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1990 Suzuki DR350 Rebuild

  1. #101
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild


    WELL THEN.

    Cracked into the DR and not what I expected.

    No smashed valves or piston. Rockers/cams are rough. Timing chain is very loose and timing way off. Probably skipped multiple times, first killing all compression leaving me stranded, then finally opening valves enough at TDC it locked up.

    Have a few spare rockers/cams so I'm feeling *slightly* optimistic I can get away with new rings/hone/cam/rockers/timing chain/cleaning & maybe valves (although they look untouched I haven't inspected the seats).

    Just starting to go over things though.

    The amount of carbon & sludge is insane. Not too long before it died I almost completely sunk the bike. Dumped a *lot* of mud & water from the air box and had to kick it for ages to get running again. The intake valves have "fresher" looking smears of goop built up on top of the typical carbon deposits, so it probably took a few nice gulps of dirt & water...












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  2. #102

    Re: 1990 Suzuki DR350 Rebuild

    Eek...this is why I run 2 strokes...you got this tho

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  3. #103
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    The KTM is pretty much my preferred bike for the woods now but keeping the DRs around for dual sport/street/camping.

    I 100% blame myself for the problems. Timing chain was nearing the end of its limits when I did the rebuild but costs were adding up fast. Combined with losing oil and running it pretty low a few times I'm still amazed it held out this long!

    Might actually be for the best, if I didn't have this project ahead of me god knows what I'd be getting into.. already been scouring CL for a blown up GSXR to play with. :0

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  4. #104
    Soul Rider Paul_E_D's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Tekime View Post
    The KTM is pretty much my preferred bike for the woods now but keeping the DRs around for dual sport/street/camping.

    I 100% blame myself for the problems. Timing chain was nearing the end of its limits when I did the rebuild but costs were adding up fast. Combined with losing oil and running it pretty low a few times I'm still amazed it held out this long!

    Might actually be for the best, if I didn't have this project ahead of me god knows what I'd be getting into.. already been scouring CL for a blown up GSXR to play with. :0
    We officially have the new Kurlon on NESR! Hahaa. Can I interest you in a cheap WR?

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  5. #105
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Paul_E_D View Post
    We officially have the new Kurlon on NESR!
    Ha, minus the substantive knowledge and experience...

    Quote Originally Posted by Paul_E_D View Post
    Can I interest you in a cheap WR?
    My heart says yes but my brain says my wife will kill me if a 5th dirt bike shows up here lol

    Sort of open to a little 250 for my better half, definitely open to a 04/05 GSXR 750/1000 project bike. Or maybe ZX10/R1/CBR1000... at this point I'll need to sell a bike or two before getting into the next big project.

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  6. #106
    Lifer Kurlon's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Tekime View Post
    Ha, minus the substantive knowledge and experience...
    Experience dealing with crap, sure... I'm absolutely not the most knowledgeable person lurking on this forum though.

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  7. #107
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Figured I’d get the ball rolling: new timing chain, crank cover & head gaskets on order. Also a new drivechain & sprocket which are due.

    Have got a used cam & rockers in acceptable condition.

    Cylinder walls & piston have no noticeable damage or significant wear. With some luck I might keep it barebones and have a running bike again for not much over $100. Further inspection and cleaning while I wait for parts will tell the whole story though.

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  8. #108
    Lifer Kurlon's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    With the short run time, I'm curious how that piston and combustion chamber got THAT carbon'd up? Any chance it was burning oil?

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  9. #109

    Re: 1990 Suzuki DR350 Rebuild

    "$100 to get going again" is the way dirt bikes shoud be....cheap fun

    which ktm do you have?

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  10. #110
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Kurlon View Post
    With the short run time, I'm curious how that piston and combustion chamber got THAT carbon'd up? Any chance it was burning oil?
    Not ruling it out but still unsure. This was a little under 1.5 years of runtime. A lot of the crap in there is just flaking/falling off and somewhat soft, which I'm attributing possibly to contamination from when I sunk it. Beneath that is a much harder typical layer of carbon deposit. Valve seals, rings, and head gasket were all new on rebuild.

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  11. #111
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by breakdirt916 View Post
    "$100 to get going again" is the way dirt bikes shoud be....cheap fun

    which ktm do you have?
    2006 250 XC-W

    Blew my mind after riding the DR for so long in the woods. Feels like I'm on my mountain bike. But the wheelies still scare me

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  12. #112

    Re: 1990 Suzuki DR350 Rebuild

    haha, yeah dirt bike technology has gotten exponentially better...a '19 will even blow the '06 out of the water

    the XC-W torque will rival that of older 4 strokes to make it such a fun bike to ride

    all things considered, the dr still has its place as relatively simple, 6 speed, inexpensive woodsy toy.

