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Update on my clutch basket... It turned out that the nut holding the balancer shaft was lose (finger tight) so the shaft had somehow loosened the nut? The clutch basket had around 1mm free play. I split the casings and replaced both main gearbox shaft bearings , and replaced the clutch basket for a better one. While the engine was in bits , i replaced the gudgeon pin , fitted new rings +50s soi gapped them 0.10 tho for a tight fit. The valves were reground and valve stem oil seals replaced. I locktighted the balancer shaft nut on and the main gearbox shaft bearings in also. I thought i had to shim out the main shaft with a 1mm shim steel washer to take up the play , but the new bearings took up all the play and the basket was a solid fit. (no wobble) I cleaned up the piston head and valve head , as to decoke them. Cams timed up and engine all tightened up n thrown back in running chassis. While i was waiting for my rings to arrive from fowlers , i smoothed out the intake ports. There is a small 2.3mm lip on the intake rubbers to the head, i filed out and smoothed with wet n dry to make the intake the same diameter hole as the intake port ( removed the sharp lip) on the ally part of the intake rubber. This gives you a bit better gas flow (throttle response) on the intake , on the higher rev range. My initial 50 miles ,(dropped oil after 20 , to check ) then replaced with new , the bike runs sweet. More power at less than quarter throttle , response is smoother, engine much quieter .. I recon once its run in , its gona fly... ugg

Hi Ive just rebuilt my 1985 XT350 motor , as i had to replace the main gearbox shaft bearing, i had to split the casings. This was done in a mates garage , n the only part i couldnt find was the decomp cable bracket on the clutch casing the cable sits in to engage on the kickstart. I cant find the bugger. so ive no decomp cable to help with starting. I find if i use the old method of finding TDC and pushing down ,then letting the kickstart come back up , a good kick n it starts fine 2nd or 1st kick cold ,or warm. Im going to eventualy fit a manual decom leaver on the handle bars , if im feeling weak , n just to help the motor start . But with full compression (my valves ground in and new rings fitted) i can still kick the 350 over fairly easy. Ive had a XT500 and 600 before so the lil 350 anit that bad. ugg

Hi i have a 1985 XT350 , my engine had a knocking sound , so checked valve clearances. They were in the specified settings. I then pulled the camchain tensioner out, this was working fine. My search moved to the clutch basket , as i recently replaced the plates/corks, and springs. I noticed that the clutch basket had allot of free play on the basket. Yesterday i removed the basket , and i found the main shaft has 2 mm play (as you pull it towards you) a small amount of up and down play. Also the cog on the left to the main shaft that engages the kick start mechanism is very worn , like it needs a washer to space it out? I suspect a worn bearing , but i cant see one on my manual? Im pulling the engine apart this weekend , top end and splitting casings, to see whats warn? I hope its just a bearing , not the crank. Ill know when i remove the piston . ugg

Hi just to add to this thread. Ive just recently stripped my XT350 down to the frame and the forks were leaking badly. Ive put new seals and dust seals on, only thing is im not sure how much fork oil to use? i could drain whats in , but they were pretty soft and didnt have much left in. also has anyone fitted a spacer to the top of the springs to stiffen up the damping? No manual yet, so am asking on here.. Thanks ugg

Hi ive just started my rebuild of my XT350 i recoverd from the scum who stole it. Its fully stripped down to frame and running gear. Im painting up my frame and have stripped the forks of the black household paint that was used to disguise the bike. looking to make it into a special, the frame has had the rear lugs chopped off that take rear foot pegs. planning to cut shape and recover the seat. The look is a mat/satin black mixed with shiney bits ....an old crosser with modern parts fitted. Dose anyone have an old dr, dt 125 or simalair headlight. ? I need a good light as im using the bike for work as well as dirt riding.. Am new to this pc stuff so dont have a clue how to put up a picture... Thanks ugg