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dr350-digest          Wednesday, May 26 1999          Volume 01 : Number 060




----------------------------------------------------------------------

Date: Wed, 26 May 1999 00:22:45 EDT
From: [e-mail]
Subject: Re: (dr350) McGyver story; changing clutch plates; sticky shifting

In a message dated 5/25/99 12:01:28 PM Pacific Daylight Time,
[e-mail] writes:

<<  I have never changed out clutch
 plates on anything.  Is it hard?  Need any special tools?  I think I
 remember someone saying an impact wrench was necessary...true? >>

Bryan,

You should soak the fiber plates in the same oil you use in the motor for at
least several hours.  There is a tool for holding the clutch basket from
rotating,
if you can't find one let me know.

Be very careful to not over tighten the bolts holding down the plates.  While
you are
in there the gland nut holding the basket should be checked for excessive
play.


<< When fully warmed, shifting
action is OK, but I'd like it to be better. >>

Check or replace the shift pawl, it's usually bent.  Also check the shift
drum bolt.


Mike

------------------------------

Date: Wed, 26 May 1999 10:17:04 EDT
From: [e-mail]
Subject: (dr350) SERVICE MANUALS

  I bought a service manual for my 97 DR350 & about half of it is for other
bikes. There are sections on the 97 350s model, 91 350m, 91 350sm, 92
350n/350sn, 93 350p/sp, 94 350r/ser, 95 350s/ses, & 96 350t/set.
     Some sections are more extensive than others. Most have specs.,( carb
settings, measurements, capacities ), wiring diagrams, cable & hose routing,
etc. I'm sure someone could find some useful info in them. If you're
interested & would send a couple of $ to cover postage, I would be more than
glad to send them to you. They are of no use to me. Thank you.

















------------------------------

Date: Wed, 26 May 1999 08:08:23 -0700
From: Bryan Cowger <[e-mail]>
Subject: Re: (dr350) SERVICE MANUALS

The way my service manual works is:

The manual is for a '90 (or around there) bike.
In '91, they added a supplement for whatever changed from '90.
Same in '92, and so on, up through '97.

For example, in '94, Suzuki went to the cartridge-style forks for the
dirt-only model.  The information about these forks is _only_ in the '94
addendum, though it applies to several later years.

So don't get rid of those sections -- many apply to your '97!

It's a pain, to say the least, but I would still recommend that anyone who
wants to work on their bikes get the factory manual.  It's worth the $65
(though I wish it went more into shock maintenance).

Bryan
'96 DR441
Sacramento


>
>   I bought a service manual for my 97 DR350 & about half of it is for other
> bikes. There are sections on the 97 350s model, 91 350m, 91 350sm, 92
> 350n/350sn, 93 350p/sp, 94 350r/ser, 95 350s/ses, & 96 350t/set.
>      Some sections are more extensive than others. Most have specs.,( carb
> settings, measurements, capacities ), wiring diagrams, cable & hose routing,
> etc. I'm sure someone could find some useful info in them. If you're
> interested & would send a couple of $ to cover postage, I would be more than
> glad to send them to you. They are of no use to me. Thank you.
>
>

------------------------------

Date: Wed, 26 May 1999 10:15:45 -0500
From: [e-mail] (Andrus Chesley)
Subject: (dr350) EPA Jets

Has anyone done a comparison between the EPA jets of the CV carbs of the
S and SE models and the normal jets of the regular Mukuni carbs????.
I changed out the 37.5  EPA with a normal 40 and it was so fat it would
not run below 2500 rpm even with the idle ajustment screw shut off all
the way. I had to take it out again but was running out of time to take
measurments on the exact open differenace of the two. In past experience
a half size on the pilot jet shouldn't of made THAT much difference.
But????? Who knows....

Andy Chesley

------------------------------

Date: Wed, 26 May 1999 09:33:53 -0600
From: "Pokluda, Gino F" <[e-mail]>
Subject: (dr350) 90/90 tires

Anybody out there running a 90/90X21 (as opposed to the 100/?X21) on there
DR350SE?  Any adverse affects?

