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1990 Suzuki DR350 Rebuild

  1. #126
    Lifer typeone's Avatar
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    Re: 1990 Suzuki DR350 Rebuild


    Quote Originally Posted by nhbubba View Post
    Couldabeenphun.
    aw yissss!

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    Beta 200RR

  2. #127
    Soul Rider Paul_E_D's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Nothing could be about it! That thing would be a weapon! Is that yours Bubs?

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  3. #128
    Burns retinas nhbubba's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    That is my 200. The DRZ is in the photo behind it. It-and the wheels-have since been sold.
    As I say, needed some brackets and some customization. I never ran it that way. I just put it together because someone claimed DRZ wheels "bolt right up" to KTMs. It's close; the axle sizes match.
    As I recall the front needed spacers cut and-of course-a brake relocation bracket.
    Rear was bolt-in, perfect.
    I think. That was a few years ago and just because I was curious and felt like I had time on my hands.

    Never ran it.

    Maybe I'll find a set of wheels again, do it up and give Kurlon a run for his money @ boxshop.

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  4. #129
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Damage/progress report.

    Timing chain didn't just skip, it slapped the living heck out of the case and chewed the guides up.





    New/replacement on top, old on bottom:



    Chain was completely gone, links seized up and dramatically stretched.



    New on top:



    Chewed quite a bit of material off the case, probably nothing structurally significant but deposited a lot of aluminum dust into the bottom end. On the bright side, it's aluminum and the chain was flinging it down into the case (not into the head). On the not-so-bright side, well, everything else about it.

    Thank goodness for oil filters.



    The cam was slapping around enough to jam the locating C ring into the cam race and take a nice bite.



    Cam gear was in rough shape too.



    All in all: cam, rockers, cam gear & valve cover are being swapped with spares.

    New (OEM) chain installed:



    New (old) cam and gear cleaned up:



    Head & valves cleaned up & inspected:



    Bottom end is buttoned up again w/ new gasket & oil filter. I'm doing one helicoil in the head I regretted ignoring last year, then final cleanup and it all goes back together. Will be flushing the heck out of it and replacing the oil filter very soon after. Then we shall see.

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    05GSXR75005SV65090DR350

  5. #130
    Lifer typeone's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    damn but excellent work getting it back in shape!

    what do you use to clean? do you have a parts washer? (it's prob in here somewhere)

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  6. #131
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    No washer - just a lot elbow grease, chemicals, and scrubbing! Not my favorite part of the process but it's gotta be done...

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  7. #132
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    Re: 1990 Suzuki DR350 Rebuild

    Medium update.

    I had exactly one M6 helicoil left, and luckily did not trash it.





    Lower head cleaned up a bit:



    New gasket and head ready to go on:



    New cam, cam gear, and chain in and timing set:



    Buttoned up with threebond, new rockers and valve lash set:



    Been another busy week but now I just need to put the exhaust, carb, throttle, etc. back on and I'll find out if she wants to live!

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  8. #133
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    Re: 1990 Suzuki DR350 Rebuild

    Stock exhaust. Starts dead easy and runs quieter. Smoking a bit, but power is good. Might be clearing out the old pipe, or needs a hone/rings. Barely run yet.


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  9. #134
    Super Moderator TheIglu's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Needs some stickers.

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    -Clayton
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  10. #135
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    They really help protect the immaculate paint job.

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    05GSXR75005SV65090DR350

  11. #136
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    Re: 1990 Suzuki DR350 Rebuild

    Smoking cleared up pretty quick and doesn't seem to be returning.

    Doing a (maybe) final oil flush again and going back to the Valvoline full synth Walmart stuff I was using. About $7/qt and served me well for a lot of hot miles. After switching to Rotella T6 on two bikes last year and burning the clutch on both of them in <2k miles I'm not very confident in it. Probably just coincidence, but...

    On to some maintenance items like new rear rotor, replace the funky ignition switch, new flasher relay, wheel bearings & swingarm bearings I've had waiting on the shelf for a while.

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  12. #137
    Super Moderator TheIglu's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    For an old air cooled bike that like, I'd just run Pennzoil conventional. You'll change it far before you'd see the benefit of synthetic IMO.

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  13. #138
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    I kind of waffled between the conventional/synthetic for a while but landed on synth mainly because this thing get *so damn hot*

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  14. #139
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    Re: 1990 Suzuki DR350 Rebuild

    It shouldn't be getting THAT hot.

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  15. #140
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    Re: 1990 Suzuki DR350 Rebuild

    It's been a while but I think 250-300F is typical for summer temps. It spends 90% of its life on slow trails in low gears.

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  16. #141
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    Re: 1990 Suzuki DR350 Rebuild

    If the DR200 is this rowdy, I can't imagine what the 350 is like.

    https://www.youtube.com/watch?v=SwjVUwXYXl0

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  17. #142
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    Re: 1990 Suzuki DR350 Rebuild

    Oh god. That's the dream right there. Nearly as good as the guy winning his class on a Sur Ron electric bike.

    https://www.youtube.com/watch?v=u6DzZK7UpNE

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  18. #143
    Lifer Kurlon's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Just did some reading on those, 110lbs, 7hp, and mods available all OVER the place..

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  19. #144
    ^ It's my bike and my car tls25rs's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by TheIglu View Post
    Oh god. That's the dream right there. Nearly as good as the guy winning his class on a Sur Ron electric bike.

    https://www.youtube.com/watch?v=u6DzZK7UpNE
    Other than having to push it for the last 2+ minutes of the race that was pretty cool. Biggest issue with electrics as always.....range.

    The Sur Ron is pretty cool, one of Tony's customers, Greg, has one and brought it out to NYST when we were there. The thing rips pretty good. I swore someone was going to eat it in the pits on it but nobody did that I know of.

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  20. #145
    Super Moderator TheIglu's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Kurlon View Post
    Just did some reading on those, 110lbs, 7hp, and mods available all OVER the place..
    I've ridden Greg's. It's a BLAST.

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  21. #146
    Lifer Tekime's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Kurlon View Post
    If the DR200 is this rowdy, I can't imagine what the 350 is like.

    https://www.youtube.com/watch?v=SwjVUwXYXl0
    That was some high quality YouTube right there. I’d love to see that on a 350, she will rip!

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  22. #147
    Your Father csmutty's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by TheIglu View Post
    I've ridden Greg's. It's a BLAST.
    So it's a giant POS that shakes like a paint mixer?

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  23. #148
    Super Moderator TheIglu's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by csmutty View Post
    So it's a giant POS that shakes like a paint mixer?
    No, much much faster. Holds it value better too.

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    -Clayton
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  24. #149
    Soul Rider Paul_E_D's Avatar
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    Re: 1990 Suzuki DR350 Rebuild

    That electric bike vid proves that we would all be faster on smaller, lighter bikes.

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  25. #150
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    Re: 1990 Suzuki DR350 Rebuild

    Quote Originally Posted by Paul_E_D View Post
    That electric bike vid proves that we would all be faster on smaller, lighter bikes.
    I wonder if it's time for AMA / FIM to remove weight minimums from offroad racing?

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