Resurrection – The ExhaustNotes Blog

The clutch cable on the RD350 was at max adjustment on the lever perch and the clutch action was a bit stiff so I removed the left side engine cover to clean things up. The cover locating dowel on the bottom was a little corroded so it took some wiggling and wobbling to get it free. Inside I was rewarded with an ignition/alternator assembly that looked nearly new. The screw heads are un-boogered and the cad plating looks like new.

I paid quite a bit for this motorcycle but it’s been worth it as the bike has seen very few ham-fisted sorties into the mechanical aspects of the thing. The sprocket area was well covered in chain grease so I needed to bag up the alternator and clean the area.

Cleaning the clutch release and countershaft sprocket area revealed that the parts were also nearly new. I dismantled the clutch actuator and cleaned up the cover.

I encourage others to leave original finishes alone but the left side cover was missing a lot of paint and had that white corrosion patina that speaks to poor maintenance. A rattle can of Rustoleum satin black matched the original engine color well so I gave it a little squirt. Note I did not polish the bare aluminum parts or touch up the points cover. That stuff wasn’t too bad.

While I had the clutch helix cover apart I decided to install a new chain. I’m not one of those, replace-it-all-or-you’ll-die, type of guys. If the sprockets look unworn I’ll slap a new chain on the old sprockets. I realize this is hearsay in the Big-Sprocket boardrooms but those guys are in the sprocket selling business. The RD sprockets look like new so don’t worry, it will be fine. One glitch was the old tire is a 3.75-18 IRC, the bike calls for a 3.50-18. The narrow swingarm of the RD can barely accommodate the extra ¼ inch. I had to adjust the chain a wee bit tighter than I like to keep the tire from rubbing the front of the gusset. That problem will be solved when I replace the tires.

The RD350 uses a 530-size chain; that’s a pretty heavy chain for a 350’s weight and power. Once these items wear out I plan on going with one of the many 520 chain conversion kits for the RD350. With small displacement engines you don’t want to waste power spinning a heavy chain.

After greasing the clutch release helix and clutch cable, along with the perch pivot the clutch is much smoother and easier to pull in. The RD350 is geared kind of high in first gear so you’ve got to give it some revs and slip the clutch to get it off the line without bogging the thing.

With the new chain and the clutch adjusted I figured I better get the bike legal because there’s no way I’m not going to ride it. I burbled down to DNA title services in Alamogordo with all my paperwork and it was a breeze to swap the title. In New Mexico we have privately run tag agencies in addition to state run agencies. The lines are much shorter at the private places and there’s an incentive to sell you a tag or they make no money. I had my choice of yellow, blue or black tags. I chose yellow because it’s old school New Mexico, like black tags are in California. The transfer, taxes and a two-year sticker cost $265 US dollars.

Arriving home from the title place there was gas leaking from the petcock. Close examination revealed that the hoses were leaking at the petcock barbs. I replaced the leaking fuel hose and added two huge fuel filters along with those springy, compression hose clamps. We will see it the leaks have stopped next ride.

I replaced the funky original Japanese swingarm and brake pedal grease fittings with normal ones that fit the grease gun everybody else on the planet uses. All of the areas were free breathing and took grease ok which makes me think they’re not clogged with hardened old muck.

I still have quite a bit of work to do on the RD350 but it’s rideable as is. I don’t trust the old tires, besides being too big the rear tire is very out of round and who knows how old the tubes are? The front end needs new oil and seals and the steering stem needs greasing. The rear shocks are like pogo sticks. I’ll get to it when I get to it, you know?

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Glenn sent me a few photos from the old days and one that got my attention was a shot of us building a Sportster in the living room of the shack we used to live in. Having a living room to work in was a luxury because prior to renting the shack I was homeless. I had an old Chevy truck with a bench seat that I could stretch out enough to get some sleep and I had a job that let me take a dry bath in the restroom after work. But when Admiralty Marine closed its doors for the evening I was on my own until the next morning. The boss let me know that the situation couldn’t go on forever and that I really needed to find a place to live.

It wasn’t so much lack of money. I was working a lot of hours, but I was only 19 and landlords didn’t want to rent to a greasy, punk kid. I can’t blame them. I would do the same thing myself. Finally a co-worker who was a full-fledged adult vouched for me when his landlord had a vacancy next door. I shaved, dry-bathed, put on clean clothes and did everything I could do to look like a respectable young man with a future. I’ll be dammed if it didn’t work. I was in after paying first, last and a deposit. Cash.

After waiting for the dust to settle the first thing I did was to rebuild my Sportster in the living room. When I bought the 1968 Sportster I was kind of shocked at how archaic the motorcycle felt. It was cool and all but the front end was so wobbly it felt like silly string and the front brake might as well have been deleted and an AM/FM radio installed in its place for all the stopping it would do.

The engine seemed to run well but I was going to ride across country on the thing, so a freshen-up was in order. I don’t know if it was a good idea because the 900cc V-Twin had some strange things going on inside and I was destined to do even more stupid stuff to the poor bike.

Someone had replaced the stock Harley intake valves with huge, unknown-origin valves. The valves were so big they had to cut the seat into the dome of the combustion chamber. Once the giant valves were removed the old seats were revealed along with the stock porting. The only advantage I could see to the big valves was a bump in compression ratio due to the valves occupying more space in the combustion chamber and the circumference increase giving slightly more flow when the valve first popped open. Once into the lift though the stock ports would probably be the limiting factor.

I wasn’t having any of it. I bought standard Harley valves and guides and set about putting things right. Admiralty Marine had a Sioux valve grinding kit so I could do all the work myself. After the seats were re-cut to fit the new valves the installed height was wrong so I had to trim the ends of the valves and shim the springs. The heads were a mess.

The Sportster’s high dome pistons were ok so a quick hone job and a set of rings finished off the top end. After that you’d think I’d leave the engine alone but I had to have a tin primary cover like the XR750 flat trackers ran.

Opening and consuming a whole ‘nother can of worms, I had to get rid of the crankshaft’s spring and ramp style compensating sprocket. The compensating sprocket absorbs the 45-degree V-Twin’s power pulses before sending smooth, less spikey power on to the clutch basket, gearbox and rear sprocket. This vital part stuck out way toofar for my tin primary so into the trash it went.

A solid front sprocket was fitted to the crankshaft and the tin primary would still not fit so I had to make a 3/8’ aluminum spacer the same size and shape as the primary cover gasket. The ’68 XLH was electric start but I wanted to eliminate as much weight as possible. At an independent Harley shop I swapped the starter motor, big battery box and oil tank for a kick-start shaft, gears and kick lever. You can anticipate the next problem: the electric-start primary case had a square-ish hump on the back to accommodate the starter Bendix. I had to weld a flat metal part onto the tin primary to cover the hole.

Without an XLH-style starter motor there was another gaping hole on the other side of crankcase. I blanked off the hole where the electric starter fit with a large chunk of angle aluminum that doubled as a battery box for the much smaller kick-only battery. Now the engine was ready to slot back into the frame. And that’s yet another can of worms I’ll write about later.

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