THE SS 350 PROJECT
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Air Box Assembled

5/12/2020

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We received our Special Order Replacement Filter from K&N (SKU: HD-2492). Thank goodness they have a special model specific for the Sprint 350! We sandwiched the filter between the three air box parts and put the unit on the bike. Smooth reinstallation was facilitated by the removal of the carburetor (which is now waiting for a Dellorto gasket kit from Ebay).

Removing the air box the first time – without removing the carburetor – was a major hassle! For a part that needs to be serviced several times a year, they didn't make it easy to access! Maybe that's why people gave up on their HD Aermacchi's in the 70s!
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Clean Carbs

5/7/2020

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Not bad for a 47 year old bike!
It was finally time to clean the Aermacchi's Dell'Orto carburetor. Trying to remove it proved tricky since the carburetor was stuck pretty well to the engine and required some persistent tapping to encourage it before we could get it to move.

For a 47 year old bike, keeping in mind its low miles, the carbs were nearly pristine, the jets barely needing any cleaning at all. The exterior of the component, on the other hand, were gummed up from overflow. WD-40, Q-tips, and skewers were indispensable to cleaning it inside and out.  

The bottom float bowl got a good polishing to bring out the shine in the finish. We used Mother's Mag & Aluminum Polish to clean it up. 
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Aluminum polish and some elbow great getting the float bowl lookin' fine with lots of shine.
This also gave us a chance to properly get the pin through the choke lever so it would sit flush with the lever surface, between the two tabs on the carb.
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New choke lever in the "off" position.
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New choke lever in the "on" position.
While this is off the bike, it'll be a good opportunity to replace the gasket. ​Time to source some O-ring cord. Hope the USPS delivers on time this time! We have a bike to put together!
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Airbox Strip and Paint

5/5/2020

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Today was the airbox assembly's turn to get sanded and painted. The original was also rusted, and looked to have the same finish as on the side panels; however, we chose to finish them on our own. Partly because we didn't want to subject it to the vinegar soak. Since it sits underneath the motorcycle seat, it's not a part that will get seen or scrutinized, but nonetheless, it needed some attention.
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The loose rust was knocked off the components with a heavy duty stripping pad. Then we prepped it in Rust-oleum 2x Primer, and applied three coats of their Black Textured spray paint. Again, it's our best guess as to what that original finish was on the Aermacchi.

An HD-2494 K&N Special Order Replacement Filter is on its way, and then the whole assembly will go back in place!
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The Chokehold

5/1/2020

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[We are now coming to terms with the fact that it takes more time than we anticipate to install parts on this bike…]

The bike in its purchased condition was missing the choke knob (same as my previous AMF Harley), so this afternoon we received our choke lever from Ebay and excitedly ran into the garage to install it.
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We managed to lift the choke rod up with some needle nose pliers, and after a some encouragement, pulled out the original pin (both ends appeared to be flanged). The new choke lever looks good and seems to function well (we haven't ridden it since the handlebars are currently off as we await tools to aid us in our speedo bracket replacement.)  ​
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Before
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After
Update 05.05.20: After being annoyed by the pin sticking out, we got in touch with the manufacturer of the choke lever who told us we needed to remove the carburetor from the bike for installation. Doh!
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