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Air leakage symptoms??
Re-torque cylinder head, check reed block gasket....

No Wade, that is a full blown complete Stage 1 Top End & both reed cavities as an option. As I told Mark, I'm just giving back a bit.

Thank you Sir .

B/R,

Daryl

Congrats! Smooth engine...
You got hear this on Bose speakers.....amazing pipes...

For those that are not technically inclined, just go with the 2015 Yamaha SR400 entire front suspension, inclusive of brake set-up. The rake is the same as the RD350. New tech, vintage looks and parts are not +35 years old...

Thats a very cool looking RD350. Thanks for posting.
Are those forks are off the RD400?

Cheers,

Daryl

That is similar to you Canadian models out here.
Wouldn't be surprised if this bike is a Canadian import.......

WHOA!
Congrats! Obtaining a bike like this is once in a life time!

Air cooled no more.

Fired her up for a quick test after giving her a heart transplant.
There is still a bit of work to finish the exhausts, carb tuning and find an air filter that will actually fit in the tiny gap between the back of the carbs and the frame.
But it was nice to hear her run after putting together a bunch of used parts. Especially the Dynatek CDI, Nology coil and Banshee stator that were bought off Facebook sites. Not much of a warranty option if parts are DOA.

Very cool Rodney.
Do you have your build under the "Haus of Projects" section? Would love to read thru...

i made one like that, on the okuma at work like 12 years ago, sort of. similar tot he triple ones.  walls were too thin for an rd cover with a decent master IMHO, so i ditched it and went with the brembo one. the plate is the easiest way for that type of a setup to bypass the worm screw. could it be done? sure. I also made mine with a drum brake cup seal. I have it somewhere buried in a box i think.

Mark - What would be the ideal travel in mm for the clutch slave mechanism or essentially the push rod to activate/disengage the clutch on a hydraulic clutch set-up ?

For a LONG time, I've been dreading the ignition part of the equation.  I'm not afraid of wiring or electrics, I understand them well, but it was probably going to be one of the biggest ticket items on the project, and my wallet has taken enough abuse already.  I was cross shopping the MZB/Powerdynamo/Vape system with the HCI.  I was leaning heavily towards the HCI system because I'm not going to have a heavy electrical load on this bike (Literally just headlight and tail light), and I liked that it was going to save me over a hundred dollars.  Well as luck would have it, one morning 2 weeks ago, I searched facebook marketplace for "RD350" as I do every morning while having coffee, and some guy down in CT had posted a pile of RD350 parts left over from his last build for 75 dollars.   In the box, no word of a lie, was a complete Vape system!   I met up with the guy the next day to pick it up, super nice dude.  We chatted bike for a bit, and he said he pulled the system off a fully running RD, so he knows it works, and it only had a few hours on it.  He's just getting out of RD's right now, and trying to get into an RZ350. 

So here's the loot.





This next part beggars belief.  You see in that picture how there was an ignition switch with a set of keys?   The little key was a match to the steering lock and seat latch on my original bike that didnt come with any keys!  What are the odds of that?

Lady luck did shine on you!
Thank you for the excellent progress report. Great job.

I took a few pictures of a Magura slave along with a spare RD350 clutch cover.  The master cylinder and the slave are of a KTM.
It' really small, flat n sleek, not bulky. See below pictures.

WoW!
Is this to scale in CAD?

Too heavy, dual disc.....
Go for Honda groom set-up...
But that's me, I trust them Japanese....

This is the route (KTM dirt bike master and slave) I would go which is a full style hydraulic clutch conversion that omits the worm gear. The KTM setup done by dwyatt on his yellow XS650 iis compact and neat. Unfortunately, I do not have access to a lathe etc. to do the machining work.

http://www.xs650.com/threads/hydraulic-clutch-conversion-any-interest.6356/page-6

RIP Marty.