DR350 Fun Build

Discussion in 'Thumpers' started by Hscarborough, Aug 9, 2016.

  1. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    It's not an exact match, but it's darn close. For little touch up spots I sprayed it into a cup and used a foam brush. Leave it alone after about 30 seconds because it dries very quickly. Dabbing the foam brush worked better than brush strokes.

    [​IMG]

    [​IMG]

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
  2. Ghostyman

    Ghostyman Been here awhile

    Joined:
    Sep 5, 2011
    Oddometer:
    426
    Location:
    LA face with the Oakland booty
    Thanks, that's very helpful.
    Hscarborough likes this.
  3. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    Blue bike update! (Finally)

    I'm waiting on a new hose clamp for the air box snorkel. Old one stripped out so I just ordered a fresh one with some other parts. Once that arrives, the pumper can be mounted. The only thing keeping me from riding it at that point is an oil change and hot-wiring an ignition. Installed the throttle tube from yellow bike and removed the old grip. Bled the front brakes. The DR650 master cylinder feels really good. Very stiff and little to no squish. Could be from the stainless braided line though. Feels good to me.

    Front brake cylinder
    [​IMG]

    I had no cups in the garage so I had to get creative...
    [​IMG]

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
    buzzword likes this.
  4. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
  5. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    I also wanted to mention my favorite method of painting... Sharpie! There were a few scrapes and marks on the throttle housing I pulled from the yellow bike and am installing onto blue. Draw on the scratches then lightly buff after it has dried.

    Before
    [​IMG]

    After
    [​IMG]

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
  6. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    More Blue Bike updates!

    New items:
    -Tires. Shinko 244's. I just can't say no to $83 for a set of tires delivered.
    -Hand grips
    -New air box boot hose clamp (old one stripped out)
    -Battery eliminator kit. Yes I know you can solder up just about any capacitor that's 25V+ and 4900 micro farad's but for $32 I couldn't resist. Looks to be nicely packaged and should make the wiring look nice and tidy. I love tidy wiring.
    -Outlaw clutch cable perch. I saw some people raving about this on the DR350 forum and I decided to give it a go. For $22 it was about the cost of motion pro but looked pretty. I like pretty things that work well. Let's see how it goes.

    Currently on order:
    -Cheap eBay keyed ignition switch

    Once these parts arrive I can mount the tires, mount the carb, do an oil change and it'll be "running". Still need to check the jets that came with the TM33. Hopefully they are stock.

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
  7. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
  8. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    Small project of the day was the skid plate. Man it looked beat up! How does the rest of the bike look so clean with a skid plate like this?

    [​IMG]

    It was bent, dented and had some good gouges out of it. First I took it to the scotch pad wheel and smoothed out all the burrs and rough edges. Next I mashed it with an arbor press in a few strategic spots to try and regain its former shape.

    After the scotch pad wheel.
    [​IMG]

    A gentle massage...
    [​IMG]

    Next up I hit it with the sand blaster to remove the paint, dirt and grime before using the more sensitive bead blaster. Sandblasting gave it a very rough surface finish and cause some pitting. The bead blaster was much better and gave it a sparkly silver finish instead of the dull finish left by the sand.

    Finished.
    [​IMG]

    Next step will be fitting it to the bike. Hopefully with all my straightening and flattening everything will bolt back up properly. We will see. Worst case, I twist and bend it a little more to make it fit.

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
    plugeye likes this.
  9. Ghostyman

    Ghostyman Been here awhile

    Joined:
    Sep 5, 2011
    Oddometer:
    426
    Location:
    LA face with the Oakland booty
    Can you post a link to the keyed ignition? Now that I picked up another DR350, I'm going to piggy back on all your good finds and ideas here.
  10. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
  11. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    Blue bike update:

    My brother in law helped me rebuild the RMZ forks. I stayed out of the lower damper rod area and just stuck to replacing seals and o rings where I could. I didn't take many photos but if you're doing these for a 2004 RMZ 250 or 450, then you're in luck because Rockymountainatv did a how to video with these forks. Link below. The forks appeared to be in good shape but the seals leaked like a sieve. Not anymore! Fresh 5w synthetic fork oil.



    All disassembled.
    [​IMG]

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
  12. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    Blue bike:

    Next step was tires! I mounted the front and back tires with my brother in law. Pinched one tube, pulled it out, patched it and reinstalled. The rear tube sprung a leak around the valve stem. Luckily we had an extra tube on hand.

    Front tire.
    [​IMG]

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
  13. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    Forks are reinstalled, both wheels are on and I have front and rear brakes. On a side note, the DR650 master cylinder with the RMZ caliper feel like a great combination. Very tight and little to no squish. I dropped the bike off the lift and tested it out. The front forks feels great. Not too stiff like I thought they were initially. I tried to find any markings on the springs but couldn't find any so I've no idea what spring rate they are. It does highlight the softer rear end though. Hopefully swapping the dirt model shock from Yellow Bike will cure that.

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
    buzzword likes this.
  14. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    Blue bike:

    A little more work done this afternoon. I cut and spliced the rear tail light to be much more tidy. There was about 12" of excess wire and the crimp job was sub par. I also installed the intake boot with just a light film of gasket maker because the oring was very flat. Installed the airbox boot with the new clamp and then realized I was missing the OTHER clamp too! Darn... So I'll need to order one of those. I also opened up the new TM33 carb and verified the jetting. It has a 37.5 Pilot and 127.5 Main. Perfect! Came straight from Amazon that way. From research this sounds like the proper jetting for the bike in its current state. Probably will need to adjust once I go big bore.

