achieved at about 1/2 turn out. The manual states typical setting should be between 7/8 to 1-1/4 turns out.

In the factory service manual, Honda refers to the mixture screw as an air screw. Clear as mud. Can anyone help clarify?

A pic of the carb for reference (for anyone unfamiliar, the engine is on the right hand side)

(https://uploads.tapatalk-cdn.com/20170809/527b2a591015542d3e5f6a5cfda62d16.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 11, 2017, 10:35:05
Any advice on mixture screw?

Meantime, here's a cold start vid.

https://youtu.be/FGFa6xLW5NI


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Title: Re: 74 Honda XL 350 - The Turd
Post by: JSJamboree on Aug 17, 2017, 09:55:53
Any advice on mixture screw?

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Nick, get yourself one of these bad boys.  They work killer and will really help you dial in the mixture screw and also help you understand where you fuel is through most of the throttle.

https://www.amazon.com/Colortune-for-14mm-Spark-Plug/dp/B000E9VGNM
Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Aug 17, 2017, 13:42:03
what is it you dont understand about the air screw adjustment out is richer

stock setting is 1.5 turns
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Aug 17, 2017, 14:22:44
what is it you dont understand about the air screw adjustment out is richer

stock setting is 1.5 turns

Ok that's what I thought. If I turn it all the way in (bottomed out) the bike still idles normal. So down a size or 2 on the pilot?
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Aug 17, 2017, 14:30:58
Old Rice has good data on these carbs.  http://www.oldrice.com/CarbStuff.htm

If you bottom out and it still idles, then you have a leak.
Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Aug 18, 2017, 15:28:10
check for vacuum leaks make sure you check the mating surface of the boot to head
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 21, 2017, 00:33:21
Time to get this thing ready for Barber, wrap it up and ride it. Re routed the exhaust for the fourth or fifth time. Fitted a Supertrapp so I had to change the pipe a bit. Needs some paint but I'm happy with it.

(https://uploads.tapatalk-cdn.com/20170921/60fcfab55bc942c1c91d4c7fe81a7b20.jpg)

Got this slick billet gas cap with a recessed vent tube.

(https://uploads.tapatalk-cdn.com/20170921/ae00bf6d8ed7b564579559839313a54b.jpg)


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Title: Re: 74 Honda XL 350 - The Turd
Post by: trek97 on Sep 21, 2017, 08:03:14
the gas cap is COOOL.  Where did you get that?
Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Sep 21, 2017, 12:51:39
did you find a 36 yet?
am i going to see you at barber? im in booth f&g 38 right across from the concession stands

i will be there from friday aft till sunday some time
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 21, 2017, 13:43:30
the gas cap is COOOL.  Where did you get that?

Came from xb33bsa. He may be banned from here but he's still got a ton of great vintage MX parts lol. Need to grab some vacuum line to run up under the bars.

I actually got it for this Vesco Desert tank I traded Mr. E for at mid-o, which will go on later.

(https://uploads.tapatalk-cdn.com/20170921/24d64245bae268e225523628822b3f64.jpg)
Title: 74 Honda XL 350 - The Turd
Post by: advCo on Sep 21, 2017, 14:02:56
did you find a 36 yet?
am i going to see you at barber? im in booth f&g 38 right across from the concession stands

i will be there from friday aft till sunday some time

Not yet. Decided to hold off on that for the moment and try and get her running right with the stock carb. I'll be at barber, hopefully I'll be able to grab a cheap one at the swap meet.


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Title: 74 Honda XL 350 - The Turd
Post by: advCo on Jan 10, 2018, 20:25:09
Been a while since I've updated this thread. Been busy with other projects but still trying to get this thing on the road.

I 3D printed a bracket to mount the new TrailTech Vapor speedo. It mounts to the stock gauge bracket and the Vapor bolts on to the bracket from underneath. Eventually I’ll have one printed in metal, but I printed this one at high fill so it should hold up for a while.

(https://uploads.tapatalk-cdn.com/20180111/95af51492e4a25a374ec4ec7f2f0952f.jpg)

(https://uploads.tapatalk-cdn.com/20180111/7965d1a48852c2c6af7b450a6647403b.jpg)

Ran the wires as cleanly as I could and used a band clamp to hold a bracket for the speedo sensor. I drilled a shallow hole and epoxied the magnet between two of the spokes. It seems to pick up pretty well although I have yet to get the thing calibrated.

