Author Topic: Project X 350CC conversion  (Read 13073 times)

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Offline Paul Dawkins

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Project X 350CC conversion
« on: March 03, 2013, 07:08:06 PM »
I have been working on this for several weeks and I have been updating this thread in the mods room.
Now its finished I have added it here.
Remember its taken several weeks but I have added it all to one post

So here goes.



So i thought I would make a start with the 350cc conversion on Projecr X
First was to remove the fuel take and drain the gearbox oil, with this done I thought it best to change the air filter to save doing it later.

So out with the old.



And in with the new.



I was surprised how rough the old one was for 2000 miles.



Job done.



Then I thought I would remove the knackered battery, this is only 2 years old but has always been a problem so a new one was ordered.



I removed the battery box just to check to see if there are any electrical problens and I found this.



I am wondering if this is the cause of our battery problems.

Heres the new battery ready to fill, £20 posted from ebay.



Thats enough for now.
RDnuts is coming round later to give me a hand



So after talking to RDnuts about this back in the summer and various discussions on the forum we figured out what we needed.







Heads
Barrels
Piston kits
Oil pump
Primary drive
Clutch basket
Rev counter drive
Gasket kit
Oil
Spark plugs

While we are doing the conversion I thought I would also change the oil lines for clear pipe and service the bike.

I have already removed the tank, drained the oil, removeed the kick start and removed the side casing.

RDnuts has arrived to give me a hand so a good few Bacon butties and we aere ready to start.



So we need to undo the primary drive and cluch basket, this is dave little trick, stuff a cluth in the cogs to hold it tight.







Now ready to undo the primary drive





Then the clutch







Daves clutch holding tool (I must get one of these)







Primary drive and cluch basket removed now time to change the tacho drive wheel for a 2r9 (400E version)
This has one extra tooth and  different profile tooth but it fits straight on.
Note the different pre-fix numbers 2R8 for the old one and 2R9 for the new one (Donated by moist)





Now fit the 350A/B primary drive.



Then the clutch basket







Set the torque wrench to 56 FT LBS



Jam the cloth in the bottom this time then torque up the cluch and the primary drive.





Re-fit the clutch plates in order.







Fit the coller and springs





Now swap the oil pumps over





















We may as well do the plumbing while the case is off.





Smear a drop of grease over the gasket to hold it in place.



Refit the case.



Refit the kickstart



Prime the oil pump This is much easier on the A/B pump with the priming wheel.



Fill up with gearbox oil.



Thats the botton end done.



The 350cc top end has gone off the Norbo for blasting, rebores and painting and as soon as I get them back RDnuts and myself will start that.

In the mean time I need to contact Zeeltronics to see if they have a map for the 350cc conversion.

Jobs still to do are.
Cut the airbox flute out, fit the new top end, refit the battery, re-jet the carbs then when its all done I need to re program the Zeeltronics with the computer.

Then run it in AGAIN ???




Now Norbo has delivered the barrells and heads so time to sort the top end.

Removed the heads





Then the carbs and barrells



Swop over the reads.


New gaskets used.



Clean up ready to fit the new base gasket



Remove the old 250 pistons.



Heres the new 350cc pistons ready to go in






Time for a tea break now.



Little end bearings arrived in the post so time to make a start



Fit the rings



Fit the pistons















Add a bit of two stroke down the barrel.



Refit the oil pump cable and torque down the heads



Next job was to fit the exhausts when I found the colleres on the 250E barrels will not fit on the 350 barrells so I have spocken to Martin Newlyn and he is making us a new set so until they arrive I cant do anymore.


These arrived in the post yesterday



So I went out in the garage early Sunday morning to finish her off.

I gave the pipes a good clean with WD40





New gaskets, I greased these so they stayed in place.



I managed to fit the right hand pipe but the collar is very tight to the engine case but I just went in.



Now for the left hand pipe, not so lucky, the collar is a bit big and hits the engine case, this is because the angle of the new barrels, problem is martin made the collars without having the bike so it was just guess work really.



There was only one thing for it, get the grider out and grind it down a few MM





It fits now





Looking good



If you have not got one of these spring pullers in your tool box then you really need one.
Its one of my favorite tools.



The bike is now finished but she needs a clean.
I wash all the black with WD40



Then polish all the shiney stuff with Autogleam polish.



Project X looks like new now.









I am not running it up until I have RDnuts comes round and we will have a play with the Zeeltronics.

When it is running well I will rtide it down for the MOT.

Thanks must go to RDnuts for his expert knowledge on this conversion and spending many days round my workshop do it.

