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93 Yamaha XT 350 Project Bike

Purchased this bike on E-Bay.

Circlip came out of wrist pin, ruined piston & cylinder.

I cut about 4 lbs of miscellaneous tabs and brackets from
frame and swingarm before sandblasting.
Also removed 22 lbs of stock street stuff.

PURPOSE-Make a light as possible Baja crusier.

Cylinder, Head, and valve cover were bead blasted and painted.

AUTOMATIC COMPRESSION RELEASE-I removed this item as the
compression is only 9.5 to 1. I machined an alum plug, .02 larger
dia than hole in head. Heated head, froze plug and inserted into
head. When cooled staked plug into head.

SWINGARM MOD- I do this swingarm mod to keep chain adjuster cam in place
when axel is removed. Handy when fixing a rear flat tire in the field.
Swingarm is drilled and tapped for a 8 X 1.25 bolt with large head.
If you do this Mod, be very careful when tapping swingarm. The material is
very hard. E-Z to break tap.

PAINT USED-Primer,Krylon-Rust tough enamel, Frame-Krylon-Rust tough-Hamm-R,
Swingarm & Engine side covers-Dupli-Color, highheat-Aluminum DH1606, Engine-
Dupli-Color, Engine Enamel-Low Gloss Black DE1634, Exhaust Header,Dupli-Color High Heat Black DH1602.

FOOT PEGS-Stock 1 1/8" Wide- 2 1/4" Long
WELD-ON PEG WIDENERS- 2" Wide- 3" long

MODIFIED- chain from 428 to 520 chain

MODIFIED MAG COVER- to expose drive sprocket and added case saver.

Engine mounted in frame, skid plate bolted on and electric wire loom in place.
Exhaust and rear fender mounted.

Tail lite, brake lite, and license plt holder installed.
I modified a universal Acerbis tail lite to fit stock fender.

OIL SIGHT GLASS- These crack and leak when ridden off-road. Remove clutch
cover, remove sight glass, machine alum plug .002 larger than hole. Drill and tap
a hole (6x1)in center of plug. Heat cover in oven, freeze plug, insert in cover.

STATOR RE-WOUND-larger wire, more winds=100 Watt. 60 watt Halogen Bulb.

Add Alum covers to Mag cover and clutch cover. More rock protection.

Install 1985 Honda XR 350 Enduro Speedo.

Install DOT Clearence lites for turn signals. Have to solder ground wire and change clicker can .
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XT 350 Picture on E-Bay
XT 350 Picture on E-Bay
1993 Yamaha XT 350 Finished  Project
1993 Yamaha XT 350 Finished Project
XT350 Start of project
XT350 Start of project
XT350 Head & Cylinder removed when purchased.
XT350 Head & Cylinder removed when purchased.
Items marked with yellow cut from frame & swingarm.
Items marked with yellow cut from frame & swingarm.
More cut off items.
More cut off items.
Stuff removed, not to be replaced- 22 lbs
Stuff removed, not to be replaced- 22 lbs
Frame & swingarm ready for sandblast.
Frame & swingarm ready for sandblast.
Painted Frame &  Swingarm
Painted Frame & Swingarm
Auto Compression Release removed, Seal leaks with time.
Auto Compression Release removed, Seal leaks with time.
Bead Blasted-Ready for Paint
Bead Blasted-Ready for Paint
Barrel,  Head, & Valve Cover-Painted
Barrel, Head, & Valve Cover-Painted
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