DisTech's DR350 rebuild

Discussion in 'Thumpers' started by DisTech, Nov 27, 2009.

  1. BikePilot

    BikePilot Long timer

    Joined:
    Jul 5, 2005
    Oddometer:
    11,959
    Location:
    Golden CO
    After playing with the base gaskets and deck height I'd check the cam timing - Suzuki isn't especially careful in getting it right to start with and it will have changed if deck height changed.

    Glad its running :clap
  2. marksbonneville

    marksbonneville Long timer

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    Arizona, Prescott more less.
    Looks and sounds great.
  3. BAD-MOD

    BAD-MOD professional fiddler

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    New Zealand
    Hey man sounds great !!! You must be gagging to ride it ?
  4. PhiSig1071

    PhiSig1071 What's ******width?

    Joined:
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    Ever want to sell it, name your price, I'll take it off your hands. Beautiful bike.
  5. FlyingWman

    FlyingWman Been here awhile

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    Jul 8, 2009
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    Great lakes state
    That's a sick bike! Makes me think what I could do with mine :D
  6. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Took a little longer than 6 months. :lol3
    [​IMG]

    Not completely done but this is the first time shes been completely dressed!
    [​IMG]

    [​IMG]

    To do:
    • break in
    • final jetting
    • steering stops
    • fix erratic tach readings
    • rebuild and respring the shock (RaceTech ordered)
    • rebuild and respring the forks (RaceTech ordered)
    • TrailTech 8" HID headlight (ebay ordered)
  7. BSR-1

    BSR-1 Adventurer

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    Sep 13, 2008
    Oddometer:
    28
    You are very hard on my wallet! after seeing all the fun you're having it makes me want to do it all over again.
    I really like riding but I think i like building projects even more so.
  8. FlyingWman

    FlyingWman Been here awhile

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    Great lakes state
    I'm interrested in what this all cost you, if you dont mind me asking
  9. slowsuki1

    slowsuki1 Been here awhile

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    Mar 4, 2009
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    118
    glad to here you got it running , that is one sweeeet looking dr350.
  10. mgdavis

    mgdavis Been here awhile

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    Silverdale, WA
    Sweet!:D
  11. juda5

    juda5 Been here awhile

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    Damn - that looks good!

    Dunno if you've seen this, but he seems to have some pretty neat break-in theories.

    Time to get it dirty!
  12. BAD-MOD

    BAD-MOD professional fiddler

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    i like the sound of it don't know about the petrol car oil ?? is that for dry clutchs only ???
  13. richthofen

    richthofen Adventurer

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    Jun 3, 2009
    Oddometer:
    10
    In short, yes, however you will find that it depends on the api rating of the oil. Too slippery oil and you might have problems with the clutch. Also car oils do not always have gearbox additives in them.
  14. juda5

    juda5 Been here awhile

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    The oil topic is a HUGE can of worms -- I would take any oil advice (other than the bike manufacturer's) with a grain of salt.

    Personally I use a cheap, easily available synthetic car oil for my DR -- I have had no issues, clutch or otherwise.
  15. Rich667

    Rich667 Been here awhile

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    Dauphin, PA
    that is one hell of a nice dr, one of if not the nicest ive seen. great job!
  16. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    I drove up the block and back and the clutch was pretty sad, so I ordered a heavy duty rebuild kit from ProCycle.
    [​IMG]

    Soak the cork.
    [​IMG]

    The patient is open.
    [​IMG]

    New clutch drive plates and driven plates.
    [​IMG]

    New heavy duty springs (although they seem identical to the ones I replaced).
    [​IMG]

    Aside from soaking the cork overnight, replacing the clutch parts took less than an hour and it's better. :norton
  17. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Now that's the headlight I wanted on there! :clap
    [​IMG]

    It just showed up today as I was finishing the clutch. A license plate was also installed today so nothing was holding me back from riding to the gas station for a maiden voyage. :evil

    Twice!! Not on purpose, I found the front end in the air while in traffic. That 12 tooth CS is ridiculous (in a good way)! :lol3
  18. jplum1556

    jplum1556 Been here awhile

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    Apr 28, 2010
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    Platteville, Wi
    *drool*
    Amazing work. I love the style of the bike and even on my stock dr350 I bet the 12 tooth front sprocket would be pretty crazy so I can only imagine on yours you can have loads of fun.:D I've been debating boring out my 350 and getting the top end redone just like you did. What did it end up costing to get the whole top end redone?
  19. BSR-1

    BSR-1 Adventurer

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    Oddometer:
    28
    12 tooth? WOW!
  20. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Both Muggy "weld" joints failed on the oil cooler during a break in run this morning. They didn't blow off or anything but they leaked really bad. My left boot is now well oiled. I made it home while there was still some oil in the bike. Removed the oil cooler for now and changed the remaining oil.

    Changed to a 14th CS, much more practical for the road. :cry

    On the break in run the bike stumbled a bit at WOT, probably need to drop the main jet size.

    Fixed the erratic Vapor tach readings by cutting my fancy hard wire to the coil and running an inch of the tach pickup line parallel with the coil lead (no wraps) as referenced here. There is a white/red wire from the CDI that goes to the factory tack. I was hoping to use that for the Vapor tach signal but there was no signal coming from it (maybe it uses resistance instead?).

    Probably try some more break in runs in the morning.