Gino

------------------------------

Date: Wed, 26 May 1999 09:37:26 -0600
From: "Kurt Simpson" <[e-mail]>
Subject: Re: (dr350) 90/90 tires

- -----Original Message-----
From: Pokluda, Gino F <[e-mail]>
To: '[e-mail]' <[e-mail]>
Date: Wednesday, May 26, 1999 9:34 AM
Subject: (dr350) 90/90 tires


>Anybody out there running a 90/90X21 (as opposed to the 100/?X21) on there
>DR350SE?  Any adverse affects?
>
>Gino


I just went with Mike's Dunlop recommendation and it only comes in one size...

Kurt

------------------------------

Date: Wed, 26 May 1999 12:17:36 EDT
From: [e-mail]
Subject: Re: (dr350) SERVICE MANUALS

In a message dated 5/26/99 8:10:45 AM Pacific Daylight Time,
[e-mail] writes:

<< It's a pain, to say the least, but I would still recommend that anyone who
 wants to work on their bikes get the factory manual.  It's worth the $65
 (though I wish it went more into shock maintenance). >>

There is very little information on the shock maintenance because Suzuki
(as well as Yamaha and Kawasaki) do not typically offer any internal shock
replacement parts.

And yes the factory manuals are by far the best in the business!

Mike
(425) 776-RIDE

------------------------------

Date: Wed, 26 May 1999 09:32:24 -0700
From: <[e-mail]>
Subject: Re: (dr350) Service Manual & Our Resident Tech.

Bryan is right; the earlier sections are complete and cover items not found in
the latter ones that pertain to your year, and address those things which have
changed *only*. Look for yourself and you will see what I mean; you will need
the earlier portions as it covers items not shown in the later, following
amendments.

I'd like to unofficially nominate Bryan as the hands-on tech. writer of the
group - anyone who can competently repair their own shock and thereafter write
an instructive, easy-to-understand tutorial deserves some honor; at the least be
available for pesky, detailed questions from knuckle-headed mechanics like me.

John




Bryan Cowger <[e-mail]> on 05/26/99 08:08:23 AM

Please respond to Bryan Cowger <[e-mail]>

To:   "[e-mail]" <[e-mail]>
cc:    (bcc: John D Gill/RSS/Rockwell)
Subject:  Re: (dr350) SERVICE MANUALS




The way my service manual works is:

The manual is for a '90 (or around there) bike.
In '91, they added a supplement for whatever changed from '90.
Same in '92, and so on, up through '97.

For example, in '94, Suzuki went to the cartridge-style forks for the
dirt-only model.  The information about these forks is _only_ in the '94
addendum, though it applies to several later years.

So don't get rid of those sections -- many apply to your '97!

It's a pain, to say the least, but I would still recommend that anyone who
wants to work on their bikes get the factory manual.  It's worth the $65
(though I wish it went more into shock maintenance).

Bryan
'96 DR441
Sacramento


>
>   I bought a service manual for my 97 DR350 & about half of it is for other
> bikes. There are sections on the 97 350s model, 91 350m, 91 350sm, 92
> 350n/350sn, 93 350p/sp, 94 350r/ser, 95 350s/ses, & 96 350t/set.
>      Some sections are more extensive than others. Most have specs.,( carb
> settings, measurements, capacities ), wiring diagrams, cable & hose routing,
> etc. I'm sure someone could find some useful info in them. If you're
> interested & would send a couple of $ to cover postage, I would be more than
> glad to send them to you. They are of no use to me. Thank you.
>
>

------------------------------

Date: Wed, 26 May 1999 12:35:51 EDT
From: [e-mail]
Subject: Re: (dr350) Do I have a stock carb?

In a message dated 5/24/99 9:02:37 PM Pacific Daylight Time, [e-mail]
writes:

<< I have a '91 DR 350S and wonder if I have a stock carb.

 I notice that most similar bikes have a carb almost identical but they have a
 round pulley arrangement that that the throttle cable turns.  Mine doesn't
have
 that.  Does anyone else have a '91 to compare to?  The throttle cable has a
 direct line into the carb top and the spring is inside the carb body.
Otherwise
 it looks much like other carbs.  It is a Mukusi (sp?)

