DR350 supermoto project on a KLR budget

Discussion in 'Some Assembly Required' started by dbarale, Nov 16, 2011.

  1. robocog

    robocog Adventurer

    Joined:
    Mar 3, 2011
    Oddometer:
    16
    Location:
    Gosport UK
    front is 110 70 17
    rear is 130 70 17
    (std GS500)

    Regards
    Rob
    #61
  2. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    1,338
    Location:
    Western NC
    Thanks Rob!

    So today was a good day.... kinda.

    Started out by giving the rear shock a good bath. Removed all the caked-on clay and scrubed it with simple green to remove the greasy crap.
    That allowed me to confirm that the shock isn't leaking and that the spring was upgraded at some point. :clap
    As an added bonus, it now smells piney fresh.:rofl

    Then back into the frame it goes...

    [​IMG]

    What's the thing in the frame in the pic above?

    .... It's the engine!

    [​IMG]

    I adjusted the valves, buttoned everything back up and the engine went back in the frame. That was a pain! Doing that kind of job by yourself sucks. But after much cussing, head scratching, and paint scratching it's finally back where it belongs. Touched up the scratches in the paint too...

    Here's the "kinda" part. I'm usually pretty confident about my work but I feel that this engine has been apart too long and I get that weird feeling that I missed something. I guess we'll find out when I start it up.

    I clean and repacked the steering head bearings and losely (loosely?) re-assembled the triples.

    Next was the fork tubes. I opened them up to drain them and first found PVC spacers, mmmh. Then, non-progressive springs... This is getting good.
    Then:

    [​IMG]

    :clap:clap:clap:clap

    Some previous owner spent some $$$$ at some point. Suspension front and rear, Vortex airbox, FMF pipe. Maybe this project is worth it after all...
    Now I just need to figure out what and how much oil to put in the tubes. Luckily, Rick/Cogent Dynamic is only 3 miles away.

    I also removed the RaceTech stickers from the fork tubes. Nothing against RaceTech, I just don't like stickers. Now, if RaceTech builds all their products like they made these fucking stickers it must be a good company to buy from.
    Took me about 30 minutes per leg...

    Good news is that the fork seals seem to be OK. I'll be running with no boots as long as I run street only. If they start leaking I'll know right away.


    Last was the carb. I had cleaned it recently for the PO so no surprises. It was rejetted with a 145 main and needle all the way up. I may drop it one slot to see, most of my riding is around 3000 to 3500ft. I also read somewhere that, for easier starting, Suzuki recommended drilling out the brass jet located in the float cage. Now if I could only figure out what drill bit to use...

    That's all for today. Feels good to be moving forward.
    #62
  3. ben2go

    ben2go Moto Flunky

    Joined:
    Jun 23, 2011
    Oddometer:
    4,057
    Location:
    Upstate SC USA
    You can get seals and wipers for about $25.I'd just change them.All the $$$ you are throwing at this bike,I wouldn't skimp on them.
    #63
  4. aposaric

    aposaric Garden mechanic ;-)

    Joined:
    Jul 6, 2007
    Oddometer:
    270
    Location:
    Zagreb, Croatia
    This is soo fun to watch :-) I often get surprised how many upgraded parts you can find in the old thumpers :-) Turns out that te more beatten up and dirty bike you find, it is filled with nice and quite $$$ goodies in its internals, and you get them for the bargain prices.

    For how long do you expect to work on this bike before it is on the road again?

    cheers

    a :freaky
    #64
  5. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    1,338
    Location:
    Western NC
    If I can get 3-4 full days in the garage it will be back on the road with the factory wheels. My goal is to get the entire project completed by March 1st...
    #65
  6. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    1,338
    Location:
    Western NC
    Needed:
    - <STRIKE>full gasket set</STRIKE>
    - <STRIKE>timing chain</STRIKE>
    - <STRIKE>GS500 front wheel</STRIKE>
    - <STRIKE>GS500 rear wheel</STRIKE>
    - tires
    - mirror
    - <STRIKE>front cam chain guide</STRIKE>
    - <STRIKE>suspension linkage needle bearing and hem joint</STRIKE>
    - <STRIKE>seat cover</STRIKE>
    - used gs500 sprocket to check gearing

    Wanted:
    - XR style tailight
    - SM front fender
    - factory clutch perch and lever (the ratio on this one seems to be all wrong)
    - <STRIKE>maybe a lighter skidplate</STRIKE>
    - SS front brake line
    - fork brace
    #66
  7. B.Curvin

    B.Curvin Feral Chia tamer

    Joined:
    Feb 15, 2004
    Oddometer:
    2,774
    Location:
    Left of the dial. Canton, NC
    Hey dbarale, you might outta swing by my place and see if I have anything you need.