Norbo for supplying all the parts at cost and donating some money to it as well plus the work he did painting the barrels and heads.

Martin Newlyn for making the new exhaust collars.

Moist for supplying the head.

Mrs Dawkins for the many bacon butties for RDnuts and myself.

I will update this in the week when she is running.

« Last Edit: March 04, 2013, 06:59:34 AM by Paul Dawkins »
Southampton

Offline mervin

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Re: Project X 350CC conversion
« Reply #1 on: March 03, 2013, 07:16:11 PM »
Great Stuff Paul !!!!! :) :) :) :)
Motorcycling is not, of itself, inherently dangerous. It is, however, extremely unforgiving of inattention, ignorance, incompetence, or stupidity"

Offline chrisg.007

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Re: Project X 350CC conversion
« Reply #2 on: March 03, 2013, 07:37:47 PM »
Hi Paul, Project X is Lookin' good.
Have you decided what jets you are going to fit in the carbs yet?
chris
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Offline Paul Dawkins

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Re: Project X 350CC conversion
« Reply #3 on: March 03, 2013, 07:43:18 PM »
Thats RDnuts department.
We are going to start with standard 250E jets and gor up,or down from there.

Dave is a genius when it comes to setting up.
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Offline davecumbria

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Re: Project X 350CC conversion
« Reply #4 on: March 03, 2013, 07:53:19 PM »
A lot of work in a very short post  Mr Dawkins & Mr Higgins, many thanks to you both for your hard work!

....did you crackle her up??
Growing old is inevitable, growing up is optional

Offline Colin987

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Re: Project X 350CC conversion
« Reply #5 on: March 03, 2013, 08:33:55 PM »
Interesting - have fun running it in!

What grease did you use on the small-end bearings?  I just smear mine with 2T, on rebuilds.

Colin
RD250A

Offline Paul Dawkins

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Re: Project X 350CC conversion
« Reply #6 on: March 03, 2013, 08:40:09 PM »
Interesting - have fun running it in!

What grease did you use on the small-end bearings?  I just smear mine with 2T, on rebuilds.

Colin

I wont be running her in, thats someone elses job.
I did it last time.
Plus I have 4 bikes of my own that need running in.

Southampton

Offline speedfreak

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Re: Project X 350CC conversion
« Reply #7 on: March 03, 2013, 08:55:42 PM »
looking good Paul :)
i notice you haven`t changed the barrel studs, i had problems with mine and ended up buying the longer studs. :-\
If you can't fix it with a hammer, you have an electrical problem.

Online GAZZATT2

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Re: Project X 350CC conversion
« Reply #8 on: March 03, 2013, 09:06:03 PM »
well done
Paul
Rd nuts
Norbo
Martin Newlyn
Moist
XSR900  350lc 400F 400f special 400F project
it did look good in a photo lance ?
Picture026" border="0

Offline mr sheene

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Re: Project X 350CC conversion
« Reply #9 on: March 03, 2013, 10:12:34 PM »
Nice job guys ;D
2 Strokes rule in worksop notts

Offline Paul Dawkins

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Re: Project X 350CC conversion
« Reply #10 on: March 04, 2013, 07:02:23 AM »
looking good Paul :)
i notice you haven`t changed the barrel studs, i had problems with mine and ended up buying the longer studs. :-\

Now theres another story mater

When we remobved the old head we found 7mm spacers under each bolt.

Turns out Project X had the 350cc conversion someone else in its life and was converted back.

That was a stroke of luck for us.

 So we removed the 7mm spacers and job done.
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Offline old rd user

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Re: Project X 350CC conversion
« Reply #11 on: March 04, 2013, 09:37:29 AM »
good work chaps , cant wait to see and hear what she goes like with the 350 bits on and tell dave to not have too many bacon butties as it will give false carburation settings  :)

Offline Norbo

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Re: Project X 350CC conversion
« Reply #12 on: March 04, 2013, 09:46:21 AM »
Nice job fellers. i think the next job would be some spokes and twin disks what do you think .

Offline Paul Dawkins

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Re: Project X 350CC conversion
« Reply #13 on: March 04, 2013, 12:48:22 PM »
I like the idea of twin disks but not for at least 2 years.
We need to get some miles on her now.
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Offline 5port

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Re: Project X 350CC conversion
« Reply #14 on: March 04, 2013, 05:52:13 PM »
Good work, interesting to see how it goes.  How much are you going to modify the airbox rubber, or fit a RD400 one?  Did you choose  31K type pistons for a reason?
Cheers 
5port