XL350 Build

CALfeRacer

Fat man on a little bike
Hello all!
Today I made my way out to the sticks to scratch an itch I've had for a while: a new bike to work on. I miss wrenching, so after cruising craigslist for a while, I found a Honda XL350 for sale, drove about two hours to check it out, and decided to buy it for $200! Bike is pretty complete, minus lights and gauges. Also appears to be in pretty good shape, has spark and compression, just needs the carb to be cleaned. Sounds good so far!
First thing's first, you may have noticed I haven't thrown out a model year yet.. That's because I'm not quite sure. The frame says 1982, however the bike is a side port, and has what appears to be a '75 tank, so honestly going in to this I thought the bike was '75. I thought the sideport was only for model years '74-'77 (ish?) and that by '82 there was a different engine and exhaust, with the two small header pipes and a high pipe on the right as opposed to the low pipe on the left mine has. who knows? hahaha ???
So, in my excitement I decided to tear in to the carb once I got back. I knew it did'nt have a throttle cable, and that it was also a push-pull cable. never seen that before! I noticed it appears to be a non-cv carb, the throttle body appears to be moving the slide up and down. However, upon removal I noticed there is another cable which controls a butterfly valve, which would be characteristic of a CV carb? Upon removing the bowl I noticed that there is no float needle attached to the floats, which were a bit of a pain to get out. The jets were clear, and other than some residue on the bottom of the bowl, it all looked pretty clean. Tank is also clean, so it looks like when it got put up, the PO did it right, which is nice. I'm contemplating swapping the carb for a Mikuni VM, I've heard it's a common swap that doesn't really have any issues. Seems like it would be nice to get rid of the two (or three?!) throttle cables and just buy a round-side. Plus oldrice has a bunch of info on carb specs for swaps.
So, to where I want to take this bike. I like the classic dual-sport style, but really want to try my hand at a street tracker-esque build, and time will tell where this build goes! being a college student, I don't have a ton of money to play with so progress will probably be slow, with my main goal for now being to get her clean, running, and street legal!
Any input is welcome, just glad to be back on the site and ready to wrench! ;D
 
Pictures

Forgot about the golden rule: Pics or GTFO
On the way home:
IMG_1125_zpse4755d89.jpg

Stock Carb, notice the butterfly valve as well as the push/pull throttle plate on the top
IMG_1126_zps9bafaf16.jpg
 
that is a 75 first year the exhaust is worth good money
you are looking at the choke is the extra valve
keep it stock it will run fine, start modding it you will have a headache
 
so the choke is done by opening and closing the butterfly valve? Can't say I've seen that before. Good to know though, thanks! :)
 
xb33bsa said:
that is a 75 first year the exhaust is worth good money
you are looking at the choke is the extra valve
keep it stock it will run fine, start modding it you will have a headache
Just curious why the frame would say '82 if its a '75 bike though???
 
Carb questions

Ok, good to know that it is in fact a '75, as I thought.
So from what I have read, the whole push-pull throttle system is just over kill and I could theoretically just run one generic throttle cable, and a generic choke cable?
Also, what are the two cut tubes for? I know the top of the two is the gas line from the tank, but what is the bottom one?
 
vent tube the stock throttle in good condition with good cables works nicely
but yeah you can run a single cable
what condition is the engine in ? is it a runner ? is the head still good ?
 
So what should the vent tube be connected to? just let it dangle like the float bowl overflow tube or does it connect to the crank, airbox, etc?
The engine has compression and spark, but the carb needed a look through. so, hopefully once that is all set I can let you know for sure! ;)
So far in the carb everything looks solid... jets are clear and barely any varnish on the bowl. only problem is it doesn't look like there is a float needle, but upon examining the diagram of the carb it doesn't look like there is supposed to be one?
Also, ob1xl, I want to say your bike is awesome!!! I saw it when I was lurking around for any XL builds! ;D
 
actually i am not sure what that one is for ??? its been too long for me now
the shop manual will tell you all that shit
get a clutch cover gasket clean the oil filter out ,adjust timing chain,and check/set the valve clearances and hopefully they aren't real loose that can be a sign that the head is scrap
 
Day One Progress

Started to make progress today, I think. ???
Went to a local bike shop and got a new brake lever (mine was snapped in half), and ordered throttle cables which should be here tomorrow.
Went to the locksmith to get a key made for the seat lock. The ignition was drilled out and the wires chopped, so it's going to go in the trash. The guy there suggested putting an on/off kill switch under the seat, which I like the sound of. Problem is, I need to make a new seat pan If I want to do a tracker seat, cuz the seat on it now is too damn nice to cut up!!!
Back on campus, with seat lock key in hand, I took the tank off to get a look at the wiring. Let's just say it's seen better days. The whole back end of the harness (tail light, battery, etc.) is gone. The rectifier is there, but plugged in to nothing (it's got nothing to plug in to ). As said earlier, the ignition is chopped with the wires just wrapped up, some dry duct tape was removed by me... It's amazing this thing had spark! :eek:
What I'm thinking is I'll end up building a new harness, hopefully this is a good bike to tackle that for the first time on? looking at the diagram isn't to intimidating, might even be simpler than Susie's!
Part of me wants to try to switch to 12V if I'm gonna do a custom harness, however I'm not entirely sure on how to go about that... I remember reading about it a little bit when looking at the wiring for Susie, but decided to just leave her as 6V. If anyone has any info or input on the 12V conversion let me know! :D
Also noticed a few bent spokes in the front wheel. Looking in to swapping a street-sized (maybe 18"?) front wheel with a big drum, so I don't have to worry about getting forks with caliper mounts. More info on that as it comes up.
 