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    Last edited by breakdirt916; 03-12-19 at 06:25 PM.
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  13. #113
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Well I haven't ridden any newer ones, but the weight difference was the most obvious difference. Shoving that DR through rock piles was a hell of a good workout though! One slight advantage of the weight is the DR definitely has some inertia. If you can wrangle it and keep the momentum up that beast will go through quite a bit of hard stuff.

    The 250 torque is awesome, and I still have lots of dialing in to do overall. Pretty much just replaced a bunch of wear items (it was ridden hard in enduro before I got my hands on it for a nifty $1,300) - rode every chance I could and never messed with the powervalves, banged up exhaust, or touched the suspension except to dial the sag way up.

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  14. #114
    Lifer typeone's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Tekime View Post
    2006 250 XC-W

    Blew my mind after riding the DR for so long in the woods. Feels like I'm on my mountain bike. But the wheelies still scare me
    if you ever run into an older Husqvarna WR144 for cheap, grab it. talk about feeling like a mountain bike ... incredibly fun and extremely durable. it would make that 250 feel like a tank.

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  15. #115
    Soul Rider Paul_E_D's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by typeone View Post
    if you ever run into an older Husqvarna WR144 for cheap, grab it. talk about feeling like a mountain bike ... incredibly fun and extremely durable. it would make that 250 feel like a tank.
    I should have bought that from you.

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  16. #116
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Paul_E_D View Post
    I should have bought that from you.
    amen. although it stayed in the fambly for quite a while! Squirrel > Timby > Jewcati ... wish i could have taken her back

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  17. #117
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    That looks fun. The Xtrainer has caught my eye due to the size. I’d love to play with a big bore & flywheel weight on the CR85 just to see what it could tackle but that’s $$ I can’t spend on such silliness. Really fun being on a bike that doesn’t have 100lbs on me!

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  18. #118
    Senior Member MHenry600's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by typeone View Post
    if you ever run into an older Husqvarna WR144 for cheap, grab it. talk about feeling like a mountain bike ... incredibly fun and extremely durable. it would make that 250 feel like a tank.
    I almost bought one of those, maybe 1.5 to 2 years ago. Wasn't your old one though. Was still in 125 trim, but had the 144 kit with it. The one you built was drool worthy.

    Ended up with a 200xcw last fall, which is suiting me well so far. Looking forward to putting some hours on this year.

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  19. #119
    Lifer loudbeard's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Tekime View Post
    The Xtrainer has caught my eye due to the size.
    Give that one a firm "pass" until you can find one at KDX pricing.

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  20. #120
    Lifer typeone's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by MHenry600 View Post
    I almost bought one of those, maybe 1.5 to 2 years ago. Wasn't your old one though. Was still in 125 trim, but had the 144 kit with it. The one you built was drool worthy.

    Ended up with a 200xcw last fall, which is suiting me well so far. Looking forward to putting some hours on this year.
    they're such fun bikes, especially with that 165 kit + 200 Kadie M pipe hop up.

    i have a feeling i'll be on a 200RR in the near'ish future ... bike is getting outstanding reviews ... just not sure when/if i'll be ready to part with my 250RR. we fit.

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  21. #121
    Lifer typeone's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Tekime View Post
    That looks fun. The Xtrainer has caught my eye due to the size. I’d love to play with a big bore & flywheel weight on the CR85 just to see what it could tackle but that’s $$ I can’t spend on such silliness. Really fun being on a bike that doesn’t have 100lbs on me!
    you should def try the cheap'ish woods mods to see how it does. FWW alone can make a nice difference but i've never tried one on a motor that size. maybe FWW + gearing but it's not like you'd want to climb mad hills ... just rip trail.

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  22. #122
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by loudbeard View Post
    Give that one a firm "pass" until you can find one at KDX pricing.
    Why’s that? Price aside, I’ve heard some reliability issues IIRC

    Quote Originally Posted by typeone View Post
    you should def try the cheap'ish woods mods to see how it does. FWW alone can make a nice difference but i've never tried one on a motor that size. maybe FWW + gearing but it's not like you'd want to climb mad hills ... just rip trail.
    Oh man it’s tempting. Still 50/50 on whether I’ll keep or sell this spring

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  23. #123

    Re: 1990 Suzuki DR350 Rebuild

    If I could get the wr144 plated in CA...

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  24. #124
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by breakdirt916 View Post
    If I could get the wr144 plated in CA...
    i was dying to do the SM (like the EU model) conversion for backroad insanity

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  25. #125
    Burns retinas nhbubba's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    1990 Suzuki DR350 Rebuild-20150403_182423-jpg

    (Plated) KTM 200 XC wearing DRZ400SM wheels. Needed a few spacers cut and one hell of a shorter chain. Couldabeenphun.

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