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corky1 | profile | all galleries >> Galleries >> 93 Yamaha XT 350 Project Bike tree view | thumbnails | slideshow

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
Swingarm Pilot Hole
Swingarm Pilot Hole		 Bolt Holding Chain Adjusting Cam
Bolt Holding Chain Adjusting Cam		 Stock Foot Pegs & Weld-On Wideners
Stock Foot Pegs & Weld-On Wideners		 Foot Peg Mod 2 wide,3 long
Foot Peg Mod 2" wide,3" long
Left Side-Frame,Swingarm,Rear Wheel
Left Side-Frame,Swingarm,Rear Wheel		 Right Side-Frame,Swingarm, Rear Wheel
Right Side-Frame,Swingarm, Rear Wheel		 Motor-Left Side
Motor-Left Side		 Motor-Right Side
Motor-Right Side
Paint Used
Paint Used		 Changed to 520 Chain & New Sprockets
Changed to 520 Chain & New Sprockets		 SideCaseModified Installed Case Saver
SideCaseModified Installed Case Saver		 Engine,Skid Plate, & Electrics in Frame
Engine,Skid Plate, & Electrics in Frame
Exhaust & Rear Fender
Exhaust & Rear Fender		 Cobra Exhaust-Slip On
Cobra Exhaust-Slip On		 Tail lite & Lic Plate Holder
Tail lite & Lic Plate Holder		 XT 350 Sight Glass-Before
XT 350 Sight Glass-Before
XT 350 Sight Glass-After-No More Oil Leak-Remove Bolt to Check Oil Level.
XT 350 Sight Glass-After-No More Oil Leak-Remove Bolt to Check Oil Level.		 XT 350 Re-wind Stator to 100 watt output
XT 350 Re-wind Stator to 100 watt output		 Leftside Mag Cover
Leftside Mag Cover		 Rightside Clutch Cover
Rightside Clutch Cover
Rear Turn Lites
Rear Turn Lites		 Turn Lite Prep-Solder Ground Wire & Change Clicker Can
Turn Lite Prep-Solder Ground Wire & Change Clicker Can		 1985 XR Enduro Speedo
1985 XR Enduro Speedo		 XT 350 Left side
XT 350 Left side
XT 350 Right Front
XT 350 Right Front
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comment | share
stevie 29-May-2016 02:09
hey, do you guys know of any aftermarket forks i can get for my 89 xt 350? i heard rumors of using the old tt forks but are they better? i blow out seals like every month or two. i am very hard on it but i like the simplicity of the bike so i don't want to go newer. anything would help guys thanks!
kenny30-Nov-2011 17:57
Hi, I have an xt 350 and want to put a bigger engine in it. A 550 maybe anyone know if it would fit?
paul 03-Aug-2011 22:16
can anyone help me with the headlight and clocks with brackets needed for a xt350 1991. thanks
nick 23-Jun-2011 03:06
hey, i was wondering where you got that rear fender from? i have a 96 xt350 and i want to get a fender like that so it doesnt look as old.
Nathan Thornton 08-Oct-2010 04:39
Hey man would you be willing to sell those guages? i broke my tach on my xt 350, and dont want to pay three hunderd bucks for a new one.lol?
Greg 21-Sep-2009 14:00
I am rebuilding one of these xt350,s for a customer, I had .040 removed from the top of the cylinder, was going to remove .060 but decided to play it safe with clearances. wanted piston flush with top of cylinder without base gasket installed. base gasket being .020 and head gasket easily add valve clearance. After it was completed running no airbox with unifilters and rejetted, Owner was very impressed with throttle response. If you want more just use the .020 base gasket as a pattern and make your own base gasket out of .003-.020 to get your desired valve clearance.
John Owens 04-Mar-2009 18:35
Great site! Do you know the chain length 0n the 520 chain?

