Saving my knee, DR350 fusion...

Discussion in 'Some Assembly Required' started by dbarale, Sep 16, 2019.

  1. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    2,671
    Location:
    Western NC
    I am just posting this to document what I am doing, it helps me for future reference. Feel free to tag along. Sarcastic comments and unsolicited advice are appreciated...

    So, I got this bike about 8 years ago and rebuilt it into a supermoto. The build was detailed here:
    https://advrider.com/f/threads/dr350-supermoto-project-on-a-klr-budget.742198/

    Since then I had two kids and turned it into a dual sport. I love this bike but I cannot keep riding it. My messed up right knee does not allow me to ride a kicker anymore if I want to avoid a very expensive knee surgery...

    I do not have the SUMO wheels anymore. The mileage is unknow but less than 5k miles since the rebuilt. At that time it got a Wiseco piston, new cam chain and tensioners, new exhaust valves.

    It's a 1990 DR350S, kickstart only.
    The bike has a bunch of goodies on it:
    - Vortex airbox with new filter
    - FMF exhaust
    - Springs and gold valves front
    - Revalved shock
    - Brush guards
    - Skid plate
    - DR650 pegs
    - IMS (I think) oversized tank
    - Probably some other stuff I forgot

    Last year I rebuilt the carb with a new slide, slide guide, needle, jets, o-rings, etc.
    It runs well and pulls very strongly.

    It still have a bunch of stock parts: clean gas tank, passenger pegs, grab handle, license tag holder, etc.

    I originally put it up for sale as-is, asking too much. I got little interest but I was offered to buy back a very clean 1996 e-start that I had restarted a while ago for very little money.

    The plan now is to combine (over the next few weeks) this ‘90 kicker and the ‘96 e-start. The final goal is a barely legal, dirt oriented, e-start bike that is as light as an old tractor can be...

    [​IMG]

    [​IMG]

    The '90 is going back to mostly stock and will be sold cheaply.
    #1
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  2. tntmo

    tntmo Oops, I did it again.

    Joined:
    Jan 31, 2012
    Oddometer:
    1,267
    Location:
    San Diego, CA
    I remember your super moto build, in fact I’m pretty sure you sent me the original front brake bracket. My buddy has it...been stalling on his GS wheel conversion.

    Looking forward to seeing you get this project done.
    #2
  3. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
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    I sold the sumo wheels after touching the peg (or the kickstand?) on a left hand turn. I was riding way too fast for the street...
    #3
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  4. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    2,671
    Location:
    Western NC
    Stuff to be swapped to the e-start:
    - Skidplate
    - Big tank
    - DR650 pegs
    - Barkbusters
    - Dirt type grab handle (alloy and much lighter)
    - Suspension bits
    - Seat (taller with added foam)
    - Muffler (maybe, still undecided)

    Stuff to be re-installed on the kicker:
    - stock tank
    - stock pegs
    - turn signals
    - S model grab bar

    Stuff to be sold/traded:
    - Vortex airbox
    - Stock muffler
    - Factory rear rack

    I will also do a starter relay delete on the e-start, replace the headlight with a chinese POS just to be street legal, replace the battery with a LiFO, all for weight savings. But first, I need to take for a quick ride and see how it runs.

    Good news on the weight loss side is that the rear wheel is the non-cush model (which is fine for my use), and that it already has the smaller starter type which is much lighter than the larger one.

    55F57BA4-E217-441D-AD6C-1F527ED8D8A5.jpeg
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  5. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
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    5,204
    Location:
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    I had a similar experience with a KTM Duke 2
    Got home after a spirited ride and thought I’m going to run out of talent real quick and hurt myself. Sold the bike the next week
    Still miss it. Was too much fun :lol3
    #5
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  6. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    2,671
    Location:
    Western NC
    Did a little work yesterday. I charged the battery but it is shot and it will need a new one. That’s OK, I want to go with lithium anyway to save weight.
    I jumped it from my truck and it started right away. No smoke or noises but it won’t rev cleanly unless the choke is on. It should be an easy fix.

    Then I started taking stuff off the SE. That bike is surprisingly clean and unmolested. It still has the stock airbox and muffler, and even the stickers on the rear fender. All the hardware is clean and correct.

    0EFE60A9-4C31-427F-805E-5F0F62DFFB87.jpeg

    B2EF5D09-3A2D-465A-A283-C29E7B1BAF78.jpeg

    C464FA02-1E14-498C-8A14-DBD9FDFAA7B5.jpeg

    I kept going for a bit until I ran out of time.

    EC27A628-E9A7-41A9-A79F-36A5FCAB42D4.jpeg
    #6
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  7. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    2,671
    Location:
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    Not much to show for a lot of work. I recently rebuilt the forks on the SE so I was originally just going to swap the heavier springs and gold valves into those forks.
    ....until I remembered that the internals are drilled to accommodate the gold valves.

    Yeah, so, won’t work.

    In the end I swapped the forks between bikes. Which means I will be selling the kicker with freshly rebuilt forks. Oh, well. It’s a good selling point I guess.

    I lubed the steering head bearings on the SE and removed headlight and dash while I was at it.

