1989 Yamaha XT350 Re Re Rebuild

I decided to finally rebuild the XT350 for the last time and go top to bottom and make sure everything is in spec.
Songs in the video:
Track: ROY KNOX x WTCHOUT - Shadows (Feat. Sviivan) [NCS Release]
Music provided by NoCopyrightSounds.
Watch: • ROY KNOX x WTCHOUT - S...
Free Download / Stream: ncs.io/RWShadows
Track: BH - Holding On [NCS Release]
Music provided by NoCopyrightSounds.
Watch: • BH - Holding On | Melo... ​
Free Download / Stream: ncs.io/HOn

[@todorow22]

Being an xt350 owner myself I have realized how important it is to kick it over just before compression stroke and not just randomly.

[@HardAngle]

Yep. I learned that as well! It seems if you just kick it randomly it'll never start, feel for the compression stroke and it'll start first kick.

[@coffeyscarburetors6437]

Same. Because of this thats how i start everybike now. Unless its my 85cc two stroke.

[@nicholasthomas9587]

Even more important on the XT500....

[@hondaxl250k0]

I run a tt350. The bigger better Xt350. These bikes eat pistons. And timing chains. I’ve had mine 15 years. Rebuilt about every 3 years. Now I ride it hard. But if you keep up on your timing chain and never run it loose they will run till almost 5-0 lb of compression. I had a Xt first. Way to light built for my kind of riding. Now the TT350 is a entire different animal same heart. And not neutered

[@HardAngle]

It definitely eats timing chains! Maybe I just ride too hard for it, it definitely acts like it lol

[@hondaxl250k0]

@@HardAngle nope. It’s a design flaw. I’ve been building these engines for years. The timing chains can’t handle the resistance of the valve train. So they stretch fast. I ride my 86 tt350 way harder than anyone could ride a Xt with out breaking it. 💯 design issue. Heavier chain would solve the issue.

[@HardAngle]

I wondered why it seemed I needed to tighten the timing chain about every 50 miles of trail riding. That seemed pretty excessive.

[@hondaxl250k0]

@@HardAngle that is a bit much. Sounds like bad /worn chain guides.

[@HardAngle]

The chain only has 100 miles on it but I can't remember if I ever did replace the chain guides when I rebuilt the motor. Might just pick up a new set to be safe.

[@erwinvb70]

I have a XT350 as well, totally worth the maintenance these bikes need. Not extremely fast, but so fun and relaxing to drive, always come back with a smile after touring with it for hours.

[@agentredbone1667]

I have an 84 xt350 that runs and rides good but the last guy who owned it took everything off that made it an enduro street legal bike. Basically it looks like an average dirtbike. I bought the headlight, speedometer and brake lights. I have yet to buy the turn signals. It's not a pretty bike but it's fun to ride. Does well in the trails. I only paid $400 for a running bike. Win win for me

[@HardAngle]

Great to hear, mine is still serving me semi well although there is plenty of signs it had a life of abuse before I got it, although I may jump it a few feet higher than it was designed to from time to time lol.

[@agentredbone1667]

@@HardAngle nice. I notice if I don't start mine up after sitting for a month it takes alot to start it. I think it needs carb work but the dual carbs make me not want to lol. I'm not a mechanic. I can change fluids and do simple stuff like replace parts but when it comes to carbs or taking a old part APART I tend to shy away from it. I mean...wtf...dual carbs? Damn you Yamaha lol

[@HardAngle]

Why use a 3 jet carburetor when you could use 2 separate carburetors to do the same thing they said lol. Mine also gets harder to start after sitting a month, I always shut off the fuel petcock when I park it and that seems to have made it much better though.

[@empireoflizards]

@@HardAngle I have an '88 XT350. The carb set-up can be frustrating. The main issue is the vacuum actuated diaphragm on the secondary...it tends to crumble apart after time. Also, the intake manifolds fail after awhile....the rubber boots separate from the aluminum flanges. Other than that, great bike. Just pulled it out of the back of the garage after sitting for over 20 years to see what I can do with it. Great vid, btw.

[@HardAngle]

@@empireoflizards Thank you! Also I had to replace the carb boots on this early on in my ownership of it, they were toast.

[@Flizzor]

I’m looking into a 88 kx250 for $800 in California do you think it’s worth rebuilding top end and cleaning the carbs plus a little more how hard is it finding the parts I need since it’s so old thanks for any help.

[@HardAngle]

I can't say if it will be worth it for you or not, but I can tell you this, as much of a pain as this bike has been to keep running and find parts for it, everytime I get it all fixed up to sell it because I'm fed up with it, riding it as a test always turns into a few hours of riding and then I can't see myself not keeping it, it has too much character.

[@hansonelectric6566]

Well done. thanks. Just curious how many miles you have on that?

[@HardAngle]

Currently the tripodometer shows 36 but can't remember if it has been reset since the rebuild but all those miles are in 1st gear in the woods. The bike itself has over 18,000.

[@josepeixoto3384]

man,i think the chain was too tight, (on the top,it was,maybe not after a few turns by the kick) and that would be bad news...it's easy to overdo with that manual tensioner, be careful, best to err to the side of a very little freeplay on that chain.

[@HardAngle]

I probably did overtighten it and being an old chain it drastically sped up the wear, since replacing the chain it has been running perfect.

[@FRANKENMOTO315]

Super good video. Thanks for making it, I learned a lot and it will help me put mine back together.

[@BriSouth]

Inspiring, never sell it

[@HardAngle]

Whenever it starts making my life harder I contemplate selling it but then I remember it's worth a lot more in sentimental value than it is monetarily and I get back to work fixing it lol. It's about due for another rebuild to fix the remaining mistakes younger me made.