Direction.?

I was thinking about what direction I want to take this build while at dinner with some friends, and realized that I am thinking about taking it in an almost "ratty" direction. Now, I said this for my last build but that went out the window, so hopefully this time I can stick to it and keep a real budget... :p
Anyways. The bike is in good shape, just cosmetically rough. I mean, what do you expect from a '75 bike that was used as a dirt bike?! I am thinking about blasting the tank to bare metal (we have a sandblaster in the shop I can use! ;D) and clear coating it, and doing the seat in whatever bare metal I can scrounge up around the shop to make a tracker-esque tail. I saw a tail on a bike that I really liked, it was simple and had a vertical piece of metal sitting further back in the seat frame that the light was attached to (I cant remember for the life of me what it was...). I like that because its simple, especially after spending HOURS fiddling with a drill and sheet metal trying to figure out how to mount the brake light on the last build.
So, that's where I'm at! I'm totally open to any suggestions, if you have any! :D
 
1414672_10153543140260221_500285588_n.jpg


Here's the xl250 I'm building, started out with the same thing as you, built new wheels with a 18'' in the front. Thought you might like to see it. It's not a classic ''tracker'' it's more of a brat tracker, I guess.

Crappy pic, I know...
 
Harness

No worries! Glad to have people posting up their projects on here! ;D
Upon tearing in to the harness, I am honestly not as intimidated as I thought I would be by wires and such... So I'm gonna go for it and make a new harness! I looked up the stock harness, which I am examining carefully, and the Oregon Motorcycle Parts Custom harness for Honda singles. I like how simple the OMP one is, but I want to integrate the stock switches (mainly cuz I don't wanna buy new ones...) and am still going back and forth on using idiot lights. If it means less wiring, I'll probably not use 'em. Still debating running signals, mainly based on whether or not I'll be able to register it. Also, the bike I got doesn't have an indicator switch, nor does one appear on the stock diagram? ???
So, long story short, I need to combing the two diagrams (pics to follow!). I'll be sure to post what I come up with whenever I do, so I can receive some constructive criticism. Have a good night everyone! ;)
 
There were no flashers on the bike? Weird, cause my bike is the same year as yours and there were no flashers, but the relay was still installed. But I agree that there's no sign of turn signals on the wiring diagram, except for the indicator light. Anyways, I know you said you wanted to keep the original switches, but if you change your mind, you should have a look at the posh mini switches : http://www.posh-factory.com/product.htm (scroll down). I put these on my build and they look really clean. Kind of a bitch to install, but once it's done, it looks awesome and you can really choose the setup you want.
 
Lee Van Cleef said:
There were no flashers on the bike? Weird, cause my bike is the same year as yours and there were no flashers, but the relay was still installed. But I agree that there's no sign of turn signals on the wiring diagram, except for the indicator light. Anyways, I know you said you wanted to keep the original switches, but if you change your mind, you should have a look at the posh mini switches : http://www.posh-factory.com/product.htm (scroll down). I put these on my build and they look really clean. Kind of a bitch to install, but once it's done, it looks awesome and you can really choose the setup you want.
The PO had it set up more as a dirt bike, so no lighting. but the flasher is in there, as I found once the harness was off and in my room. I haven't exactly decided what to do as far as signals, but I do need to get some sort of switch for them. Did you buy the posh ones off of their website or a dealer? I'd kinda rather not have to buy things in yen from japan... Those are cool though.
 
Brainfart...

So, remember how we thought it was stamped as a 1982? funny story there. Upon receiving my Clymer manual, it showed what each VIN should be year by year. So, mine IS a 1975, just number 1,982. ::)
Anyways, I'm in the budgeting/planning phase of the build right now. Wiring harness is almost set to be built, I'll order wires and connectors soon so I can start after thanksgiving break. Looking at buying either a CB360 or XS360 front wheel, to give me a way bigger drum, spokes, and an 18" front wheel. Also thinking about cutting off the big stock muffler and putting on a 17" reverse cone from DCC. If anyone is interested in the muffler, I'll sell it to you! ;) I'd rather not chop up the pipe since they're rare and all, but I don't want to spend the money to make a full custom header pipe and such. Maybe I'll just keep the stock exhaust until I have the money to do that...
Happy Thanksgiving Everyone!
 
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