Xt350 520 chain conversion

[ross/xt350]

Since it is winter and I am bored I decided it's a good time to put a new chain and sprockets on the old XT. For whatever reason I dont really think the 428 chain it comes with is adequate so I am converting to 520. I have been assured by many dubious online sources that this is possible and will update as I go.

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[ross/xt350]

The big problem here as i see it will be weather or not the yamaha sr250 sprokets will fit and clear everything as i was assured they would on the random internet forum i saw it on. I was assured that yamaha sr250 sprokets will swap right on so this is what I got. The sprokets are jtr845.46 and jtf569.17 . Hope they work.

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[ross/xt350]

Well a few minutes into this seemingly simple job its not going well. The Philip's head screws to get the covers off are half stripped already and very tight so I get to use my impact driver. Also smashed my hand trying to use said driver but I got the covers off. Pretty sure my shift lever is bent but it still works so I'm leaving it. That deserves a beer.

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[ross/xt350]

Next was to break the old chain and put on the new front sprocket. The old one looks totally different but it seems to work with the new one. Nothing rubs even with the cover installed.

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[ross/xt350]

Rear wheel off I checked the bearings and they seem fine so were gonna bend those annoying tabs out of the way and get the new sproket on.

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[ross/xt350]

So with both sprokets on it's time to break the new chain and install the master link. Something always seems so wrong about breaking a brand new chain. With that done it's time to set tension and put everything back together. Everything looks good. No rubbing anywhere so I think it will work. The original chain and sproket were 19 and 55 tooth and the new one are 17 and 46 so were are going from a .345 ratio to a .369 ratio. A slightly taller set up but I doubt I'll even notice.  I'll update on how it runs when it stops being so white out there. Hopefully get some new tires and I'll be ready for the rally!

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[sandhillrider]

If I'm looking at your picture right you need to turn your master link clip around so open end faces away from direction of
Chain travel. It can get knocked off if chain rubs on something
with the clip facing the way your picture shows.

[ross/xt350]

Good catch. I totally spaced that and just threw it on. Thanks.

[Abercrombie]

If I'm looking at your picture right you need to turn your master link clip around so open end faces away from direction of
Chain travel. It can get knocked off if chain rubs on something
with the clip facing the way your picture shows.

You beat me to it.

[grubbie]

Cool bike. Be careful not to scratch the paint on that Kubota bucket, new paint jobs are SPENDY!

[ross/xt350]

Decided it's time to do valves and replace some lights while I'm at it here. The xt350 is really showing its dinosauric lineage here with its 25mm shims. I can find what I need but not all at the same place. It looks like I need a 2.35 2.45 2.70 and 2.75. I found 3 at z1 enterprises and the 2.45 I can get through the local dealer. Had to order the special tool so I didn't have to pull cams as well. Kind of a pain. Plus the headlight is weird. Gonna try and go to an h4 led. I think I can make it work. Anyone have experience with these 25mm shims. Also I think an led will work with the ac voltage for the headlight. Anyone know if I'm right. It's not too expensive so I might just try it and see.

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[Hank]

I might have a box of those shims, but I'll have to look.    I had a old Honda CB750F that took something real similar.

[Bogus Jim]

4into1.com has 25mm shims, but $6.50 apiece? Maybe they're all $$ due to rarity.

I worked on a Honda twin once that used 25mm, but it was a while ago; the dealer carried the shims.

[ross/xt350]

The dealer has to special order them if I buy any. As far as I can tell as this bike is the last year of the xt350 I think its the last bike to ever use these shims. Yeah hank the cb750 used the same shims. If you find some your looking to sell I we might be able to arrange something. I doubt this will be the last adjust she ever needs. I dont know why but I really love this bike lol.

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[Fletch]

buy  yourself a set of JIS screwdrivers. ($40) and you won't have to worry about stripped screws (hint: they aren't Phillips)