[@callsign_x-ray]

i know this post is old but is there something on the right side case that holds the shift rode from moving back and forth?

[@nathanielkarle5309]

encouraging me to rebuild mine

[@HardAngle]

I was dragging my feet to do it again but now that I can ride it again when I want I am glad I did it.

[@chadgraves2618]

We learn from our mistakes ....hopefully

[@dfuss2756]

Love your projects. And the starter comedy. I hope you bring it down to run the trail. Good luck on the Truck rehab.

[@joaoc_PT]

Wow, for a chain to stretch that much, maybe it overheated a lot/lack of lube. Even with 30years, properly maintained parts do last. Then again, its an air-cooled, so its not hard to overheat. Huge luck with new valves. And good job, tks for the video.

[@HardAngle]

So far with the new timing chain the XT has been holding up well. Just hit 100 miles yesterday and that's all mostly 1st and 2nd gear riding around in the yard.

[@70sport37]

Your defiantly learning the hard way !

[@HardAngle]

It sure feels like it!

[@chriszbodula1894]

Would have like to see the timing chain alignment procedure. I have one of these engines I need to put back together

[@carlossierra194]

Get the manual from "Amazon " is available ,I have a 91 and it help a lot.

[@alexleggett6270]

He posted a new video recently where he had to rebuild it again and does a great job pointing out all the areas on the engine that have to be in alignment when installing the timing chain.

[@jean-francoispelletier2970]

Hy I'm a xt 350 owner 1998 I noticed you put an mechanical chain tensioner did your old one failed I here it's a weak link should I put one on mine or and oem automatic I got 16000km on mine and I'm doing am valve adjustment thank for your opinion and I liked your video jf.

[@HardAngle]

Yes my factory tensioner failed, the bike jumped timing 3 times and ruined a lot of valves. If yours still works you can leave it alone if you like as the manual tensioner does add an extra part to check on, but if yours has already failed it's a very cheap replacement.

[@jean-francoispelletier2970]

@@HardAngle I took mine out yesterday to inspect it looks very flemsy I think I will order a manual one from Amazon and install it before the oem one fails j.f.p.

[@geofox9484]

Always use a MCCT

[@fasstimes9122]

Are the carbs hard to tune on these?

[@HardAngle]

They are pretty straight forward, nothing too confusing.

[@AliMuhammad-sj1ib]

​@@HardAngle Hello, I've got the same bike and I can't find any information on how to set up the fuel lines on it. It just dumps fuel. Could you do a video showing how to disassemble and clean these carbs? Also showing how to put it back together. I would be grateful!

[@artbentley8594]

Hello, I have a 85 X-ray 350. Where do you get all your parts.

[@artbentley8594]

XT sorry

[@HardAngle]

Usually Ebay, but parts are getting so scarce at this point if I can't find them there my backup is to go to Google and look up whatever I need and get it from whatever website I can find it at.

[@sistertheresiafadhe787]

@@HardAngle ill be trying this too for my 350 xt my carb is leaking from the bottom

[@coffeyscarburetors6437]

When you had it bored over did you have to change your jeting inside the carbs??? I have the same exact bike year and all. My motor locked up from running lean and getting to hot. After looking inside with a bore scope i saw large scratches on the cylinder walls. Havent torn it apart but am debating it. I want to give it what it deserves, kinda same story as you bought it before i could drive but was in a bit better shape and it was my first bike.

[@HardAngle]

I did not change any of the jetting in the carb but it seemingly runs fine, has really good power. I wish they were water cooled, the XT engine gets VERY hot riding trails in 1st and 2nd gear.

[@tiagomonteiro2678]

@@HardAngle Don't kniw if you still own the bike but it's precisely that heat that will make the intake rubber/metal manifolds fail. They either fail both or one at a time. You will feel it of course. Tge other thing to pay attention is the exhaust curves. They can rust and break easily if not properly taken care of. The bike is pretty reliable until it get a bit abuse out in the woods and slow city traffic.

[@HardAngle]

@@tiagomonteiro2678 I do still have the bike, it seems to have jumped timing again. It would be pretty reliable if I would remember to check the manual tensioner once in a while. When I originally got the bike I had to put a new set of the rubber intake boots on as they were both shredded.

[@tiagomonteiro2678]

@@HardAngle I would use the original tensioner. The other thing to take in account is the cakibration if the valves. Remember that tappy valves are happy valves, but not so much. I sold the bike a long time ago. It left good memories and the performance was actually quite fair. But eventually it had to go. Careful with the extreme heat as it can generate a crack a the sparkplug thread.

[@4N2IN0JA]

Great video! I really need to get mine running again.

[@HardAngle]

Even for an old outdated bike it still brings a smile to my face to give the throttle a twist and bring the front wheel up!

[@4N2IN0JA]

@@HardAngle I love the bike but I am in over my head with it lol. I could never get it running perfect and I always felt like it was missing power. Now it’s impossible to start and compression test said 90, it seems like I need a new top end. I’m no mechanic and I don’t want to play as one and rebuild mine. Looks like it’s going to shop. I just want to ride it again at this point. Have you had to replace the diaphragm in the secondary carb? I can’t find a replacement.

[@HardAngle]

I haven't had to touch the 2nd carb at all yet thankfully. Unfortunately though you are correct, any part at all for these old XT350s are becoming nearly impossible to find.

[@kevinragsdale6256]

did you need any special tools to get this engine apart?

[@HardAngle]

Nothing that I would call special. Just some Alan key sockets for some of the engine bolts.