(https://uploads.tapatalk-cdn.com/20180111/549ad8a210feadb81d015a5ba5045bd0.jpg)

(https://uploads.tapatalk-cdn.com/20180111/df2d83e7509cd8241d9d406f007c1494.jpg)


I got the bike running well enough and had it out around the neighborhood a couple times. The last time I had it out, I romped on it a bit in the sandy stuff down by the creek and something went amiss. I was able to limp it home but it seemed to be misfiring like crazy and hard to start. I bought a set of OEM Honda points to replace the crappy ND ones I had originally installed and re-set the timing but still hard to start. I plan to go back and check the tappet clearances again to make sure nothing loosened up, and I'll go back and clean the carb again just to be 100% certain the pilot isnt blocked.
Title: Re: 74 Honda XL 350 - The Turd
Post by: 2strokeTRush on Jan 12, 2018, 20:24:22
been lookin for a update :)
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jan 14, 2018, 20:25:05
Ok I got the old girl running again today and changed out the oil. The pilot and main were partially blocked. Bike idles sporadically and barely wants to stay running without running in the idle screw a bit. and the plugs still look fouled even after a ride.

(https://uploads.tapatalk-cdn.com/20180115/a1055e75e21ae1a0c2cef4c776d52b36.jpg)
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jan 14, 2018, 21:59:34
Have you ridden it enough to break in the rings-  Lots of full throttle, no throttle, up hills then down hills dropping the gears to create back pressure, etc etc?  Worn rings will cause a 4 stroke to foul plugs, but in your case this motor is a fresh rebuild, so if the rings haven't broken in the same results may apply.  You also mentioned way back that you didn't remember the needle position, so you put it in the middle.  That should be fine, but have you messed with the needle since and have you changed any jets since rebuilding the carb?  I assume you pulled it apart again and blew cleaner through all the ports and jets to insure everything is free and clear.  I would also make sure you have fresh ignition and perfect timing.  Weak spark and retarded timing will also cause this. 
Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Jan 15, 2018, 07:25:07
yup to breaking in the rings mine smoked like crazy started letting off as i broke it in

i now have probably 150 miles on it im still not using wide open but its clear of  even a whisp of smoke till i get

it hot and over 6500 so its coming along nice
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jan 15, 2018, 09:44:00
Yep I have been working on breaking in the rings, haven’t had it up over 3/4 throttle and varying RPMs, always keeping load on the motor.

As far as the carb goes, it’s been cleaned over and over. I rebuilt the ACV as I had it blocked off before. I haven’t messed with any of the jets or the needle at all.

I just replaced points with OEM Honda points and the timing is right on.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jan 15, 2018, 09:50:07
Yep I have been working on breaking in the rings, haven’t had it up over 3/4 throttle and varying RPMs, always keeping load on the motor.

As far as the carb goes, it’s been cleaned over and over. I rebuilt the ACV as I had it blocked off before. I haven’t messed with any of the jets or the needle at all.

I just replaced points with OEM Honda points and the timing is right on.


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It's not keeping loading on the motor, it's putting it on, then taking it off then putting it back on.  Full throttle, off throttle, decel and downshift- basically putting pressure on both sides of the rings.    That said, if everything else checks out and you can get it to stay running fine, then put some miles on it and see if it improves.  Do some proper plug chops.  Get on a road with a pocket full of plugs and the necessary tools and get it to top speed- cut it off.  Pull the plug and check.  Do it in varying ranges of the throttle.  Also, what is your air cleaner situation? 
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jan 15, 2018, 09:54:49
It's not keeping loading on the motor, it's putting it on, then taking it off then putting it back on.  Full throttle, off throttle, decel and downshift- basically putting pressure on both sides of the rings.    That said, if everything else checks out and you can get it to stay running fine, then put some miles on it and see if it improves.  Do some proper plug chops.  Get on a road with a pocket full of plugs and the necessary tools and get it to top speed- cut it off.  Pull the plug and check.  Do it in varying ranges of the throttle.  Also, what is your air cleaner situation?

Yeah I’ve been keeping varying RPMs and all that. Been pretty meticulous about it since the rebuild.

I’m using the stock airbox with a UNI foam element.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jan 15, 2018, 10:08:08
Yeah I’ve been keeping varying RPMs and all that. Been pretty meticulous about it since the rebuild.

I’m using the stock airbox with a UNI foam element.
Do you have something you remove the airbox and install to see if that changes things? 
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jan 15, 2018, 10:11:02
Do you have something you remove the airbox and install to see if that changes things?

