1976 XL 350 Vintage Baja Project!

[1962siia]

wow, pics of carnage are great ... in focus and close up, can really see on-line ...
the con-rod pic is simply beautiful ... there’s art for you ... just cell phone pics?

does EdCo not mess with cams? seem to recall he fixes all sorts of damage on our KLRs ...

won’t say anything about your front suspension plans ... :thumbup:laughing

love your restoration threads ... :ride

Thanks J. Yeah IphoneX does ok I guess. I am not sure if edco can fix the cam or not but megacycle (who made the cam) is in San Rafael so figured I'd just take it to them. Maybe I'll just drop it all at edco.

So let me know your opinion on the forks. I can take it. :thumbup:ride

 

[1962siia]

One of the best threads going right now! :thumbup

:love


Here is a 1980 cr 250 on cl with 1985 forks that look pretty much identical to the '87 forks I want.

https://bakersfield.craigslist.org/mcy/d/bakersfield-1980-honda-cr250-elsinore/6869178343.html

 

[SFMCjohn]

So let me know your opinion on the forks. I can take it. :thumbup:ride

the ‘76 is going to have such a better life in your garage than it would ever have with me ... :thumbup

just talking personal set-up stuff ... usually like to
leave my bikes stock ... if I ever got a stock ‘70 SL350 for Baja
I might try to set it up with racing mods from 1970 but
don’t think I’d ever put later model triple clamps on ...

you’re a better wrench and rider than I’ll ever be,
so mods you’d like wouldn’t make sense for me ...
I’m always happy to just ride slower, not that I’m anywhere
near the limits of stock ‘76 suspension ... :rolleyes

also fun to think about your carnage pics, which look
like the sort of damage I’d expect from a high-compression
big-cam air-cooled engine ... wonder if we’d have seen
the con-rod wear or head gasket issues with a similar mileage/use stock engine ...?

the coolest thing in the world is to see a well-loved
bike being ridden ... mods don’t really matter then ... :gsxrgrl

 

[1962siia]

I agree with keeping things stock in general but since it’s already in a custom frame I’m feeling a bit liberated to do what I want. I’m not going to stick usd gixxer forks on it though. :laughing

The cr250 fork mod was common. Still torn about 78 or 87 forks. I think I can get away with the cartridge forks and still look period to those who care (me included to some degree)! Anyway thx for following along and weighing in. :thumbup

Speaking of carnage my garage chaos finally got to me so I’m trying to reorganize and find a home for all the extra sprint stuff and make a space for the xl engine on the bench. Anybody need a Landrover project?

 

[1962siia]

One more pic of the wheel weights.

 

[1962siia]

So I pulled the engine out today and pressure washed the frame. Can’t decide if I should figure out the suspension first or send the frame out for powder coating. I think I’ll deal with the suspension and give myself some time to figure out if I need to weld anything on the frame before it gets powder coated. Thinking about a chain guide. Also found a broken engine mount. I hope it’s a stock Honda piece so I don’t have to make one.

 

[ThumperX]

Sexi Thang!!

 

[OldGuy]

That's some pretty serious carnage. Someone must've run it out of oil; these things are pretty indestructible.

Megacycle is the cam source for these. I think they can hardface your core; worst case, they'll have new replacements available in various grinds. FWIW, I had the middle of three grinds in mine... pulled great everywhere in the rev range. Rockers might be more of a challenge... they were unobtanium for years, and guys were welding up and refinishing the old ones. I heard a rumor a few years back that someone was manufacturing them again, but never confirmed.

I'd go with the newest forks that won't compromise the aesthetics. The Yamaha double-leading shoe drum is the hot setup; works well for a drum, relatively lightweight.

The motor mounts are C&J, not Honda OEM. They're still in business, so you might be able to score an NOS one. If not, it's a simple piece for any machine shop to replicate.

 

[1962siia]

That's some pretty serious carnage. Someone must've run it out of oil; these things are pretty indestructible.

Megacycle is the cam source for these. I think they can hardface your core; worst case, they'll have new replacements available in various grinds. FWIW, I had the middle of three grinds in mine... pulled great everywhere in the rev range. Rockers might be more of a challenge... they were unobtanium for years, and guys were welding up and refinishing the old ones. I heard a rumor a few years back that someone was manufacturing them again, but never confirmed.

I'd go with the newest forks that won't compromise the aesthetics. The Yamaha double-leading shoe drum is the hot setup; works well for a drum, relatively lightweight.

The motor mounts are C&J, not Honda OEM. They're still in business, so you might be able to score an NOS one. If not, it's a simple piece for any machine shop to replicate.

Hey OldGuy-Thanks for the good info. When I first drained the oil, the screen was full of what looked like organic debris. I cleaned it up but yeah this thing had a hard time before I got it.

The rockers dont actually look that bad considering how damaged the cam is. I'm pretty confident they can be cleaned up and used. One of the tappets is rough so I'll replace it.

I went to a local salvage yard to look for forks yesterday. They didn't have what I'm looking for but my first swap attempt will be 86-88 43mm cr125,250,500 showa cartridge forks. I think they will look normal, have the travel I want and work great. I'll wait for shocks until I have the forks figured out.

I haven't made much progress this week because work was too busy and Virginia City Grand Prix is this weekend and I've been focused on getting ready for that. Next week I'll get back on this project.

Oh and good call on asking C&J about the engine mounts. Worst case I'll make them myself.

 

[Junkie]

I was gonna offer to give you a hand with the motor mounts if needed as they appear to be a pretty simple part, but it sounds like you have the ability to DIY.

I'd go with the skinniest cartridge forks you can find, for looks. Not sure what that means though.

