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Old 11-27-2009, 07:01 PM   #1
DisTech OP
Studly Adventurer
 
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Joined: Sep 2008
Location: Seattle
Oddometer: 616
DisTech's DR350 rebuild

Last winters project was my DR650 and I had a blast with it this summer on some of the local trails. Winter is almost here again and I want a new project. mx_rob and ProCycle had me psyched about putting a big bore kit, high compression piston and web cam on the DR650, but then I started thinking what if I wanted to take some epic journey into a land of low octane? Also on tight trails the DR650 girth is limiting/exhausting. Better to leave the DR650 as my reliable long haul adventure bike.

Still liking the idea of a big bore project, wanting a less limiting bike for single track and being a sucker for brand loyalty I selected the DR350 as my next subject. I want it to be at least 75lbs lighter than my DR650 and with the right components I should be able to approach the stock DR650 HP and torque.

Here's what I have so far.


1994 DR350 (no plastics, no tank, no seat) $250


1993 DR350S (broken cylinder, damaged head, no wheels, completely disassembled in boxes, premium paid for WA street title) $450

The PO said the rod broke and it ate the piston, cylinder and chewed on the head some. He was going to rebuild it but lost interest.


The cylinder will be re-sleeved for a big bore kit. So is this usable?


That left valve seat is out of round and has some gouges. Is this head repairable? Top of the head looks good, no scoring.

The 94 motor is complete. So if the 93 top end is shot it's not the end of the world.


2007 200xc forks, wheel and I have the brakes as well. Let's just say these cost more than both DR350's.

To do:
  • Sand blast & powder coat the frame
  • New bearings everywhere
  • 441/450/480 big bore
  • MegaCycle cam & springs
  • Performance exhaust
  • Excel rim, black for rear
  • Rebuild/jet TM33
  • Rebuild dirt shock
  • 4860 WP forks
  • LED dual sport light kit
  • HID headlight?
  • Trailtech Vapor
  • Renazco seat
  • Acerbis tank
  • Maier rear fender
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DisTech - Suzuki (1993 DR350S & 1994 DR350, 1996 DR650/DR790), BMW (1999 R1100GS)

DisTech screwed with this post 11-27-2009 at 07:11 PM
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