The DR350 and I go on a diet

Discussion in 'Thumpers' started by hondabtr, Oct 18, 2017.

  1. hondabtr

    hondabtr Been here awhile

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    Greetings to all. I recently had the opportunity to purchase a 1995 DR350 for $300. After bringing it home we started it enough to determine there were no weird noises from it. Weight at 297 with oil and no gas.
    [​IMG]

    I have read a couple interesting threads on weight reduction and decided to see how far I could go down the weight weenie rabbit hole. Wisconsin winters are looong and boooooring.
    https://thumpertalk.com/forums/topic/1042548-weight/
    https://thumpertalk.com/forums/topic/993917-my-new-cr-125-afs-aluminium-framed-mugen-powered/

    My plan is to tear it down and rebuild it with an eye to weight reduction using the following outline: If you can remove an item, excellent! Nothing is lighter than anything.
    If you can't do without it, can you replace it with a lighter version that will still do what it needs to do?
    If you can't replace it, examine it for unnecessary weight and drill or grind or cut wherever possible.

    To make it interesting ( to me anyways) I plan on donating $5 for every pound of weight I reduce the bike by to a great organization called the Steel Shoe Fund. The STEEL SHOE FUND has been established as a non-profit, tax-deductible organization to assist flat track motorcycle racers who have been seriously injured during competition within the continental United States by providing funds to be used to pay their medical bills or assist in their most immediate needs following a serious racing accident.
    http://www.steelshoefund.org/index.php

    I know there are always the people who say " Lose some of your body fat, its the cheapest way to cut weight". I believe that so I am also going on a diet myself and pledge to lose as much weight as I reduce the bike by. I will also donate $5 for every pound of body fat to the Steel Shoe fund.
    [​IMG]

    I can't wait to get good and rolling. I will try to keep detailed records of weights and reduction on components. I have some ideas about where to cut, but if anyone has any thoughts please shout it out.
    #1
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  2. bhorocks

    bhorocks Been here awhile

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    very cool, get er done!
    #2
  3. dcwilcox

    dcwilcox Been here awhile

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    :thumb
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  4. Jeff@TheQuadShop

    Jeff@TheQuadShop TAT survivor

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    :lurk
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  5. plugeye

    plugeye dreamer

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    Diggin your thread
    #5
  6. hondabtr

    hondabtr Been here awhile

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    OK. Let's take the low hanging fruit first.
    Front reflectors: 82g
    Speedo drive and front cable: 331g
    Hi/lo switch:178g
    Front signals:493g ( Bike had no rears)
    Speedo, tach, key assembly:850g
    Rear pegs:1231g
    Kick stand safety switch:134g
    Horn: 260g
    rear fender support:1726g
    Tool box and tools:541g
    SE grab handle:791
    Mirrors: 619g
    Total weight off and not returning: 7236g or 15.95 lbs!!! Yikes, i better get to the gym.

    Dropped out motor for cleaning and painting frame. Won't bore you with that.
    #6
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  7. Rebuilder

    Rebuilder Been here awhile

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    Can the rear sub frame be cut off and made out of aluminum?
    #7
  8. LT Traveler

    LT Traveler Adventurer

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    Nice work and way to self motivate to get healthy with a cool project. Good luck to you and I look forward to following your progress.
    #8
  9. CDN Rick

    CDN Rick Canoodia Eh?

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    This is fantastic! I'll be following for sure.

    (Might get moved to Some Assembly Required though)
    #9
  10. hondabtr

    hondabtr Been here awhile

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    Terry , the rear fender support is what is called the subframe on these. Its a big ass heavy piece of metal that bolts to the frame and supports that god awful tailight and license light. Ill be replacing the whole mess with a nifty enduro fender/light combo. Weighs boats less than the stocker
    [​IMG]
    #10
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  11. Jeff@TheQuadShop

    Jeff@TheQuadShop TAT survivor

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    Is that one made for the DR is it going to be a retro fit?
    #11
  12. hondabtr

    hondabtr Been here awhile

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    Going to have to hack and chop, Jeff. Its a Honda enduro thing
    #12
  13. Tekime

    Tekime Adventurer

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    :lurk

    Cool project. I've had weight reduction in the back of my mind lately, especially after doing a street conversion and adding all my gear.

