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1990 Suzuki DR350 Rebuild

  1. #26
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild


    Oil leak fixed, was just a head cover bolt that was partly stripped at one point and replaced.

    Still no start after a few hours of pounding on it but I have two major suspects: exhaust valve rocker and carb. One of the rockers had significant wear. The rocker shaft didn't want to come out easily so I used the old rocker but it definitely needs replacing. So I'll swap that out.

    Carb was cleaned w/ ultrasonic and pine sol but after sitting a year I noticed a whiteish film/dust buildup, so I'm not convinced the carbs operating at 100%. Have a full rebuild kit/needles/jets coming.

    Heading to the mountains this weekend but hopefully knock those out next week if the kit comes expediently. Until then have a few washers & misc bits to order, new clutch cable coming, and a Vapor dash to set up.

    Also gotta decide on paint & plastics... all the black & black seat it looks like some zombie apocalypse bike not really my taste, thinking I might go to Suzuki yellow, looking at plastics and some CEET tank graphics. Kind of like the yellow seat now that I'm looking at it.. needs a cleaning though. Will worry about that if/when she runs again though!


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    Last edited by Tekime; 01-13-17 at 02:15 PM.
    05GSXR75005SV65090DR350

  2. #27
    Soul Rider Paul_E_D's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Before you go chasing phantoms how are you trying to start it? I have done many dry rebuilds that required bump starting on a good incline. Kicking is not enough to get the carb flowing properly.

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  3. #28
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Just kicking so far. Thought about bumping it but the rocker & carb need to be done anyway so not in much of a fuss yet. Easy work.

    Really good to know though, this is my first dry rebuild. The DR isn't the easiest bike to start as it is. I'll push her up the driveway if she puts up a fight.

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    05GSXR75005SV65090DR350

  4. #29
    Super Moderator TheIglu's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Either that or a little gas in the carb inlet via a small syringe. That's how you get snowblowers started (primer button).

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  5. #30

    Re: 1990 Suzuki DR350 Rebuild

    on my rm125 I had to kick and roll for quite awhile (although I was told 2 strokes shouldn't usually be that difficult)

    4 strokes I've had to roll...I've even tried towing behind a truck and dragging it on pavement LOL

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  6. #31
    Day late, dollar short carsick's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    I've had a few that would refuse to start unless they were pop started at high speeds. Once they were fixed they became first kick starters. You'll want to kick yourself for all the time and effort wasted. Valves too tight on an XR250, low compression. Blocked pilot circuit inside the carb body- WR400 (the decompression lever routine made this many times more frustrating- auto decomp exh. cam now installed.) Too rich factory jetting on the KDX, constantly fouling plugs, leaned out the pilot and main- no more plug changing! Lean pilot jet on the YZ450- refuses to start or idle below 30 degrees.

    So they have FI on bikes now? Hmmm.

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  7. #32
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Awwww yeaaas. Not quite running yet but I replaced an exhaust rocker, set the valves again, and got it to turn over for about 3 seconds with a squirt of carb cleaner in the jug. First sign of life in about two years!!!

    Going to do that carb kit soon as possible, then I'm starting to feel hopeful...

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    05GSXR75005SV65090DR350

  8. #33
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    AAAAAAWWWWWWWW MIIITHAFIIIICKIN YEEEEEAAAHHH!!!!!



    She liked that carb rebuild. Second kick start!!

    Still a few issues to sort out:

    - some oil weeping where I reused washers
    - clutch is wonky, no resistance, but I have a couple full packs & new cable installed so... hopefully just the pushrod is off
    - ugly as hell

    After that, time to install the Vapor tech and start tuning her up!

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    05GSXR75005SV65090DR350

  9. #34
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Fixed the clutch issue. Springs in there are incredibly stiff, to the point of cramping my hand up in minutes. I have another set that look slightly shorter, so I'm guessing these were "upgraded" at some point. On the fence about whether to go back to stock springs or just man up.

    Starts and goes good, but running extremely hot, popping on decel and the revs are hanging quite a bit. I've messed with the idle & idle mixture without much change. Pretty sure it's running very lean. Plug doesn't look too bad though - a little black but mostly peanut buttery at the gap.

    Temps are ridiculous though. 5 minutes of idle and some tame revving and she's at 375F


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  10. #35
    Your Father csmutty's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    What kind of choke does it use? guessing it doesn't have a hot start?

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  11. #36
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    It's a Mikuni TM33 carb, pull choke, no hot start. The airbox is cut so I'm also wondering if that's contributing to lean conditions.

