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Blood Sweat Tears and Grease => Projects => Enduro / Dirt / Scramblers => Topic started by: irk miller on Feb 22, 2017, 20:28:10

Title: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Feb 22, 2017, 20:28:10
So begins a more appropriate cross country enduro I hope to raise a little hell on. The bike came up on Craigslist for $300.

(https://uploads.tapatalk-cdn.com/20170223/252e786cfd63a86a19c4e1d7c8643e8e.jpg)

The plan is not to go nuts, but instead to build a 70/30 enduro I can take into the mountains or to the shore.

A major issue with these dirt bikes is scorched heads...

(https://uploads.tapatalk-cdn.com/20170223/0476026ee4b2e5e1a935a4f20e8d1169.jpg)

Mine is extra glorious with a special cam..

(https://uploads.tapatalk-cdn.com/20170223/1ee3cdf66e01286d5973747bffaa11cb.jpg)

Replacement heads aren't super plentiful, and seem a bit pricey when they show up on eBay. Right now, I can get a decent head and rocker assembly for $420 plus shipping from Portugal, or a NOS head minus valves, cam and rockers from Singapore for $700.

So, the plan is to machine the journals, and convert it to needle bearings and a split bronze bearing...

(https://uploads.tapatalk-cdn.com/20170223/911b9af977ec3fbc6aa36980f7d23d92.jpg)

(https://uploads.tapatalk-cdn.com/20170223/ee32bdf2670641e411b54b9d54ed1004.png)




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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Feb 22, 2017, 21:17:33
As I get parts in for the head rebuild, I'm going forward with the rest of the bike.  I replaced the entire front controls, plus the front caliper from an RM. I'm considering moving to an RM front end eventually, which I happen to have, but for now I'm sticking with the good stock forks I have on it now...

(https://uploads.tapatalk-cdn.com/20170223/f513031decf561957fca98bd67da810d.jpg)





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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Feb 22, 2017, 21:21:12
Going dual sport on wheels with a Kenda front and a Shinko rear...

(https://uploads.tapatalk-cdn.com/20170223/c112346843e9e5418afc2bf77435f6ce.jpg)

(https://uploads.tapatalk-cdn.com/20170223/5c7fed183753282a1f572d732d89af25.jpg)


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Feb 22, 2017, 21:36:48
I cut the stock can off the exhaust and rebuilt a Supertrapp I got for cheap at Barber this past fall...
(https://uploads.tapatalk-cdn.com/20170223/b94142ee70710da63935823a6dc8bd79.jpg)
(https://uploads.tapatalk-cdn.com/20170223/583024bd770006fa74ebd9c48b7cff76.jpg)

The can was pretty banged up from use, but also because someone decided to pound a reducer like you get from Autozone on the end of it.

How I straighten a tube is with a one-inch steel rod (in the second pic all the way to the left).  The rod is threaded at one end so I can thread a handle onto it.  Simply lay the tube on an anvil, dent down, and bang the dent out making sure the rod hits flat to the surface.  With a handle threaded on, roll the rod and tube together to stretch the dent out, much like working with an english wheel. 
 
(https://uploads.tapatalk-cdn.com/20170223/5f95a8cdef7871a029e64ea508af6a7d.jpg)
(https://uploads.tapatalk-cdn.com/20170223/f8b6f69d23047c5f1c465bd491b2b13c.jpg)
(https://uploads.tapatalk-cdn.com/20170223/8a3383d31afc31389ac0bf3b628cb321.jpg)





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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: Hurco550 on Feb 22, 2017, 22:13:00
I'm in
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: Ply318ci on Feb 23, 2017, 02:17:46
Me too.


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: cyclefreak on Feb 23, 2017, 09:22:14
Me three.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: SONIC. on Feb 23, 2017, 09:50:13
Yessir.
The force is strong with this one.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Feb 23, 2017, 10:31:21
Thanks for the support fellas. 
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: JustinLonghorn on Feb 23, 2017, 11:30:40
Why not.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: Tune-A-Fishİ on Feb 23, 2017, 18:27:14
I am pretty sure Cycle World had great reviews for handling on those, you can dig up the article and read up somewhere. The Soooooper Trap is spot on period correct.

I'm in


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Feb 23, 2017, 18:54:06
I am pretty sure Cycle World had great reviews for handling on those, you can dig up the article and read up somewhere. The Soooooper Trap is spot on period correct.

I'm in


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Thanks Tune.  There's an article somewhere that someone sent me about a guy that rode one of these across the country, but I can't remember the link. There are definitely plenty of stories that praise the merits of this bike.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Feb 23, 2017, 19:50:17
Got me a few goodies to put towards rebuilding this head....


(https://uploads.tapatalk-cdn.com/20170223/b426fb622d6a6f6672604dfbaa1fb3ea.jpg)

Plus a couple Supertrapp decals, one for the rebuilt can.


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: WhyNot on Feb 24, 2017, 08:32:59
I'm in.....been watching all your builds Eric, why not one more.........

Wish I had the gumption you got to get some of my projects up and running..............
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: VonYinzer on Feb 24, 2017, 13:49:30
Following along and whatnot.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Feb 24, 2017, 13:55:09
Well guys, the band is back together.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: julian.allard66 on Feb 24, 2017, 17:24:43
That looks like an enduro DR350, not the tamer dual sport DR350S, it'll have higher compression, a hotter cam and possibly a flat slide carb.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Feb 24, 2017, 22:03:11
That looks like an enduro DR350, not the tamer dual sport DR350S, it'll have higher compression, a hotter cam and possibly a flat slide carb.
You're exactly right.  It's a DR350, the dirt model, and another reason heads can be hard to source since they ran two completely different heads all the way through 1996. Carb is a Mikuni TM33 flatside.  Still a 6-speed, but different gearing ratios.  Compression is the same though, at 9.5:1.  Cam specs are the same too.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Feb 25, 2017, 22:58:02
Milled new journals...

