Ben's MT350 Rebuild

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neoxerox

Re: Ben's MT350 Rebuild

Post by neoxerox » Wed May 16, 2012 10:47 pm

Finally some real work on the bike!

Lets see; I've done all the wheel bearings including rear sprocket bearings - all now new Koyo's. Interestingly only about a third of the bearings taken out were actually knackered....

Replaced the rusted exhaust studs on the engine, putting the new ones in I nearly scuppered the whole thing by slipping one of the exhaust nuts nown the exhaust port :shock:

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A little bricking myself moment but got it out fine with some MIG wire - I'm just glad it didn't go any further...

Putting the CDI/coil on I found the tags to be missing, got some replacements welded on and red-oxided up - don't worry i'll be going over in the green ;)

Got the rear rack, mudguard, footpegs, airbox, carb and battery box all in too with a new nuts/bolts and a new carb rubber (Thanks shop keeper Mel!). New pads in both calipers and ready for new fluid once the bars are populated. Waiting on a new rear brake pedal switch too. Forks are back on, as is the front wheel with a metzeler enduro 3 tyre on it - turns out mine weren't road legal marked and tbh were a bit agressive for the majority of what i'll be doing. The wiring for the rear lights/indicators has been made up and attached to the original cut loom.

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The rear tyre has also been replaced, but in the process I ended up ham-fistedly destroying the inner tube (5 groups of holes! :oops: ) - that's when I looked up how to change a MOTORBIKE tyre and wacked some fairy liquid and a bit more care on the next one - that went fine. Rear wheel is now ready to go on!

One final thing - I got back today to find a nice litte custom bit had turned up :D :D :D :D

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The dash plate back from the anodisers looking great in satin black - Should have the dash wired/bolted in this weekend hopefully!

Right that's it for now - more to come following the weekend, and more pics!
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Xerxes2K

Ben's MT350 Rebuild

Post by Xerxes2K » Thu May 17, 2012 8:31 am

Dash plate looks real nice!
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neoxerox

Re: Ben's MT350 Rebuild

Post by neoxerox » Fri May 18, 2012 8:47 pm

Quick update, today i made a new rear brake pushrod from an M6 bolt turned down, new clevis pin too. Attach them to the bike tomorrow!

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Bunker
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Re: Ben's MT350 Rebuild

Post by Bunker » Fri May 18, 2012 8:51 pm

Nice job there Ben
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neoxerox

Re: Ben's MT350 Rebuild

Post by neoxerox » Sat May 19, 2012 10:59 pm

Got the dash mostly sorted today.

Bolted a little recess bracket to the speedo
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Used the dash as a guide to drill the mounting holes in the original plastic

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Cut away the unwanted original dash plastic, leaving 5 plastic tabs to bolt the new plate to (tidied up since this pic a bit)

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Then populated the dash

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neoxerox

Re: Ben's MT350 Rebuild

Post by neoxerox » Sat Jun 02, 2012 10:27 pm

Forgot that i've not posted here in a while.

Things are moving again, now done:

Rear wheel is now on
New x-ring DID chain on
Front and rear calipers on
Brake lines routed (still not sure on the rear routing though - it looks a little close to the exhaust - can anyone shed some light on the "proper" routing - I have an aftermarket hose that has no metal sections...)
New rear brake pin & combined banjo/switch on
Exhaust rubbed down, painted with stove paint and front section on with new Mikalor clamps (waiting on the rear to cure before putting that on)
New throttle cables on
Aluminium fork spacers machined and in
Fork oil in
Engine oil in
Spark plug fitted. Also new non-metal plug cap fitted.
Some wiring done

Had the engine going last week too - though foolishly we hadn't put all the electical earths on so once it started the kill switch didn't work (read wasn't connected...) cutting the fuel stopped it alright eventually though! Oops! It was good to hear it going though.

Still to do:
Wiring...power, RPM and wheels revs to new dash. Get all controls and lights working, wire up starter properly (rather than jumping)
Fit new headlight (after smashing the original :( )
Bleed brakes
Make clutch adjuster adaptor and adjust clutch - maybe new cable
Rub down & spray barkbusters, and fit.
Find an ignition barrel retaining nut...there wasn't one with the barrel when i bought it.
Glue magnet to wheel and hall effect sensor to fork leg.

Finally I've had a set of rear pillion bars sent to me by Gary (Worz) - Many thanks! These i'm going to weld some pannier racks/plates before fitting. They should serve as support for a set of canvas pannier bags i've bought or let me ratchet strap dry-bags to them. I'll be building them strong enough to mount rigid panniers to in the future if I end up taking that route too.
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neoxerox

Re: Ben's MT350 Rebuild

Post by neoxerox » Tue Jun 05, 2012 10:47 pm

One step forward, two steps back yesterday...

Got the bike to this stage

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All the wiring done and working, exhaust on, brakes bled...then she wouldn't start up :(

Fresh fuel and a battery charge later...still no luck. Checked timing, strong spark, took off the air filter etc finally it looks like there's something up with the carb (despite having started last week) so that's now off for a full rebuild - gasket kit on its way!

In better news i'm bidding on a couple of random pillion/rear seats of various bikes with the intention of sorting a QR pillion seat for the front half of the rack.
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neoxerox

Re: Ben's MT350 Rebuild

Post by neoxerox » Sat Jun 09, 2012 1:31 pm

Carb is rebuilt now - there was a fair amount of sh*t in it!
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Replaced parts
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It'll go back in the bike later today or tomorrow and we'll go from there
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neoxerox

Re: Ben's MT350 Rebuild

Post by neoxerox » Sat Jun 09, 2012 10:32 pm

I managed to get an hour in on the bike this evening and the rebuilt carb seems to have done the trick...video below!
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There's no airbox on and the throttle's not linked up yet since this was just to make sure it was flowing. Finish up the rest tomorrow :D
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neoxerox

Re: Ben's MT350 Rebuild

Post by neoxerox » Sun Jun 10, 2012 9:25 pm

Got the airbox and battery tray back in today, along with the wiring for cigarette lighter power socket.

Then I made a start to the rear pannier racks. I've got a couple of 58 webbing rucksacks with straps, I just wanted something to keep them away from the shocks/wheel/exhaust.

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The bits that stick out the back have a nut welded to the inside, and a bar will be made up to bolt between them. This should stiffen everything up. It's bolted rather than welded to help keep the parts "flat-pack" if I want to take them off for any reason in the future. If this all looks a bit too square then i'll cut back the protrusions and make a angular U shaped piece that'll bolt in.

They'll be rubbed down and painted (maybe in satin black for the time being rather than green but i'm not sure yet...) this week.

Once the headlight adjusters turn up I can get that in and then I think it's pretty much off for an MOT.
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