 

[OaklandF4i]

My opinion on a 12" travel VINTAGE Baja bike entry this winter with cartridge forks? Cheater......

What is Scott's DT1 going to have, like 4"? Though I think travel is going to be the least of his issues. :laughing

I still think 8-9" might look better and be mid 70's appropriate for modified long travel. :x But we arent going to have a committee judging bikes for vintage authenticity. Your fellow riders might have less respect for you. :laughing arty You may have a gaggle of two strokes block passing you all the way to the bar in Baja this winter. :teeth

Husqvarna project will begin in June if not sooner........

Vintage Baja dirt trip. What could go wrong? :wow

 

[1962siia]

Thanks Junkie. I’ll be able to handle the engine mounts. I’m pretty sure these 43mm showas are going to be the skinniest cartridge fork with the long travel I want. eBay here I come.

I stopped by megacycle cams today and spent half an hour or so chatting and getting awesome info. Looks like my cam was made by Kenny Harmon back in the day. My head also has stiffer valve springs. I’ll be getting a new cam from megacycle and they will machine my head to fit the cam. The rest of the cylinder and head work I’ll leave to EDCO. Hope to drop it all off later today if I can.

Just FYI the folks at megacycle cams were super helpful and spent time with me to help me pick out the right cam for my bike and were just full of knowledge and were super friendly. Thanks!

 

[1962siia]

Top end is at EDCO! Next up split the cases and determine what needs to be done there. Probably crank rebuild at the very least. $$$

 

[OldGuy]

The rockers dont actually look that bad considering how damaged the cam is. I'm pretty confident they can be cleaned up and used. One of the tappets is rough so I'll replace it.

My opinion on a 12" travel VINTAGE Baja bike entry this winter with cartridge forks? Cheater......

I still think 8-9" might look better and be mid 70's appropriate for modified long travel.

You might want to ask Megacycle for a second opinion on the rockers. You don't want to compromise your new cam!

I ran the Simons with 12" travel initially, but the geometry was less than optimal. Even after Phil Douglas shortened them for 10" travel, had 'em ~3/4" above the top triple clamp.

That thing should be a hoot when it's done! :thumbup

 

[1962siia]

Somehow I missed Oakland4fi’s message! One Honda 4t vs random 2t’s in Baja? We shall see who gets to the margaritas first. :laughing

I had megacycle look at them this morning. Also had edco look at them and I said replace them if there is any concern. My guess is that they will be replaced. Also ordered all new tappets and valve springs, etc. Nothing will be skimped on with this build.

So OldGuy before you had the forks shortened what length shocks were you running? I’m thinking I’ll get the forks I want and then have race tech build appropriate shocks. I don’t really know anything about all this stuff but I want the long travel and I want the thing to handle well. I’m also seeing this thing running LAb2V, Sheetiron as well as Baja.

 

[OldGuy]

So OldGuy before you had the forks shortened what length shocks were you running?

Well, it's been about 35 years (!) since I ordered 'em from Kirk Wittorff at Santa Clara Cycle Salvage, when they were still in the original storefront on Halford. Am I dating myself? :laughing If memory serves, I kept the same length as the gas S&Ws, which looked exactly like the ones you have. If you go too long on the shocks, the swingarm angle gets wonky; you don't want to go overboard. I think I had between 9" and 10" travel in the rear, and I never bottomed it. The quality of the travel is more important than the quantity.

Also, if you're not running a chain tensioner, you're going to want to add one. Mine was an Up-Tite. You can see it in the lower right of the attached pic.

 

[1962siia]

So the bike is all torn down. I found a set of 43mm Showa cartridge forks from a 1988 cr250. The top end is at edco getting the full Monty. New cam, new rocker, bigger valves, new seats, new piston, new cam chain.

I bought a second bottom end and will be using the crank from it because it seems tighter better but edco will be inspecting it to be sure. They will also be helping me set up the engine for an oil cooler.

Next up is finding a modern chain guide and welding tabs on the swing arm for it and then it will go to the frame will get fresh powder coat!

Then the triple clamp machine work will happen to mate the cr250 triple to the 1” ID stem bearings. I tried to find bearings that would fit the cups in the frame and the 26mm stem but they don’t exist. Stem will be shortened and turned down to 1” instead.

That will leave wheels and shocks I think. Getting there!

 

[ThumperX]

So the bike is all torn down. I found a set of 43mm Showa cartridge forks from a 1988 cr250. The top end is at edco getting the full Monty. New cam, new rocker, bigger valves, new seats, new piston, new cam chain.

I bought a second bottom end and will be using the crank from it because it seems tighter better but edco will be inspecting it to be sure. They will also be helping me set up the engine for an oil cooler.

Next up is finding a modern chain guide and welding tabs on the swing arm for it and then it will go to the frame will get fresh powder coat!

Then the triple clamp machine work will happen to mate the cr250 triple to the 1” ID stem bearings. I tried to find bearings that would fit the cups in the frame and the 26mm stem but they don’t exist. Stem will be shortened and turned down to 1” instead.

That will leave wheels and shocks I think. Getting there!

I have a sexy set of wheels off the ATK, don't know if they can be modified for tis project but you are welcome to them.

 

[1962siia]

Ok so four months later the top end is done! Not anyones fault just took that long to get cam made, locate parts etc. Good news is the crank from the spare motor is good according to edco, so now its time to put this thing together! Woot! Might take a few weeks while I finish up the triumph project but I'll be getting back on this one asap.

 

[295566]

I'm so envious of your toys. Also, thank you for these build threads and giving us something to drool over! :drool