110,114,116 or 120
Andrew 05-Dec-2008 03:42
I just rebuilt the engine in my 89 XT350, but now I feel like I should have done the whole thing like you did when the engine was out! Nice work, dude. No suspension upgrades though? You must be happy with stock...rear tire on mine bottoms out like crazy. My 89 XT600 suspension does great in Baja, but the bike weighs a ton. A couple sites list the stock weights of the 600 and 350 both at around 330 pounds...I believe it for the 600, but it can't be true for the 350. What's your new dry weight?
zack 08-Sep-2008 16:09
I'm looking for a bolt on pipe and replacement plastics either OEM or aftermarket in black. The tank is metal so I'll just paint it. Any suggestions for either of these things?
darrell wellborn 03-May-2008 04:15
hey man great job were did you get the exaust from and what was needed to remove the decompresion lever also what was the chain and sprocket conversion from
chris 11-Apr-2008 03:21
anyone know how to install a rear sprocket on a xt350 i did it but it moves back and forth before it catches on the tire what do i do?
Marty Bennett 30-Jun-2007 17:59
What bike did you cross reference the sprockets from to get a 15 tooth on the front and a 48 tooth on the back, and a 520 chain? Was it another Yamaha, like a TT or something? The numbers that I got off of the sprocket in your pictures, the dealers couldn't cross reference them from the numbers on the pictures. I need to know the model of bike that you got the sprockets from so I can get them ordered. Thanks.
Lee 14-May-2007 13:06
Very nice! Where did you get the stainless steel can from?
Henry 25-Apr-2007 01:55
Awesome! I just bought a '04 XT350. Any ideas on jetting? I've never had a bike with a one/two primary/secondary carb setup. Thanks!
Kendall 16-Jun-2006 02:58
I'm interested in the 520 chain conversion and lower gearing for trail riding. What sprockets did you use?

Kendall
Mike 12-Apr-2006 21:30
Hey, i love the work u did to the bike!! i have a 1992 XT 350 and was just wondering a few things. First, would u be able to hook me up with a set of the signal lights u made up??? I was also wondering what could i do to give my bike a little more power?? And 1 more thing, were did u get ur exhaust system?? thanx alot
Joe 25-Mar-2006 07:42
can you please tell me the model number for the rear sprocket you have shown. I also want to upgrade my chain to a 520 .
Grammer 02-Feb-2006 23:25
Hey great job on the on the mods of and xt nice colour scheme. I fine this bike quite boring when it comes to power. What did it take to acquire and mods for the exhaust system?
John Horn 16-Dec-2005 19:49
Nice job!
Do you still have the old speedo/tach cluster?
Thanks...
John Horn 16-Dec-2005 19:49
Nice job!
Do you still have the old speedo/tach cluster?
Thanks...
Marty D. Dunn 13-Jun-2005 04:33
I love what you did to a much forgotten bike. I have a 91 XT350 and it has been a great ride. I made the 428-520 chain upgrade, lowered the gears a little, and put on a knobby tire. I also added a Clark tank to have more fuel. I changed out the turn signals with small ones like on crotch rockets so they would not snag on anything and I could still ride it on the road to and from the trail. My question is do you have info. or ideas on building a little more umph. into the motor if I was going to rebuild? Thanks...
Tonnsracing 17-May-2005 13:32
Corky great job on the bike man , looks first class all the way. I love the contrast of the black and aluminum on the engine. Nice job!
Jeff Young 25-Apr-2005 20:04
I have the opportunity to pick up a 1998 XT 350 with a blown engine. Owner says the oil pump failed and with no oil light, he didn't realize the failure until the engine seized. What do you think it would cost to have the engine rebuilt? What do you think the bike is worth as is? It is in good shape and only has 4000 miles. Thanks, Jeff Young
Jeff Young 25-Apr-2005 20:02
I have the opportunity to pick up a 1998 XT 350 with a blown engine. Owner says the oil pump failed and with no oil light, he didn't realize the failure until the engine seized. What do you think it would cost to have the engine rebuilt? What do you think the bike is worth as is? It is in good shape and only has 4000 miles. Thanks, Jeff Young
Ivan 25-Mar-2005 16:18
Great pics of the XT project. Good job. I have an 87 xt350 and I have kept it stock, but, I am interested in your sprocket/chain conversion. I really want a 17 tooth front and no one makes it for the xt. How did you find a 520 sprocket that would fit the xt? If I could find sprokets to fit in the right tooth combination 17/57 or so, I would also upgrade the chain so I could get rid of the 428 mini-bike chain that was stock!!
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