(https://uploads.tapatalk-cdn.com/20170226/f712aa0a8887a6fee8b212f004b16d85.jpg)

(https://uploads.tapatalk-cdn.com/20170226/76e67bb04c312199a3234058ea6fe3c3.jpg)

(https://uploads.tapatalk-cdn.com/20170226/7de14dee7696ef94226ecc8c9b225fd5.jpg)


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: Tune-A-Fishİ on Feb 26, 2017, 08:37:33
Izat an XL350 rocker box


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Feb 26, 2017, 09:24:24
They really do look similar, don't they?
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: SONIC. on Feb 26, 2017, 12:41:42
That was quick :o
Title: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Feb 27, 2017, 02:02:10
(https://uploads.tapatalk-cdn.com/20170227/33a895e9d5cd32eb059f1c227d3be521.jpg)

The center bronze bearing has to be split, so I machined two, marked them with an Exacto, then cut them 1 mm above the line and filed them down.  The plan is to pin the bottom half.

(https://uploads.tapatalk-cdn.com/20170227/09f6eb5a4ccc0948d42e7d31dbad129e.jpg)

(https://uploads.tapatalk-cdn.com/20170227/54698473b67312d864b18c66c283bf27.jpg)

(https://uploads.tapatalk-cdn.com/20170227/4120523fb87c53de5cea28bbd0ba0163.jpg)

(https://uploads.tapatalk-cdn.com/20170227/ddc343a06d7f19a17f798a0865ff682d.jpg)


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: cxman on Feb 27, 2017, 07:42:17
awesome bit of work

now i have a xl 350 head that needs this done so how much????
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: Tune-A-Fishİ on Feb 28, 2017, 08:17:16
X2 my XL350 is in good shape but I'm thinking this will bullet proof the top end... nice work mang!


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 03, 2017, 12:53:21
I do the bearing mod with the expectation that rockers will come in to follow up. I contacted Babbitt's last week to order the rockers. They tell there's a set in the Atlanta warehouse. I'm like, "Hell yeah, I'm just two hours down I-20 in Augusta." Wednesday rolls around and nothing. An email arrives in my inbox with tracking. Here is the route my rockers have taken:

(https://uploads.tapatalk-cdn.com/20170303/ec943066d50c7e33c1894e12922fac85.jpg)

They go from warehouse to store. Then packaged in store for shipment to me. Oh, the efficiency of modern technology! I'm really glad I'm not building a race bike or something I need a quick turn-around.


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: Tune-A-Fishİ on Mar 03, 2017, 13:00:58
I do the bearing mod with the expectation that rockers will come in to follow up. I contacted Babbitt's last week to order the rockers. They tell there's a set in the Atlanta warehouse. I'm like, "Hell yeah, I'm just two hours down I-20 in Augusta." Wednesday rolls around and nothing. An email arrives in my inbox with tracking. Here is the route my rockers have taken:

(https://uploads.tapatalk-cdn.com/20170303/ec943066d50c7e33c1894e12922fac85.jpg)

They go from warehouse to store. Then packaged in store for shipment to me. Oh, the efficiency of modern technology! I'm really glad I'm not building a race bike or something I need a quick turn-around.


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Why is this not surprising to me lol


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: Hurco550 on Mar 03, 2017, 13:10:27
I'm really glad I'm not building a race bike or something I need a quick turn-around.


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nah, if you were building something that needed quick turn around, they would have gone to California, 3 of the Hawaiian islands, Alaska and then got lost at your local post office
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: canyoncarver on Mar 03, 2017, 13:31:21
You guys get an pics of the setup to do these mods?  You know, like lathe and mill magic of some kind?
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 03, 2017, 13:53:40
You guys get an pics of the setup to do these mods?  You know, like lathe and mill magic of some kind?
It's up a few posts.  We set the head up on a 90° mill jig, then ran a 24mm reamer with no bottom cut, so when it hit max depth it wouldn't cut through the head.  You can buy end mills the right length, but they cost big bucks.  I didn't want to use tooling that costs more than buying a brand new head.  We had to use a corn cob reamer to rough out journal all the way at the back of the cam, since it was originally the smallest dimension on the cam.  So, the original plunge "bottomed out" ahead of that final journal.  If you start from the outside of the head on the cam, the bearing ODs are 25mm, 24mm, 24mm.  I turned the cam down to 18mm, 16mm, 16mm for the ID on the bearings.  The bearing bronze was bought in a nominal size with enough meat to turn down to 24mm OD and 16mm ID.  They are 14mm wide, which is the dim on the journal so they will keep the cam from floating back and forth in the head. 

Not sure if that's what you're looking for.  Let me know, and I can mock up some more pics tonight.   
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: canyoncarver on Mar 03, 2017, 14:02:31
.......ah geez, I'm multitasking too much and should have seen that.    I see the magic now... 
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: clem on Mar 04, 2017, 11:02:59
All you pretty boys and your lathes!......man I wish I had one.

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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: advCo on Mar 04, 2017, 14:45:31
Real nice work man. