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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    Looks exactly like the CRF450 I am using.
    [​IMG]
  2. hondabtr

    hondabtr Been here awhile

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    OK, footpegs. Finally got the DR down off the table. I decided to use CRF450 mounts and pegs after seeing it done elsewhere. The selection is much bigger than the DR and the weight is far less. It moves the pegs down and back. Why not? Rebuilder made me a 3/8" aluminum adapter and they went right on.
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    First try they were way too angled. had to grind some off the back of the pegs to get the angles right
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    A comparison between old height and new
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    Here is the total for the brackets, titanium pegs, Ti pivot pin, and Ti bolts. Old peg assembly with NO bolts 1184 grams New peg assembly 769 grams -415 gr. (14.63 oz). Pretty nice savings. I did use steel 10.9 JIS bolts for top main bolt. I worried about the stretching of titanium because of my weight.
    [​IMG]
    Te Hopo and Bultaco74 like this.
  3. hellotimmutton

    hellotimmutton Adventurer

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    doh! completely missed that the crf450 master cylinder was an integrated one. how does having the pegs back and lower affect comfort?
  4. kojack

    kojack AMF!

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    Just stumbled upon this thread this morning...Awesome. I started eating better last February, I have lost 38 lbs. I went from 235 to 197. I did however load up during Christmas. I am back on the wagon again now, and losing again. I went from 197 to 206 in 2 months. OOOPPPSSS! I dig the donation of weight loss too...Awesome. Old iron whether it be the bike or us needs some fixing up at times..ha ha! keep it up!
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  5. hondabtr

    hondabtr Been here awhile

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    I am 6'8' tall, so my legs are a little longer than normal. It opens up the cockpit and makes it a little easier to get standing on the pegs, along with the bar risers. Some people add a taller seat, I have one on the 650, but I'm not going that deep on this project.
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  6. 2Fat2Pedal

    2Fat2Pedal Adventurer

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    Great project(s). Much respect to you and Rebuilder.
  7. brownvv

    brownvv Been here awhile

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    Just realized today that my 99 has a smaller starter on it than the 95 I am working on. The longer mount arms make up for the shorter barrel on the starter. There might be even lighter small staters out there that could work. The one from the 01 exc520 I am working on looks tiny in comparison 20180107_130051.jpg 20180107_130058.jpg 20180107_130136.jpg
  8. hondabtr

    hondabtr Been here awhile

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    Chains. Old non-ringed chain 1570 grams. New RK GB520MXU X ring chain 1494 grams -76 grams
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    Another thing that shocked me. I tried to save all the steel bolts, nuts, clamps, brackets, etc that I removed. I failed miserably but was still able to collect 1455 grams worth. 3.21 lbs. Most were replaced by titanium, some with aluminum, and some came off permanently.
    [​IMG]
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  9. Anthiron

    Anthiron Adventurer

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    This is amazing. Just read what you have done so far this morning in one go. Inspiring.
  10. hondabtr

    hondabtr Been here awhile

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    Really getting down to it now. Brake lever old 349 gr. New speed-holed, gun drilled, and new aluminum toe piece 276 gr -73 grams. I think the only things left to weigh are the new muffler and brake lines.
    [​IMG]
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  11. hondabtr

    hondabtr Been here awhile

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    Boo-ya!!!! Couldn't help it, did an autosum in the loss column. WAY more than I ever would have dreamed of.
  12. MrPulldown

    MrPulldown Long timer

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    What. You are in about as deep as you can go.

    Ohh you are killing me by not showing me that number.

    I told my wife about that Ti swing arm pivot bolt. She was not impressed.
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  13. MrPulldown

    MrPulldown Long timer

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    So is this a direct swap. Do the mounting holes and brake pedal just line right up? Hose routing?
  14. hondabtr

    hondabtr Been here awhile

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    Cant speak to hose routing as hose hasn't arrived. Mount bolts are the same. The angle of the plunger looked funny although they look exactly alike when compared side by side.I did drill a new clevis hole, although it might not have been necessary. Minor alterations still qualify to me as a direct swap
  15. MrPulldown

    MrPulldown Long timer

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    I might try one. But I will wait for your install post first.
  16. Slytheslayer

    Slytheslayer Ride or Die!!

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    I have a DR650, wonder if it would work on that? I'd like to get rid of the tube and reservoir on it to make it cleaner. Any thoughts?
  17. Hario

    Hario Been here awhile

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    This thread is a great read, congrats on your progress so far!

    I went on a bit of a weight loss program with my 99 350SE, in fact its my bike you linked a pic of the crf footpegs from earlier, i dont have my notes with me but if i remember correctly i got my bike to a point where it was just a few kg over a stock dirt model, and without any Ti or significant machine work so you will get there easily i rekon

    you said:


    this is from Pablo83's great rebuild thread, deffo worth a read if you haven't already:

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  18. Hario

    Hario Been here awhile

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    One huge weight saving i didn't see mentioned is the exhaust, any thoughts on that?

    the lightest i could find was a supertrapp, it was several kg under the stock one, i will look for the exact weights later if you like.

    I would also expect the cartridge fork front end from the dirt model is lighter, it has a different caliper with alu vs steel bracket, different front wheel hub and disc, and even the spoke nipples are aluminium, and i think the spacer between the bearings is alu vs steel on the SE

    Do i get a prize? :lol3

    other thoughts are
    -fork springs, ive seen claims that the aftermarket ones are lighter
    -the steering stem, alu ones are not uncommon, and the dr's steel one is heavy!
    -perhaps alu or Ti spacers in the rear linkage
    -swingarm, there was a scotts one made for the DR, rare though! there has been talk about RMX ones fitting the DR and being kilos lighter
  19. MrPulldown

    MrPulldown Long timer

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    I think the "miss anything "was referring to differences between a S/SE and a dirt.

    But yes you get a prize. A pint shared with me. You just have to make it over to where I am. Standing offer to any ADV member.

    As for the Scotts swing arm. Don't bother yourself looking for one. I spent years and jsut over $1K chasing one. I even bought an entire DR just so that I can have a Scotts swinger. Turns out they were built too light and stiff. The one I pulled off the bike was cracked in 8 places. Many people report the same issue with theirs. I later bought a 2nd one that someone welded up all the cracks. I have yet to install and test as all the bearing need replacing. The RMX swingser is fully boxed. Stiffer but not sure it is any lighter. I have one off the bike and can weigh. There are 2 main issues with the RMX swinger, one is that the mounts are different, end mounted vs center mounted; this can be worked around. The 2nd issue however is that it's linkage ratio is off. This too can be tuned I believe but will take some tweeking.
  20. Hario

    Hario Been here awhile

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    I meant the alu spoke nipples and bearing spacer etc.!

    there is a thread somewhere on adv rider where the rmx swinger is discussed and i think weighed and fitted to a dr350, as you say it has issues with the linkage, but importantly its very close in width at the pivot point.

    im not trying to sell the idea at all, its just something to consider and a possible significant weight loss. Not for everyone but a man machining parts and fitting titanium......

    one other thought is the wiring loom, rebuilt in thinner wire with the nonsense parts removed it is much lighter

    also, Hagon here in the UK make a DR shock that seems to be without the gas bladder and associated hose and mount https://www.hagon-shocks.co.uk/catalog/partdetail.aspx?partno=M63033