    Random ideas to shave ounces, although some of these might not jive with the hard trails and my tendency to fall, some already done:

    • Lighter muffler/pipes
    • Remove counterbalancer (bold choice)
    • Aluminum handlebars
    • Aluminum rear sprocket
    • Titanium bolts
    • Replace glass headlight with lighter LED/plastic
    • Shorter/aftermarket front fender
    • Shorten/cut rear fender plastic
    • Aluminum subframe
    • Lighter turn/brake/tail lights
    • Aluminum airbox (might save a few grams??)
    • Aluminum pegs/levers
    • Replace mirrors w/ aftermarket plastic mirrors/use one mirror
    • Replace cable guides/guide mounts w/ plastic fasteners
    • Replace fork boot clamps w/ zip ties
    • Remove/cut passenger peg mounts

    Now drain a little oil, run it low on gas, and bleed some fork oil out, heck strip all the paint off for those last few ounces and rip. :lol3:photog

    (Obviously, those last items are not recommended)

    Good luck, it'll be interesting to see how the little tweaks add up!
    #13
  14. hondabtr

    hondabtr Been here awhile

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    Thanks Tekime. Good ideas you have there. I'd be nervous about aluminum pegs ( didja see the scales in first post) but titanium is a legit option. I just cut off the passenger peg brackets and the kick stand switch bracket
    for 132 grams
    #14
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  15. hondabtr

    hondabtr Been here awhile

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    I don't know if anyone cares, but here is a partial list of weights of stuff.
    Mirrors 619
    side panels ex. Screws 489
    grab handle 791
    seat 2115
    toolbox and tools 541
    battery 2527
    battery rack 525
    seat bolts 24
    subframe
    fender and light 1050
    chain 1570
    rec/reg 228
    horn 260
    front sprocket 182
    top motor mounts 112
    sprocket guard 93
    shift lever 188
    gas shield 419
    air boot 311
    air box/filter/mud guard 1292
    cdi 400
    carb 695
    coil 228
    kick stand safety switch 134
    rear master 874
    kick stand 574
    chain guard 208
    rear pegs 1231
    speedo/tach/key 850
    skid plate 587
    front signals 493
    foot pegs and mount 1184
    hi/lo switch 178
    head light 710
    throttle 146
    headlight shroud 217
    clutch perch/lever 172
    tank bracket 110
    front master 394
    handlebars 1175
    speedo drive and cable 331
    fender front 568
    front reflectors 82
    Rear caliper 870
    top mounts 111
    front mounts 65
    rear mount 33
    passenger and kick switch brackets 132
    rear sprocket 910
    #15
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  16. plugeye

    plugeye dreamer

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    ooo, dislike the frame mutilation. the next poor owner will hate it
    #16
  17. MrPulldown

    MrPulldown Long timer

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    Ohh your going to hate this topic then Plugeye. I think Rebuilder is talking about actually cutting off the back portion of the frame that supports the seat, battery, etc... I have seen someone do this to a DR650. They then built an aluminum sub frame, welded tabs to the main frame, and bolted on this subframe. I am sure it will save some weight but that is some serious hacking.

    I have been working on a similar project. Take a electric start DR and chop off as much weight as you can. I however still keep some of the street legal stuff like lights, horns and turn signals. Need to weigh mine to see where I am at.

    A couple of things that I see you can still take off:

    -Chain guard and mounting tabs.
    -Kick stand safety relay (not just the switch) and mounting bracket. You will need to do a little bypass wire job.
    -Dirt pegs do not have the rubber flex mounts and are lighter. Also uses a shorter mounting bolt x4.
    #17
  18. plugeye

    plugeye dreamer

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    swap out the shock too, its hefty
    use a light one or a strut
    #18
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  19. MrPulldown

    MrPulldown Long timer

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    Replace shock with a 2x2 with 2 holes drilled in it.
    #19
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  20. hondabtr

    hondabtr Been here awhile

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    #20