Bad-mod's dr350

Discussion in 'Thumpers' started by BAD-MOD, Apr 19, 2011.

  1. BAD-MOD

    BAD-MOD professional fiddler

    Joined:
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    hey guys heres my dr350 soon to be big bored after blowing the clutch.

    Bit o history the bike was a wedding present from my best man:clap BUT
    it did not go broken wires two stroke needle in the pumper carb insane huge main jet buggered shocks buggered tires buggered susp linkages crappy paint crappy super trap ... you get the picture
    i have now painted it replaced all the suspension bushes, painted the frame, put two newish tires on it, new wheel bearings, made new foot pegs (replaced the rubber inserts with welded in steel bushes), big header made new exhaust, cut down the rear mud gaurd, new brake pads and finaly got the jetting close.
    three hard core trail rides in and the clutch died and i mean died complete with crack in the basket :kboom I later found out that it had been running on some shitty old car motor oil 15w40 of some shit :becca

    I have found a new clutch "thanks Mr Bender" and after measuring the piston and big end ect have decided to go the whole hog. After all it's prob the only thing i haven't had to fix.

    here are some photos though you may want to see hope you enjoy any feed back would be awesome .

    oh and since i can't get a vortex im gonna make my own version ill chuck in some pics of that to,oh and a box job like pablos. Shot pablo!!.

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    #1
  2. Drif10

    Drif10 Accredited Jackass

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    Your best man did you one hell of a favour, mate. :thumb

    Your garage time during this crucial point in your new marriage will set the tone for the rest of your married life, trust me.

    You owe him several beers, even if the bike is causing you grief. :lol3
    #2
  3. Greg Bender

    Greg Bender Long timer

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    Fun stuff! Let me know how that clutch works out for you. :>

    Regards,

    Gregory Bender
    #3
  4. Pablo83

    Pablo83 Sleep, Wrench, Ride

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    Wow, that's bike's seen some better days. looking forward to seeing how it turns out.
    :beer
    #4
  5. BAD-MOD

    BAD-MOD professional fiddler

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    hey come on guys it not that bad lol it's quite good NOW.
    ill keep up the posts as i go ordered new valve guides. so ill be able to fit them soon. Head porting work is all done and looking good {shot night shift}:rofl .
    im not gonna pay mad $$$$$ for the special reamer 10.8 mm im gonna get a 11 mm one. I got a mate with a cylinder grinder we gonna grind that shit down.
    I have almost finished the cardboard mock up of the new air box,
    and got the sheet today to box the swing arm ala pablo.
    just waiting on $$ now can't afford much on a apprentice wage dam it :ddog
    #5
  6. Greg Bender

    Greg Bender Long timer

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    It doesn't look bad to me! Sure, I appreciate the lovely DR350 builds with fresh paint, polished aluminum, powder coated rims, and all the lovely accessories. They look great.

    My DR is nothing like them. I try to keep it in solid mechanical condition and then I just ride the thing. I have other bikes I keep clean, but not the DR. I prefer it dirty and ready to ride :>

    Regards,

    Gregory Bender
    #6
  7. BAD-MOD

    BAD-MOD professional fiddler

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    chur im about reliability performance and looks in that order
    #7
  8. Pablo83

    Pablo83 Sleep, Wrench, Ride

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    Sorry, I got the list of what you've done confused with a to-do list. So did you rebuild the shock? I need to do that to mine soon.
    #8
  9. BAD-MOD

    BAD-MOD professional fiddler

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    a friend of mine did he re shimmed it an modified the valve dressed up the shaft new oil,gas and changed to a cr250 spring. man one of the best mods ever!!! can do big doubles and tripples now no dramas on the rear need to do the front though its still a bit sketchy.
    i love distechs shocks i want some
    #9
  10. BAD-MOD

    BAD-MOD professional fiddler

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    Clutch turned up today brom the us of a from greg bender awesoem news it's right and in good nic.
    also found a NEW set of clutch fiber plates on trade me. kevlar to suit dr350/rmx250 $75 nz stoked !!
    #10
  11. Greg Bender

    Greg Bender Long timer

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    Sweet! Glad to hear it is going to work out for you :>

    Regards,

    Gregory Bender
    #11
  12. slowsuki1

    slowsuki1 Been here awhile

    Joined:
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    118
    delo 400 is 15-40w and is one of the best oils to use in thumpers.
    #12
  13. BAD-MOD

    BAD-MOD professional fiddler

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    Yea it was regular motor oil without the friction modifiers for the wet clutch.
    From what i hear it needs to be propper motobike oil otherwise it buggers your clutch ?
    #13
  14. jessepitt

    jessepitt Ride More

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    Just to clarify: regular motor oil HAS friction modifiers which should be avoided with a wet clutch, not the other way around. Friction modifiers make your clutch slip.
    #14
  15. BAD-MOD

    BAD-MOD professional fiddler

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    cool it's good to have that sort of stuff cleared up saves face when quoting lol
    #15
  16. BAD-MOD

    BAD-MOD professional fiddler

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    Well it's been a few weeks but some jobs are well on the way .
    Saving $$'s for motor bits so on with cheep jobs to keep interest up , New air box as follows almost done I just need got filter and alloy pipe for carb.
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    i have painted the engine case nice Black propper engine case stuff and gave it a nice bake in my bake oven.

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    Both intake and exhaust porting is done just a clean up and a bit of a reshape, I also port matched the intake and exhaust to the manifolds.

    Because i can't afford to buy a nice new header pipe to replace my crusty std one i decided to use some spare time at work to try make one so here goes. i have access to free {work} 2" pipe i want 47mm o/s diameter so i made a wrap around the to mark the cut out i needed to make .

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    I then made them quite round and clamped them up to tack the inside of the segments.

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    Then it was a matter of tack tack tack twisting the segments to give the angle of the dangle. {making sure not to penitrate}
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    once i had tacked up the bits i had cut i set up a purge to weld it out.

    Acid welds and polish just need to make the rest now :evil
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    Thats the good news the bad news is i found bad spalling on the 2nd gear so i need to get a new one of them, Thumper talk oem is cheapst so far $60 us.

    so onward and upward keep you posted.:freaky
    #16
  17. Greg Bender

    Greg Bender Long timer

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    Glad to see you are making progress. That is a lot of work on the header pipe :>

    If any of these gears will work, let me know. I'll make you a great deal on anything you see on that page (about ready for the trash heap).

    Regards,

    Gregory Bender
    #17
  18. BAD-MOD

    BAD-MOD professional fiddler

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    i would be keen on the gear sets on the right W/o the shifter drum ect {don't wanna have to freight them} can you let me know how much for the

    -gears set assy delivered w/shafts.
    -two second gears only.

    please :wink:]

    P.S being factory fitter can be a really good job on weekends/nightshift :evil
    #18
  19. Greg Bender

    Greg Bender Long timer

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    PM sent :>
    #19
  20. BAD-MOD

    BAD-MOD professional fiddler

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    Mar 29, 2011
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    Hey guys I am rebuilding my DR350 and making it a 455 , I am now ready to do the con-rod but i am un-sure of the procedure :hmmmmm can any one help me out here ?.... I am quite capable/have access to most gear and would really like to do it my self,
    BUT if it is something that NEEDS to be done by a motor shop can someone recommend a place in south Canterbury
    #20