    I have a 93 DR350 that I currently ride (and it's for sale). A 94 DR350 I bought with a dropped valve (might have some parts you need). A DR250 engine in a box. A few seats. SM front fender. SM wheels that I built. And a load of other crap. If you want to stop by this week shoot me an email.

    B.Curvin@gmail.com

    I'm in Canton.

    [​IMG]

    [​IMG]

    [​IMG]
    #67
  8. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    1,338
    Location:
    Western NC
    Those are some purty wheels! Probably waay out of my budget though but I still need to meet with you. I need a few odds and ends...

    I'll shoot you an email.
    #68
  9. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    1,338
    Location:
    Western NC
    Thanks to B Curvin I get to check a couple more things off the parts list. Quite a bit of progress this past weekend, update to follow...

    Needed:
    - <STRIKE>full gasket set</STRIKE>
    - <STRIKE>timing chain</STRIKE>
    - <STRIKE>GS500 front wheel</STRIKE>
    - <STRIKE>GS500 rear wheel</STRIKE>
    - tires
    - mirror
    - <STRIKE>front cam chain guide</STRIKE>
    - <STRIKE>suspension linkage needle bearing and hem joint</STRIKE>
    - <STRIKE>seat cover</STRIKE>
    - <STRIKE>used gs500 sprocket to check gearing</STRIKE>
    - <STRIKE>rear brake caliper</STRIKE>

    Wanted:
    - XR style tailight
    - <STRIKE>SM front fender</STRIKE>
    - factory clutch perch and lever (the ratio on this one seems to be all wrong)
    - <STRIKE>maybe a lighter skidplate</STRIKE>
    - SS front brake line
    - fork brace
    #69
  10. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    1,338
    Location:
    Western NC
    This winter project has been suffering from a lack of... winter.
    It's been unusually warm and I've been spending a lot of time doing other outside/outdoor stuff. Well, now it's freakin' cold. So I got busy.

    First I cut a new spacer to fit in between the inner rear wheel bearings. The factory one was steel and, apparently, tool grade steel. After 20 minutes of trying to re-bore it I finally gave up and cut one out of aluminum. It just works on compression loads so it should be strong enough. Maybe...

    I then popped in the new wheel bearings and turned my attention to the rear caliper. Turns out the sliding pins were completely frozen by corrosion. After two hours of drilling, cutting, bleeding, cussing, I finally had it apart. But now I needed to buy new pins, rubber boots, and probably replace the seals.

    Fast forward a couple days and I got to meet B.Curvin. His garage his full of crazy projects, and parts. He offered me a caliper in great shape for a great price. Well, yes I will...

    Put the wheel in for a quick fit test. As expected, the right side needs to be machined about 5mm to allow the rotor to center in the caliper.

    [​IMG]

    BTW, the GS500 rotor has been ground to 220mm diameter and 4mm thickness to fit the DR caliper. Pics to follow as soon as I pick it up.

    I also got from B.Curvin a trick rear sprocket. A 520 conversion sprocket from his SV650 track bike. It's aluminum, has the right pattern, and should be the right tooth count. Best of all, it was really cheap! :clap

    It should get the gearing in the ballpark. I'll adjust by replacing the front sprocket that has seen better days.

    [​IMG]

    The lip on the left side of the wheel still needs to be machined off. The bearing will also need to be replaced with a sealed one. No big deal.

    I flushed all the gunk, mud, sand, and whatever else out of the forks. I then refilled them and put the front end back together.

    Quickly cut a couple of spacers to center the front wheel. Easy, but there isn't much room left between the rotor and the fork leg on the left side. Sorry for the bad pic, best I could do:

    [​IMG]

    I still need to work out the caliper mount. I may grind down the fork tube a bit to make it easier. I'd just have to use spacers when I switch back to the factory wheels. Still in the air.

    ... And then a couple days of tedious work. Every part is inspected, cleaned, painted if needed, and re-assembled. It's slow and not really gratifying but at least I get a good look at everything before it goes back on. I re-wrapped the entire wiring harness as it was falling apart, another three hours of fun...

    Anyway, the goal was to get the bike back on its wheels by the end of the weekend. Mission accomplished (-ish).