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    05GSXR75005SV65090DR350

  12. #37
    Awesomeness, Inc. MattR302's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Kientech Engineering Home Page

    This guy Jesse is pretty much the DR guru when it comes to building/tuning them, his website sucks thought. You can drop him an email with what size jets and intake/exhaust mods you have and he can probably recommend something

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    Last edited by MattR302; 01-28-17 at 07:24 PM.
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  13. #38
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    I haven't spoken with Jesse but heard he's the dude. I'll probably grab a couple different sizes to experiment with, not sure yet but thinking I'll end up with an FMF exhaust. I like this big gun but don't think I can get it street legal.. it's loud as hell.

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    05GSXR75005SV65090DR350

  14. #39
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Just got a fistful of jets in the mail today to test. Been working/traveling a bit the last few weeks but did a little more work.

    I have two seats and the seat height is about 2" too high, so I cut the foam down on one seat and gave the cover a good scrub.



    It looked like angel food cake and made me hungry the entire time...

    I'll probably get lowering links at some point, but happy enough with the ride height now. Made a substantial difference.

    After a shitload of tinkering with the carb I finally have it starting up & idling somewhat reliably. Idle still hangs and it's running HOT, like 415F (confirmed with a second laser thermo). Hopefully the bigger jets will be the ticket!

    Still ugly as hell, not even trying to pretty her up yet and still not sure exactly what direction to take it... but I'm kinda liking the black & yellow thing



    She pulls like hell & shifts smooth... nothing blowing up... yet.

    Soon as the mechanicals are 100% sorted it's on to the street kit. Started polishing the rotten header pipe down and trying to make a decision on the exhaust.. I like this Big Gun a lot but the spark arrestor was removed and I don't think it'll pass inspection.

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    05GSXR75005SV65090DR350

  15. #40
    Your Father csmutty's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    That seems way hot for just a jetting problem, especially with the cool temps of winter.

    I'd be looking at valves.

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  16. #41
    Lifer typeone's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Tekime View Post
    Started polishing the rotten header pipe down and trying to make a decision on the exhaust.
    not sure what you're using but i used to use Mothers Mag & Aluminum polish on my Buell headers. worked a treat.

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  17. #42
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    Re: 1990 Suzuki DR350 Rebuild

    Ignoring the heat, how does it run, and what's the plug look like when you do a proper plug chop?

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  18. #43
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by csmutty View Post
    That seems way hot for just a jetting problem, especially with the cool temps of winter.

    I'd be looking at valves.
    Would you think opening them up a bit more might help? I've adjusted them twice and they're right in the middle of spec. Although previously it was getting up to about 375F max, I just figured it hit 415 because I was running it for longer but maybe the valves drifted out a bit.. hmm..

    Either way I agree though it's crazy hot especially for winter

    Quote Originally Posted by typeone View Post
    not sure what you're using but i used to use Mothers Mag & Aluminum polish on my Buell headers. worked a treat.
    I'm just getting the rust off now with sandpaper, tested a bit with some polishing compound but can't remember what brand right now. Will check out the Mothers

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    05GSXR75005SV65090DR350

  19. #44
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Kurlon View Post
    Ignoring the heat, how does it run, and what's the plug look like when you do a proper plug chop?
    Actually runs good, pulls good, shifts good once warmed up. Definitely some popping on decel. Plug looks OK, mostly brown at the spark but some blackening, but I haven't done a proper "chop". I have 4 plugs coming in the mail tomorrow so I can test some more.

    Edit: maybe worth mentioning, it was running a bit shitty and cutting out and I noticed the fuel line was running empty. I was using a larger diameter hose and the tank was also not secured so tipping the bike filled the line up again. I've got that sorted I think, but it was almost definitely getting fuel starved.

    Also, cool temps outside but I haven't been running it on the road or at speeds over 5-10MPH, nowhere to run really with ice & snow everywhere. So it's cold, but not getting much airflow at all while running.

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    Last edited by Tekime; 02-08-17 at 11:20 PM.
    05GSXR75005SV65090DR350

  20. #45
    Soul Rider Paul_E_D's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Your valves are likely a tooth off OR, the water pump isn't moving coolant. That ain't a jetting problem. I would start with cooling. Take the highest hose connection apart and thum the starter.

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  21. #46
    Member TripleTaco's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Paul_E_D View Post
    Your valves are likely a tooth off OR, the water pump isn't moving coolant. That ain't a jetting problem. I would start with cooling. Take the highest hose connection apart and thum the starter.
    DR350 = Air Cooled

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  22. #47
    Soul Rider Paul_E_D's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Hahaaa!!! DOH. I forgot what we were talking about here. So yeah, about those valves...

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  23. #48
    Your Father csmutty's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Case closed!

    Water pump is fooked!

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  24. #49
    Soul Rider Paul_E_D's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Hahaaaaa! Epic

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  25. #50
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    Re: 1990 Suzuki DR350 Rebuild

    NEEDZ MOAR FINZ!

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