    Removed the Vortex airbox from the kicker so it can be sold to help finance the project.

    5B7F12F2-1ED9-4025-82F1-15160475CE38.jpeg

    FAC6063A-F397-4BEA-99A4-95CF9BAC0342.jpeg

    I already have a buyer who’s also sending me his stock airbox so it can go in the kicker.
    I removed the factory rack from the SE, it will probably be sold too. Installed the dirt grab bar on the SE and S grab bar on the kicker.

    Took the Clarke tank off the kicker and roughly re-installed the stock one just for a quick pic. Just to have an idea of what it will look like when it’s sold.

    1BE546FC-78AD-4C12-9240-3037CCF6C5D3.jpeg
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  8. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    2,671
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    And yes, my garage is a disaster...
    #8
  9. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
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    2,671
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    Found four matching, brand new turn signals in a box. So they’re going on the kicker:

    C169C018-1A0F-4419-AD67-D84CDE743804.jpeg

    Yeah for free stuff. But on the other hand:

    B59648E3-0B68-4100-8C20-F889846DBFC6.jpeg

    That won’t work... So I ordered a brand new one (throttle cable). Nice new parts for whoever is buying it.
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  10. dbarale

    dbarale Squiddly slow

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    Kicker is almost done, I just need to find the LED flasher relay that I know I have, somewhere...

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  11. dbarale

    dbarale Squiddly slow

    Joined:
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    And the SE is getting there. New headlight, grips, handlebars, removed the instrument cluster and made a bracket for the keyed ignition. Dug a tail light out of the parts pile, and installed it. It started right up but I think the float valve is leaking. Didn't really have a chance to mess with it as it started raining as soon as I got it out...


    IMG_2748.JPG LDMG8386.JPG OULT7456.JPG
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  12. buzzword

    buzzword Been here awhile

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    Sep 24, 2015
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    495
    Location:
    SF CA
    soooo you’re selling that Vortex, huh?
    #12
  13. dbarale

    dbarale Squiddly slow

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    Oct 20, 2008
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    Sorry, it's already gone...
    #13
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  14. plugeye

    plugeye MC rescue

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    May 11, 2007
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    6,615
    Location:
    Garland, Texas USA
    watching
    #14
  15. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
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    Location:
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    The kicker is ready to go with the exception of the turn signal relay. I can’t find the one I know I had, so I ordered another one...
    I took it for a short ride and it still runs great. Hurts to sell it.

    It hurts even more because I then took the SE for a ride. Made it to the end of the street, pushed it back home. It stumbles badly and doesn’t want to rev. I suspect high float bowl level or leaky o rings, even though they’re pretty new. I ordered a new battery, that will make troubleshooting easier as I won’t have to jumpstart it from my truck.

    I also found out that the battery wasn’t charging, cleaning the contacts of the rec/reg plug seems to have fixed that issue.
    #15
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  16. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
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    The kicker is sold, I will miss that bike, the power delivery was just great, but...
    A local kid bought it, he was thrilled so that made me feel a little better. So now I have some funds to put towards the SE but I am taking the kids camping this weekend. Nothing to see here.
    I did order a new battery though.
    #16
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  17. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
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    Another non-update: I am having some serious remorse right now. The bike I sold ran fine and the SE, well, doesn’t run. It starts right up and revs up ok. Then it starts stumbling and will no longer rev. Finally it dies and won’t restart. I was thinking fuel level but it’s not leaking out. Maybe electrical?
    So freaking frustrated ...
    #17
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  18. mentolio

    mentolio Been here awhile

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    Jul 14, 2016
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    608
    Hang in there, you'll get it figured out!
    #18
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  19. jays100

    jays100 Been here awhile

    Joined:
    Aug 1, 2006
    Oddometer:
    363
    Location:
    CT
    Check fuel delivery:
    -clogged petcock
    -filter(?) clogged
    -clogged tank vent
    -collapsed fuel line
    -carb/float chamber vents clogged

    Sounds like it’s just running out of fuel!
    #19
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  20. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
    Oddometer:
    2,671
    Location:
    Western NC
    It was actually running like it was flooding, similar to what happens when the float needle is going bad. But no gas on the ground or in the airbox.
    I took the plug out and it was black and wet. OK, so I am on the right track. I took the carb out and found raw fuel in the intake. Still on the right track. At that point I am thinking float height or leaking O-rings. Easy fix, I am a great mechanic...

    And this is when the mechanical gods bitch slapped me right in the mouf with a good dose of humility:

    00BF8792-422B-4A4B-ADD0-CBCBC029309C.jpeg

    Yep, that’s the way I found it. I never screwed in the main jet and it was just resting at the bottom of the bowl. I am a moron.

    Surprisingly enough once I reinstalled it and installed the new lithium battery (incredibly small and light for $80), it started right up and seems to have great throttle response.

    Happy!

    I was finally able to reinstall the plastics and take a picture.

    FE9BF19C-DA2F-4943-8819-1A6A1DDC4F95.jpeg

    I still need to swap out the tires and front sprocket then go for a quick ride. Then oil change, mount the skidplate and get it registered.
    #20