604e Project

[Mr Shiney]

I am about to embark on converting one of the 350's I got recently into a 604. ANy advice gratefully appreciated. I am particularly interested in any mods required to mount it, carb choice and exhausts. Will the standard exhaust down pipes and mid section fit? I am looking to have the SS rear section modified by Apophis to one that breathes well. Are all the electrics the same, CDI, coil etc?

My plan is to build and use this bike for the Morocco trip.

[DSG]

Plenty of padlocks and somewhere to carry a baseball bat - perhaps one of the long tubes!

Good luck

Dave

[Franc]

Hi Shiney....
My 604 runs with standard harley carb (42 slow jet, 185 mainjet).
Standard pipes front to back....with the baffles knocked out, and the exhaust head collers reversed to clear the head, airbox mod done, standard airfilter.
Bike starts and runs very well, maybe not max power but I don't have megabucks to throw at it, and I figure as long as its running I can upgrade bits as and when I can afford it.

[Mr Shiney]

Thanks Franc, did it just bolt directly in?what sprockets did you use?

What range do you get on a standard tank?

Is the 185 jet the standard 350 jet? The 42 is the one that people put into improve warm up?

Cheer steve

[mustaphapint]

I started with the 350 carb, exhaust and airbox. I swapped to a Del Orto because it was easier to tune. Then I junked the airfilter box and fitted a freeflow filter, but you could still tell it wasn't breathing as well as it should.
Mine's a 640 though as it was cheaper to fit a big bore kit than rebore and fit a new 604 piston.
I recently fitted a full exhaust system from Apophis with the larger diameter pipes and that made a real difference.
Next step is to have it dyno'd where Mr Kay and Bunker took theirs.

[Green Goblin]

Ive not done this my self but arn't there some spacers /reducers in the 350 you have to put in the 604 for the swing arm shaft.

[ZIP TIE]

Ive not done this my self but arn't there some spacers /reducers in the 350 you have to put in the 604 for the swing arm shaft.

Good point yes there are some top hats that press into the cases to accomodate the smaller spindle.

[Mr Kay]

Ive not done this my self but arn't there some spacers /reducers in the 350 you have to put in the 604 for the swing arm shaft.

There are indeed. There are a pair of 'top hat' bushes that fit into the swingarm spindle hole to reduce the dia from 16mm to 14mm. These take a fair belt to knock out and often require heat. Once the bushes are seated properly in the 604 on the bench, assemble the swinging arm on the back and tighten the spindle. The spindle should move freely up and down but with no side to side play, you may need to mess with the shims that sit between the spindle and the journals.

edit: too slow...

[Mr Shiney]

Where do I get those spacers from?

My plan is to bin the air box and fit a K&N directly as this one won't be a wet off road bike.

I have a mikuni that came off a 604 but might stick with the Harley carb for a start.

Anything else?

[ZIP TIE]

Where do I get those spacers from?

The 350 motor.

I have a mikuni that came off a 604 but might stick with the Harley carb for a start.

I'd use the Mikuni. (What size is it?)