 Dave >>


Dave,

The '91 DR 350S and DR650 are the only bikes that came with a single throttle
cable
and do not have the bell pulley. (Don't know if the D.O.T. ever caught that
one?)

The best carb swap is to fit the DR350 dirt PUMPER carb on the 350S/E and use
a '91 DR650 throttle cable and the throttle housing and manifold/air box boot
from
the '91 DR350.

That Mikuni pumper is about the best carb they have ever made!

Mike
(425) 776-RIDE

PS It is highly recommended that you replace the stock vacuum petcock with
the DR350 dirt one.............

------------------------------

Date: Wed, 26 May 1999 10:46:32 -0700
From: Scott Aldrich <[e-mail]>
Subject: (dr350) T-venting the carb

  I've finally seen the carb hesitation problem on my '98 DR350SE.  I
ride mostly trail, and don't normally get much air time.  Last week I
took my DR on the MX track and was shocked at the hesitation and
burbling (best description I can think of) after doing the small jumps.

  I found that pulling out the choke seemed to clear it up, and I went
ahead and replaced the spark plug just in case.

  What I'm going to do is leave it alone for now, and the next time I
hit the track, if I see the hesitation (which I'm sure I will), I'll
bring along a "T" and extra hose.  The first mod I'll do is just route
the line down and see what happens.  The next mod I'll do is put the "T"
in and see if I notice any difference.  I'll report back what I find,
but it may be a couple of weeks before I get the chance.

  Another thing I noticed which may be along the same lines is that when
I start the bike in the morning, I use full choke, hit the button and
she starts right up.  But if I tip the bike to the right, I can make the
motor stall out if I hold it there long enough.  It doesn't seem to do
it if I tip it to the left.

- --
Scott Aldrich

------------------------------

Date: Wed, 26 May 1999 10:59:12 -0700
From: jessekientz <[e-mail]>
Subject: Re: (dr350) SERVICE MANUALS

Hi, Jesse responding to your message. The factory manuals start with the 90 year
model and only publish updates not covered in the year behind so Items covered
in your 97 supplement are only the changes from the years before, you will need
the early sections of your manual.   Jesse

[e-mail] wrote:

>   I bought a service manual for my 97 DR350 & about half of it is for other
> bikes. There are sections on the 97 350s model, 91 350m, 91 350sm, 92
> 350n/350sn, 93 350p/sp, 94 350r/ser, 95 350s/ses, & 96 350t/set.
>      Some sections are more extensive than others. Most have specs.,( carb
> settings, measurements, capacities ), wiring diagrams, cable & hose routing,
> etc. I'm sure someone could find some useful info in them. If you're
> interested & would send a couple of $ to cover postage, I would be more than
> glad to send them to you. They are of no use to me. Thank you.
>
>

------------------------------

Date: Wed, 26 May 1999 11:11:46 -0700
From: Bryan Cowger <[e-mail]>
Subject: Re: (dr350) SERVICE MANUALS

> There is very little information on the shock maintenance because Suzuki
> (as well as Yamaha and Kawasaki) do not typically offer any internal shock
> replacement parts.

Yes, but replacing shock fluid every once-in-a-while is a must, IMO, and I
would think they should have at least covered that procedure....

Bryan

------------------------------

Date: Wed, 26 May 1999 11:25:31 +0200
From: "Christian R." <[e-mail]>
Subject: Re: (dr350) DR 650 RS

Oups I'm sorry...

I was thinking about tachometer and I've writen Odometer...

There is already an odometer but I wanted to add a tachometer on my DR650se
...
thank you anyway....
- -----Original Message-----
From: Bryan Cowger <[e-mail]>
To: [e-mail] <[e-mail]>
Date: Wednesday, May 26, 1999 12:51 AM
Subject: Re: (dr350) DR 650 RS