Like a K&N filter? I don’t. I wanted to keep the intake all stock. I want to put a VM36 on it so I’ll change the intake then.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jan 15, 2018, 10:23:32
Like a K&N filter? I don’t. I wanted to keep the intake all stock. I want to put a VM36 on it so I’ll change the intake then.
Can be a Uni, just something to run it and see if it fixes the situation.  Not suggesting a permanent fix.  Could be that your Uni in the stock box is the issue. If it's not getting enough air, then your plugs will foul the same as if you have the fuel mix to high.  Speaking of which, where's the fuel mix screw set? 
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jan 15, 2018, 10:25:42
Can be a Uni, just something to run it and see if it fixes the situation.  Not suggesting a permanent fix.  Could be that your Uni in the stock box is the issue. If it's not getting enough air, then your plugs will foul the same as if you have the fuel mix to high.  Speaking of which, where's the fuel mix screw set?

A/F is about 3/4-7/8 turns out. I’m using the stock cage in the airbox, just UNI foam to replace the original element.
Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jan 15, 2018, 10:28:44

A/F is about 3/4-7/8 turns out. I’m using the stock cage in the airbox, just UNI foam to replace the original element.
Oh shit, that's probably your issue.  The further in the mixture screw the more rich the mixture.  You have that set really rich.  It should be about 1.5 turns out.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jan 15, 2018, 11:32:04
That’s what the manual calls for with stock setup.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: irk miller on Jan 15, 2018, 11:35:22
That’s what the manual calls for with stock setup.


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You don't have the stock setup.  You have a Uni filter amongst other things, including a rebuild.  Use those numbers as a guide.  It's clearly rich, so those numbers may be hardly relevant.  There are all kinds of specs throughout the motor that have changed.  Also, as Trek pointed out, factory numbers tend to be on the rich side anyway for cooling.  Also, don't forget things change according to atmospheric pressure, humidity and whatnot.  There's no such thing as a universal setting.
Title: 74 Honda XL 350 - The Turd
Post by: irk miller on Jan 15, 2018, 12:39:03
I assume you have this carb...

(https://uploads.tapatalk-cdn.com/20180115/7f622c399932ce506abd5c2abc643a17.jpg)

Make sure your air cutoff is functioning properly, is complete, and is assembled correctly. It will prevent air mix if it’s wrong, and low vacuum will fuck it up too.

(https://uploads.tapatalk-cdn.com/20180115/95574472496d3f270a113a3012a8ab81.jpg)

1: air from atmosphere
2: valve that allows air to air mix circuit. Normally open by spring pressure.
3: opening to fuel/air mix circuit. There must be a good o ring here.

(https://uploads.tapatalk-cdn.com/20180115/f58003a1a87d9339659467dcdac3d50b.jpg)

4: Opening to intake. Vacuum here closes the valve (2) and blocks air to fuel/air mix.

(https://uploads.tapatalk-cdn.com/20180115/7af126b58cd2a1b6e4608b1b853840b6.jpg)

5: this nipple must face out. It opens the valve (6) here:

(https://uploads.tapatalk-cdn.com/20180115/2d58ad58304c10196e1f2633a1646195.jpg)

This system can be eliminated as long as you still provide access to atmosphere.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jan 15, 2018, 21:16:13
Yeah. I have that carb. I just rebuilt the ACV (i had it blocked off previously) because I had a hunch that it was screwing with the A/F mixture. When I get a minute I'll pull it off and make sure everything is assembled properly.
Title: Re: 74 Honda XL 350 - The Turd
Post by: advCo on Jan 20, 2018, 18:48:18
Ok I started with the basics. Cam chain and tappet adjustment. Haven’t touched the valves since rebuild so they were a bit too loose from heat cycling a few times. Cleaned some of the carbon off the plug and she fired up first kick, running strong.

Did a handful of laps around the yard and all seemed good. Once I got it nice and warm I parked it and started to set the mixture. Seemed to be most comfortable at about 1-1/8 turns out. Shortly thereafter heard the same sound as the first time this happened, almost sounded like a quiet backfire. Bike died and started doing the same deal misfiring and won’t idle now.

Possibly coil failing? Advancer malfunctioning? Running out of ideas.


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Title: Re: 74 Honda XL 350 - The Turd
Post by: cxman on Jan 20, 2018, 19:30:24
oil on the points? clean and see