TT350 Not XT350

Discussion in 'Thumpers' started by zerohype, Feb 2, 2008.

  1. Lenz1

    Lenz1 Been here awhile

    Joined:
    Jul 11, 2010
    Oddometer:
    141
    Location:
    Queensland Australia
    Steve is the guy that runs the show at Betta Bikes. He is able to tailor the electrical output to suit the application required by the customer. So if you're looking for as much output as possible at low revs (dropping into a creek bed / waiting at lights etc etc) or higher rev range max output, he can adjust the wiring and circuitry to suit.

    In my case since I'm going to LEDs, the rectified and regulated output will be entirely DC and supplemented with a gel based 12V 7Ah battery. The output of my existing large format, single copper wire (> 1mm dia) wound lighting coil will be established and a second coil produced to fill the currently vacant space for a third coil on the backing plate. The new coil will be attached to the backing plate, joined in parallel with the existing lighting coil and the shared output and return wires extended to match the length of the existing magneto wiring harness.

    I'm not absolutely certain of the cost of the work for my job but it's around $Au 160 per coil and around $Au 160 for a combined rectifier / DC regulator.
    The end result bike will be a highly cost effective , seriously versatile little critter
  2. Ted farkas

    Ted farkas Adventurer

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    24
    No worries let us know how you go - good headlight and an oil cooler and i,d be happy
  3. beerbuzz

    beerbuzz Been here awhile

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    Mar 26, 2013
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    Central Albabamba
    Been watching this thread for weeks figured I'd do the first post thing-
    I'm rebuilding an 86 tt350 right now I picked up for a couple hundred and a pack of smokes. The PO had no idea why it wouldn't start anymore "just wouldn't start one day" Got it home and found the timing chain ten. Had failed and I had 2 bent intake valves. Straightened them out and threw it back together and have had a blast since...
    So far ive found the 05-06 wr250r front brake line fits like a glove. Anybody ever done a fork conversion on one?
  4. becki

    becki Adventurer

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    Mar 4, 2008
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    28
    Location:
    Germany
    yes, my ex bike (stolen) got a ohlins 46 fork of a yz 426. You can lathing a new stem and press him in the ys clampe. With this solution you get problems with the gas tank.
    Second solution, lathing some adapters to the yz stem. That was my one.
  5. Lenz1

    Lenz1 Been here awhile

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    Jul 11, 2010
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    I can't speak for other operators of the long production life TT350 however my experience with the low km unit I have suggests it will provide a tough economical dual sport platform.

    I've massaged the cylinder head porting, raised the compression, rebuilt the inlet manifolds, realigned the inlet tract, deleted airbox for oiled foam air filters, dialed the cams to absolute std valve timing after adjusting shims to mid tolerances (calibrated feeler gauges), adapted the auto cam chain tensioner to a manually adjusted unit, installed twin oil coolers, deleted the rubber blocks between cylinder head / barrel cooling fins for improved cooling airflow.

    The rear shock has been rebuilt, front suspension drained and re-oiled with 5w oil, new chain and sprockets, seat re-covered.

    There is undoubtedly a significant amount of additional power available from this engine if you're prepared to look for it.

    I'm not convinced that going over to the complexity, cost and vulnerability of on-board computers for suspension adjustment, fuel management and braking plus an additional 80kg - 100kg vehicle mass is where I need to go (Triumph 800XC or KTM 990 Adventure)

    I've cleaned up the engine, added major oil cooling and am in the process of installing 80 watts of LED lighting plus a 12 litre fuel bladder ..... have I missed something
  6. JensEskildsen

    JensEskildsen Long timer

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    ...Pictures? :clap
  7. Lenz1

    Lenz1 Been here awhile

    Joined:
    Jul 11, 2010
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    141
    Location:
    Queensland Australia
    LED lights on order - week or two