>
>> But does anyone know how to add an odometer on it ??
>
>I'd recommend using a mtn bike computer.  Start with:
>http://www.geocities.com/Baja/Trails/1501/harvanek.htm
>
>Instead of the magnet mounting method shown on that web site, I bought a
>couple little (~1/8" diameter) rare earth magnets from radio shack.  Drill
a
>hole in your brake rotor to just accomodate the magnets, stack them on top
>of each other, and epoxy the two into that hole.  They end up slightly less
>in thickness of the rotor itself.
>
>Place the sensor (using a couple zip ties) so the end of the sensor (not
the
>middle) is close to where the magnets pass by.
>
>Zip tie the coax cable (see the web page) to the brake line, and run it up
>to the handle bar mount.
>
>A front disk guard (like from Maier's) does a good job of protecting it
all.
>
>Bryan
>'96 DR441
>Sacramento
>
>

------------------------------

Date: Wed, 26 May 1999 16:18:42 EDT
From: [e-mail]
Subject: (dr350) 1992 Plastic tank on a 98 DRS

Does anyone know if the Plastic tank from a 1992 DR350 Dirt will work on a
98DRS.

I can buy one for $125.00 used. I like it because it seems slimmer than the
new IMS for the DRS.  ether way Id like to put my stock one away before i
dent  or Scratch it or it dents me in the Knees. Also I think its white( the
92 DR that is?)or is it yellow?

Mike N.
Orlando, FL

------------------------------

Date: Wed, 26 May 1999 16:29:30 -0400 (EDT)
From: [e-mail] (john miller)
Subject: (dr350) power loss

I'll post this again and hope to get some responses.My friend and I have
identical 98 DRSE models.He has the FMF megamax2 muffler and the carb
jettet up to 135 from127.5. My bike is completely stock we raced to see
his gains and my bike beat his by a good margin.What could be wrong with
his bike?We are both shocked and confused I am now going to wait to buy
my muffler till we figure this out.His upgrades cost him about 300 bucks
and his bike is slower than a stock unit.I dont think he has all the
discs in his muffler.What could be wrong?

------------------------------

Date: Wed, 26 May 1999 13:54:13 -0700
From: <[e-mail]>
Subject: Re: (dr350) 1992 Plastic tank on a 98 DRS

Mike,

I have a stock steel, a stock plastic, and an IMS. All have been in place at one
time or another.

The dirt-only OEM tank will fit, and the color is white, but you will need to
have post/nuts braised on the side of the front of the frame oil reservoir.
Drain your oil and remove the filler/dipstick before applying the heat. Then you
need to buy the dirt seat/tank bracket ($10; The IMS comes with rear mounting
bracketry) and front tank mounting hardware ($?; not req'd w/IMS) from the
dealer. If you buy this $125 one then make sure you get as many parts as
possible; the cost of hardware adds up fast.

If you need the range, then go with the IMS; it is not really wider than the
stock - althought it does *appear* so - it's actually taller and lower. The OEM
plastic dirt tank stores 2.5 gal. of gas but the last 0.5 gal. hangs uselessly
lower than the petcock; the IMS has the same strange setup.

John




[e-mail] on 05/26/99 01:18:42 PM

Please respond to [e-mail]

To:   [e-mail]
cc:    (bcc: John D Gill/RSS/Rockwell)
Subject:  (dr350) 1992 Plastic tank on a 98 DRS




Does anyone know if the Plastic tank from a 1992 DR350 Dirt will work on a
98DRS.

I can buy one for $125.00 used. I like it because it seems slimmer than the
new IMS for the DRS.  ether way Id like to put my stock one away before i
dent  or Scratch it or it dents me in the Knees. Also I think its white( the
92 DR that is?)or is it yellow?

Mike N.
Orlando, FL

------------------------------

Date: Wed, 26 May 1999 15:14:00 -0700
From: Bryan Cowger <[e-mail]>
Subject: Re: (dr350) Service Manual & Our Resident Tech.

> I'd like to unofficially nominate Bryan as the hands-on tech. writer of the
> group - anyone who can competently repair their own shock and thereafter write
> an instructive, easy-to-understand tutorial deserves some honor; at the least be

John, you're far too kind!


> available for pesky, detailed questions from knuckle-headed mechanics like me.

"Knuckle-headed" riding a self-built DR/MX441??  I don't _think_ so, Tim!
:)

Bryan

------------------------------

End of dr350-digest V1 #60
**************************