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Old 05-30-2017, 10:30 AM   #1
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92 Suzuki DR350SE


the latest project.
owner couldnt find the title, 1 week later he handed me a certified copy.
barely ran, petcock leaked, carb overflowed, wouldnt shift into 3rd, front brake mushy, forks feel strange.
94 SE engine, CDI & harness. 98 or 99 gas tank, dirt headlight, no instruments, no mirrors, no TL, dented header, etc.
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Old 05-30-2017, 10:31 AM   #2
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Re: 92 Suzuki DR350SE

replaced petcock from big clarke tank i'm not using.
replaced carburetor with a spare BST33 already setup.
duct-taped the airbox to near-stock.
replaced throttle cables with a spare set.
starts and runs normally now.
re-index the clutch arm, but still wont shift into 3rd.
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Old 05-30-2017, 10:33 AM   #3
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Re: 92 Suzuki DR350SE

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Old 05-30-2017, 10:56 AM   #4
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Re: 92 Suzuki DR350SE

Looks fun! I had n older DR200 basket case years back that I fixed up. While it was not capable of a few things, it was a total blast to ride!.
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Old 05-30-2017, 10:59 AM   #5
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Re: 92 Suzuki DR350SE



couple of bad guys
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Old 05-30-2017, 11:46 AM   #6
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Re: 92 Suzuki DR350SE

That thing was ridden hard AF. ouch.
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Old 05-30-2017, 12:57 PM   #7
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Re: 92 Suzuki DR350SE

Quote:
Originally Posted by Polk540 View Post
That thing was ridden hard AF. ouch.
its fairly common to bend the shifter shaft when dropped.
the bent drum stopper is sometimes a result of torquing the drum bolt without removing the stopper spring. everything else inside looks good, including new clutch basket, hub & discs
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Old 05-30-2017, 01:07 PM   #8
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Re: 92 Suzuki DR350SE

Quote:
Originally Posted by plugeye View Post
its fairly common to bend the shifter shaft when dropped.
the bent drum stopper is sometimes a result of torquing the drum bolt without removing the stopper spring. everything else inside looks good, including new clutch basket, hub & discs
Was thinking that was the third gear shaft and fork, but now I can see it'd have to be the shifter shaft as you say, since the gear would actually have teeth all the way down. Still, good find?
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Old 06-05-2017, 08:04 AM   #9
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Re: 92 Suzuki DR350SE



front wheel service
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Old 06-05-2017, 08:08 AM   #10
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Re: 92 Suzuki DR350SE



nice overspray job



fork service
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Old 06-05-2017, 08:28 AM   #11
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Re: 92 Suzuki DR350SE



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Old 06-05-2017, 08:32 AM   #12
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Re: 92 Suzuki DR350SE

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Old 06-05-2017, 09:16 AM   #13
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Re: 92 Suzuki DR350SE

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Old 06-19-2017, 07:50 AM   #14
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Re: 92 Suzuki DR350SE





in the meantime waiting for some parts, straightened a couple bent brake levers & rebuilt the BST33
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Old 06-19-2017, 07:59 AM   #15
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Re: 92 Suzuki DR350SE





pulled apart the rear end for service





one bearing is shot. looks like it was neglected



choosing replacements





pressed in new shock bearing



sealed & lubed. reassembled & swapped the 14t to a 15t.
replaced the front brake components & rebuilt the m/c, now i can ride it with an operational f-brake.
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Old 06-19-2017, 03:39 PM   #16
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Re: 92 Suzuki DR350SE

Nice. This little project bike is coming along well.
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Old 06-22-2017, 09:12 AM   #17
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Re: 92 Suzuki DR350SE

rides fair enough except for clutch drag & low end bog
next on the list:
carb inspection
swap airbox & filter
chain service
plug inspection
add a speedometer
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Old 06-22-2017, 09:43 AM   #18
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Re: 92 Suzuki DR350SE

Like it.
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