    [​IMG]


    [​IMG]


    I cheated a bit as the rear wheel needs final machining, so it's not really on. Both wheels need paint and tires. The supermoto front fender also comes from B.Curvin's stash. The problem is that I now decided to paint the entire bike black.

    Tomorrow I'll put the carb back together and try to get an oil filter. I plan on working on the exhaust later today. Hoping to re-start the beast on Wed, hopefuly.

    Expected completion date is still March 1st. Fingers crossed...
    #70
  11. B.Curvin

    B.Curvin Feral Chia tamer

    Joined:
    Feb 15, 2004
    Oddometer:
    2,774
    Location:
    Left of the dial. Canton, NC
    That's a mighty fine lookin' caliper you got there. :clap

    Looks like it's coming together nicely.
    #71
  12. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    1,338
    Location:
    Western NC
    Finally got the exhaust and carb back on. Checked the battery, 10.1V, not good. But I connected it anyway and tried to kick it with the spark plug out, I was getting a weak blue spark.

    I hooked up the tank and there was just enough gas in there to fill up the float bowl.

    Kicked about 6 times and got one single burp. That's when I realized that the headlight was still connected.

    Disconnect the headlight.

    One kick.

    IT'S ALIVE! :freaky

    Let it run for about 30s and killed it. It now starts reliably on the 1st or 2nd kick.

    I am thrilled, this bike was near impossible to start cold before and a real bitch to start hot. Even if it takes 5-10 kicks to start cold it's definitely something I can live with. Now to paint the plastics, finish the wheel setup, paint the wheels, tires and it will be road ready.


    Might still make my March 1st deadline.
    #72
  13. rubberband

    rubberband Will ride for tacos

    Joined:
    Jul 16, 2010
    Oddometer:
    439
    Location:
    Michigan
    progress baby....progress.....Nice!
    #73
  14. BUGSMAK

    BUGSMAK BUGSMAK

    Joined:
    Apr 16, 2011
    Oddometer:
    7
    Location:
    Asheville NC
    Looks great Daniel! Sorry man but I think I'm gonna need my DR back! She's just looking so sexy now and I'm suddenly starting to miss her! Just the thought of her gettin turned on so easy now is killin me!! And that black thing it's like her darker side is coming out!! Mmmman!

    Naaa!! Maybe she'd be happier with you...
    :cry
    :flip
    :deal
    l:evil
    :dunno
    #74
  15. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    1,338
    Location:
    Western NC

    Well, you still have the title... :D
    #75
  16. MrPulldown

    MrPulldown Long timer

    Joined:
    Aug 18, 2009
    Oddometer:
    3,684
    Location:
    Truckee
    Nice job. Today is march 1st. You out riding her?
    #76
  17. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    1,338
    Location:
    Western NC

    ........ No ............

    But it's close.

    The re-assembly is mostly complete so I pulled it out on the driveway for a couple pics:


    [​IMG]


    [​IMG]


    The seat cover is not attached as my staple gun is not strong enough to go through the plastic seat bottom. I'm starting to like the purple/yellow with the black. What do you guys think?

    The rear wheel still needs to be machined. I haven't had time to bring it back to the shop. :cry

    After I took the pics I put the factory rear wheel back. I also worked on the caliper relocation bracket for the front. It's about 90% done. Just need to make a trip to Lowes for some bolts. Then... test drive around the block.

    Good news is that it starts from cold in 4-5 kicks! :clap:clap

    New deadline, March 15th. Fingers crossed...
    #77
  18. TheOtherBart

    TheOtherBart Long timer

    Joined:
    Jan 16, 2006
    Oddometer:
    2,053
    Location:
    DeKalb County, Illinois
    You might have some trouble getting that thing to hook up. :freaky

    It's looking great. I really wanted 17" spoked wheels for my XR moto project but the cast wheels were a zillion times cheaper, and once I had them on I decided they looked awesome.
    #78
  19. BUGSMAK

    BUGSMAK BUGSMAK

    Joined:
    Apr 16, 2011
    Oddometer:
    7
    Location:
    Asheville NC
    Damn!! I musta lost it!! Can you believe that?!?! What luck!!:lol3
    #79
  20. wkbogie

    wkbogie Adventurer

    Joined:
    Jun 20, 2011
    Oddometer:
    17
    Location:
    Raleigh, NC
    Wow, This is awesome! :thumb
    I got a non-running, very cheap Dr350 with a 440 kit. I now want to convert it to a supermoto! Ohhh decisions....
    Thanks for all the details. Can't wait to see this complete. Good luck.:clap
    #80