    Also mounted the Outlaw Pro clutch lever setup. Obviously I haven't ridden with it yet but it feels great! Smooth action and nice fitment. $22 well spent.

    No pretty photos from today's work. Stay thirsty my friends...

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
  15. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    Blue bike:

    Small changes today. I fixed some spotty wiring on the turn signals, mounted the TM33 Carb, remounted the headlight, and started looking at the ignition setup.

    Carb test fitted.
    [​IMG]

    Next up, was to make a template for the dash. The last template I made was stolen with my truck... I hate thieves. Anyways, here's the general idea. I'll drill and tap two bolts into the upper triple for mounting.

    [​IMG]

    Here it is with the Trailtech roughly in place.
    [​IMG]

    I'm planning to add a 90 degree flange coming off the right side for the ignition. With such a small amount of space, I think this is a good solution.

    Rough idea
    [​IMG]

    I finished the night with a small amount of touch up to the frame where I'm mounting the capacitor. Just above the passenger footpegs mounts on the left side of the bike.

    That's all for one weeknight...

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
  16. brownvv

    brownvv Been here awhile

    Joined:
    Sep 23, 2012
    Oddometer:
    776
    Location:
    colorado
    I liked that outlaw clutch so much I put it on almost every bike I own. The difference that bearing makes is huge
    Hscarborough likes this.
  17. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    Blue bike:

    I got to work on a dash for mounting the Trailtech. I've made dashes before in the past and boy do I hate it... There's so many options and so few unknowns that I get all wrapped up in the possibilities. Anywho, here's what I did.

    For the cutout where the clutch cable, brake hose and decompression lever cable go through, I sliced a piece of 5/32" polyurethane tubing and slid it over the edge. To make sure it stayed put I drilled a few small holes and used zip ties.

    Pre-zip ties and trimming
    [​IMG]

    Final edge protector.
    [​IMG]

    Next I drilled a hole to dodge the boss where the stock number plate mounts. This gave me one fixed point of reference. With the dash fairly fixed in space, I drew a line on the back of the headlight and placed a strip of foam along the line. This meant I had to press the edge of the dash into the foam and then pop the boss through the hole. It helps to support the end of the dash and keep it from bouncing up and down.

    Line
    [​IMG]

    Foam
    [​IMG]

    Assembled
    [​IMG]

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
  18. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    Continued...

    Annoyingly if you mount the Trailtech flat onto a piece of sheet metal WITH the Trailtech dash, the light bulbs for the 4 indicators will not clear the dash. To fix this I had to drill 4 holes under the indicators. I also chose to mount the ignition switch on a flange on the right side of the bike. This cleared up space on the dash. It's surprisingly crowded with just the Trailtech.

    Ignition with light bulb holes
    [​IMG]

    Dash layout
    [​IMG]

    Last step is to drill the 2 mounting bolt holes to insert the factory grommets in the photo below. In addition I'll need to make a small rectangular cutout right in the middle for the main unit's wires to pass through. Then it'll be time to finish wiring everything together.

    [​IMG]


    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
  19. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    Yellow bike update!

    Nothing big today. Just a bunch of parts. Amazon had a price drop on the Acerbis gas tank so I couldn't help myself... It arrived today and will both help with my clearance problem with the BST carb AND improve the look of the bike (in my opinion of course). It makes the bike look a lot more modern than it is.

    In the mail I also got a second Outlaw Pro clutch perch in black (no yellow available). I liked it enough on Blue Bike and for $22 I could hardly get a boring looking bike master branded perch and lever. So I went for it. This does not include a mirror mount so i purchased a pair of 10mm mirror mounts on eBay for $6. One for Blue and one for Yellow.

    [​IMG]

    The third thing that arrived is an Emgo OEM replica tail light. The dirt model tail light doesn't have brake light functionality. I'm hoping this one bolts right in seeing as it's a replica. Cost was $25 free shipping on eBay. Can't go wrong with that. I actually like the look of it better than the tiny aftermarket one on blue bike so I might steal it for Blue...

    [​IMG]

    Lastly are the infamous Greg Bender Oring kits! I ordered two of these kits (one for each bike) so I could change all the orings as I come across them. Cost was $10 per kit and about $1 for shipping. It comes with a great cheat sheet so you know where each oring is supposed to go. Everybody should just buy one and replace the orings every time you pull one out. Special thanks to Greg for putting these together for us all. These kits can be found here: http://thisoldtractor.com/for_sale_dr350_orings.html

    [​IMG]

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/
  20. Hscarborough

    Hscarborough Been here awhile

    Joined:
    Aug 8, 2016
    Oddometer:
    800
    Blue Bike

    I did some good work but didn't take many photos today. I installed the new taillight I meant to use on Yellow Bike. Surprisingly none of the holes lined up with the fender. I thought perhaps my rear fender was aftermarket but it's got the Suzuki label on the side... So I'm not sure how it's an OEM replacement but the plug went right in so that's a win. I drilled a few holes and 20 minutes later it was installed.

    [​IMG]

    I also connected the throttle cables, adjusted the free play and installed the gas tank for hopefully the last time for a while. Last thing of the day I took the plastic fork guards off, scuffed them with a scotch pad and painted them white. I'm not a huge fan of painting plastic but I can't for the life of me find new white ones aftermarket. Only black. I feel better painting white on white since if (more like when) it scratches it'll be the same color underneath.

    Painted one on the left, unpainted on the right
    [​IMG]

    See my build thread here: http://advrider.com/index.php?threads/dr350-fun-build.1166102/