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smokey 91 xt 350

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hey all, new guy here. just bought the bike a couple months ago with 11k, put about 400 miles on it so far. changed the oil when i got it, changed the air filter. its burning some oil, and smokes a bit. The smoking is very inconsistent, sometimes its real bad at cold start up and goes away, other times its not so bad at cold start and comes on a few minutes after. any ideas?

also need a right side panel cover if anyone knows of one.

I have been looking through the posts here and have found some similar threads, but didnt know if anyone had any other input

thanks in advance!

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Thanks PD, thats kinda what I have gathered, its a start anyways. what kind of job is this for a novice? I dont have a manual yet, but I have a clymers manual on the way. Im pretty mechanically inclined and thorough when i try something new. but i dont wanna screw it up bad.

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You can download a FREE manual from :

http://www.carlsalter.com/motorcycle-manuals.asp

That and the Clymer should get you through . And , of course , this site . :smashpc:

It's just nuts and bolts and a hunk of metal or two . Really , the top end is dual overhead cam , fairly simple .

Best advice I can offer : Be meticulous . Read the manuals before you pick up a wrench and keep them handy after . Lay things out in the order and position that they were removed in . If you don't have that much space , tag , tag , tag ...

Keep everything Clean .

Something else you should do is make sure the valves have good mating surfaces . With only 11000 miles , I would think only a light lapping should be needed .

Pay attention to proper torque on all bolts . Remember that you're working with soft aluminum that has to hold steel bolts .

And don't be afraid to ask us for help . 👍

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Just a torque wrench and a decent set of tools with sockets ( preferably 6 point ) and wrenches .

I use one of these and a piece of cut away tubing as a valve spring depressor :

17t_sm.jpg

I use a medium grit valve lapping compound .

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cool, thanks PD, just read your whole thread on the rebuild! very impressive! I will certainly "bother" you with any other questions I may have! Thanks for your help! i will update as I learn more once I get the manual and dive in to this tiny project!

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I have also read in other threads about "special tools" needed for valve adjusments on this bike? this is new to me. never dealt with adjusting valves? any hints? tricks? tips?

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Here's a video . It shows a CB750 valve adjustment , but the rules and procedures are the same . The shims and buckets are interchangeable between our '85 - '00 XT350s and the '79 - '82 CB750 - 900 Hondas .

Valve Adjustment :

DO NOT ROTATE THE CAMS WITHOUT A SHIM IN EVERY BUCKET .

Check all clearances ( cam lobe pointed straight away from the shim face ) and record them on a chart like the one below . Record the initial clearance in EXHAUST #1 & 2 top squares on the chart .

After recording the clearance , remove the underlying shims , one at a time . Measure it and put it back in the bucket . Record that initial shim size in the corresponding square . DO NOT ROTATE THE CAMS WITHOUT A SHIM IN EVERY BUCKET . If you do , serious bucket damage could and most likely will result .

Do the intakes as described for the exhaust . Just make sure you record the clearances and shim sizes in the correct squares . When you know each valves clearance and shim size , do a little math and figure which shim will work where and which will need to be exchanged for a correct thickness . Remember the correct clearance for the exhaust is .005" - .007" and intake is .003" - .005" . Considering how hot these XTs run , .003" seems a bit too tight . I run mine at .005" - .006" .

Hopefully , you have a good relationship with your local Yamaha or Honda dealer and better yet the shop manager . Ask if they will do a shim exchange . They probably have a box buried in the back of the shop and figure that doing an exchange might just get them some of your other business . Most shops don't do very many valve adjustments that use these 25mm shims anymore . The newer bikes use a smaller shim about the size of a large pea . So , it's not taking anything out of their pockets.

Here's the worksheet I use . I use this for my CB750 4 cylinder 16 valve . Just use the #1 & 2 squares . Keeping a record for future reference comes in handy when it comes time to adjust again .

IMG-1-1-1.jpg

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