    Upgraded magneto backing plate - week or two

    Major rewire / simplification - when the gear turns up

    Clutch tweak for easier neutral location

    Hopefully I'll be through these tasks in a month. Just bought a boat that needs a little TLC but it's the right tool for the job also so there's no shortage at projects at my place. Some good engineering ahead as opposed to the shitty little rebuild I had to do today replacing/rebuilding the drive hub on a power window assembly - not a fan of bonded rubber cush drives - steel good

    Pics of the "work in progress" bike when it's out of rehab
  8. Lenz1

    Lenz1 Been here awhile

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    Jul 11, 2010
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    Location:
    Queensland Australia
    The TT350 evolution continues -

    - upgraded stator/backing plate with 2 mega lighting coils hooked up in parallel

    - 12V DC regulator with AC to DC bridge rectifier (very std)

    - LED light bars x 2 (10w Cree LEDs x 4 @ 900lumens ie 3600lumens each bar)

    The backing plate is installed, rectifier/regulator mount fabricated and installed, lights are waiting at the Post Office due to a public holiday tomorrow - bugger

    I'll pull some wiring through tomorrow and take some additional pics when I get the lights after the holiday tomorrow.

    The clutch has been massaged with the steels lightly ground on a flat steel plate with kerosene on 600 / 800 grade wet and dry sandpaper. Just a light touch on the friction plates - enough to remove the high polished areas. Total pack height is approx 1mm less than the maximum height so I added 1.0mm high tensile flat washers under the clutch springs to maintain correct spring load.

    We'll see how the clutch works out after a little bedding in.
  9. Ted farkas

    Ted farkas Adventurer

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    May 30, 2012
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    24
    Lenz,

    How did it workout, and can you supply info on the oil cooler. Thanks

    Thanks
    Ted
  10. BIG ED XT FAN

    BIG ED XT FAN Long timer

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    Finger Lakes Western New York
    :ddog
  11. Lenz1

    Lenz1 Been here awhile

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    Location:
    Queensland Australia
    My apologies for not posting pics of the finished job - that's cause it's not quite finished.

    The electrical / lighting upgrade is finally done - what a bloody marathon - one of the new LED lights was fine just off a battery but when the bike was running it was blowing 35amp fuses. I was convinced I'd screwed up with the combination of AC and DC systems but eventually I found the light was shorting down to earth with engine vibration. So now we have 4 x 10watt CREE LEDs in a flood pattern as low beam plus an additional tighter pattern 4 x 10watt CREE LED as a combined HIGH beam (high beam = 80watts of CREE LED) And yes I am very satisfied with the results. It's hard to show a down-the-road result in a pic but it's daylight ahead for several hundred metres.

    The final task is finishing off a "cargo" platform to primarily carry the 12litre fuel bladder/s I sourced from liquidcontainment.com in SE Queensland plus reduce the main jets a touch.

    End of the week and I think I'll be able to post pics of what will be close to the finished product - but we all know these critters are a work in progress ....
  12. Timmie

    Timmie Adventurer

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    Jan 4, 2010
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    15
    Location:
    Arse end of nowhere, QLD, Australia
    Lenz, you are a godsend. I'm in Queensland too and also have a TT350 (once I get the time to get it back from the old man). I want to convert it to 12V to make everything a bit simpler but I'm not looking to go as far as you and get new coils or anything.

    Just wondering, with the original single wimpy coil, did it still put out over 12V before the rectifier? My plan was to (pretty much) replace the current 6v rectifier with at 12v one, put in a 12v battery, then just run all the lights straight on DC after replacing the indicators and possible taillight with LEDs. Would this be possible?
  13. Lenz1

    Lenz1 Been here awhile

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    The original electrical setup runs the ignition, headlight and taillight on AC and makes 6VDC - which rises much higher than 6VDC under revs - to power indicators, horn and brakelight. The regulator is an AC regulator only. I can't tell you what your voltages are gonna be because I don't know about the type of lighting coil on your bike. If you're gonna get creative my suggestion is to get busy with a meter first up.

