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92 Suzuki DR350SE

Joined
Dec 19, 2007
Messages
1,149
Location
garland
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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.
 
Joined
Dec 19, 2007
Messages
1,149
Location
garland
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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Joined
Jun 14, 2007
Messages
2,989
Location
Rhome,TX
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!.
 
Joined
Dec 19, 2007
Messages
1,149
Location
garland
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
 
Joined
Apr 27, 2017
Messages
124
Location
Huntsville TX
First Name
Prentice
Last Name
Smith
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?
 
Joined
Dec 19, 2007
Messages
1,149
Location
garland
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in the meantime waiting for some parts, straightened a couple bent brake levers & rebuilt the BST33
 
Joined
Dec 19, 2007
Messages
1,149
Location
garland
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pulled apart the rear end for service

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one bearing is shot. looks like it was neglected

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choosing replacements

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pressed in new shock bearing

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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.
 
Joined
Dec 19, 2007
Messages
1,149
Location
garland
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
 
Joined
Dec 19, 2007
Messages
1,149
Location
garland
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before

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not much happening while waiting for a part, but the airbox & filter are swapped
 
Last edited:
Joined
Dec 19, 2007
Messages
1,149
Location
garland
Hope your garage is cooler than mine, nice work and pics on the 350.
thanks.
doubtful about garage heat. i have the oscillating fan going & usually keep the door closed for skeeter & humidity control. still sweat like crazy most days
 
Joined
Dec 19, 2007
Messages
1,149
Location
garland
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brother DR stands as silent witness to surgery

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plenty of replacements.
installed new clutch thrust washers (should have done it the 1st time)
and a different clutch pack.
much improved.

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ghetto instrument bracket. its intended to be only temporary
 
Last edited:
Joined
Jul 20, 2013
Messages
695
Location
helotes texas usa
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front wheel service
i see two old bearings and one seal removed. i just changed my front bearings and the kit came with two bearings and TWO seals. is there not a seal under the speedo drive? I only removed one seal but i did install one under the speedo drive.
 
Joined
Dec 19, 2007
Messages
1,149
Location
garland


i'm giving the 94 a break & riding the 92 for a couple weeks to evaluate. so far, a smooth machine.
 
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