    You'll need a combined rectifier / regulator to convert the AC lighting coil output to manageable DC voltages. Be aware that the later TT350 AC lighting coils have a secondary circuit with a yellow lead and a white lead coming off the same larger format stator coil. The yellow runs the headlight, tail, instrument lights while the white goes into the rectifier to produce 6VDC.

    You could try using the yellow lead on its own as the AC source for the regulator / rectifier then supply DC to battery and then on to lights. The two AC lighting leads yellow and white don't like being joined. My concern is that the 12V battery won't get enough regular charge to cope with the lighting demand and lack of alternator output at a fast idle / lower revs. Your solution puts you part of the way to a 12VDC lighting system and if it turns out there isn't enough DC charge available then the next stage is to delete the existing lighting coil and install one or more rewound stator coils from Betta Bikes in South Australia.

    Depends on your usage - I wanted bulletproof reliability so I went to 2 large format stator coils, regulator / rectifier, 4ah flooded leadacid battery and the lights are good at ANY engine speed - including with the engine off. The LED headlights I installed have a claimed operating voltage range from 9VDC - 30VDC which could possibly be a good thing for a low output lighting coil set up. I just got fed up with "maybe this'll work" and went for something that worked everytime , all the time.
  14. Lenz1

    Lenz1 Been here awhile

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    Location:
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  15. Lenz1

    Lenz1 Been here awhile

    Joined:
    Jul 11, 2010
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    141
    Location:
    Queensland Australia
    No expert with posting pics so the above images are best viewed in full screen - start from extreme right and work to the left
  16. BIG ED XT FAN

    BIG ED XT FAN Long timer

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    8 lights? Must light up the night real good!!!:eek1:eek1
  17. Lenz1

    Lenz1 Been here awhile

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    Jul 11, 2010
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    Like daylight for several hundred metres - worth every cent with suicidal wildlife at night in Australia. Also gives me something in reserve for those fools who refuse to drop their high beam for motorcycles. Almost as satisfying as riding at night with a few good size stones in a left-side jacket pocket .....
  18. oceansfiftyseven

    oceansfiftyseven Adventurer

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    Jan 9, 2013
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    Pacific NW
    Lenz1, That is an awesome machine! Reminds me of Melanie Griffiths custom mustang in that old movie Cherry 2000 LOL! Thanks for sharing.
  19. Lenz1

    Lenz1 Been here awhile

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    Jul 11, 2010
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    Location:
    Queensland Australia
    I'm not sure if I should take your Melanie Griffiths mustang comparison as a compliment - or not LOL - glad you like it

    The silence from the rest of the crew is kind of an anticlimax - what - not even any "We're all very dissappointed in you son" ....

    A few little jobs on the list: rear chain guard to stop the chain lube being flung over me and the bike, two simple side mounts for a fishing rod (found a few backroads into some barramundi spots (saltwater sport/table fish), drop the carbie float level a touch or reduce the main jets a little.

    It's time to enjoy this critter
  20. Kiba

    Kiba Dances With Huskies

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    Nov 8, 2013
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    2,055
    Location:
    Houston, Motorcycle Purgatory
    I hereby resurrect this thread. No posts since 2013.... gee, TT350/250 owners must either be a lazy bunch or we're too busy out riding to post here.

    Either way, I'd like to bring the TT350 back into the mix of projects, advice and general bullshitting that we do here on ADV. :freaky

    In case anyone's interested, here's the <a href="http://advrider.com/forums/showthread.php?t=964470">project thread</a> to my TT350.

    I'd love to hear how Lenz's bike worked out, if he still frequents ADV.

    I'm curious about performance mods to these bikes too. There doesn't seem to be much out there for them, but some arcane knowledge probably exists, somewhere.

    I'm also looking to properly dual sport mine since we in the states received barely legal TT350s. The lighting kit is enough for a naked supermoto but I'm thinking of using my TT350 as a desert bike, possibly with hard panniers, and as such will need better lighting up front due to the darkness of nights out in the country, in back because it'll be loaded down with crap and the awkwardly placed dirtbike taillight isn't quite enough, etc.

    Check the last post on my build thread for more details if you're interested.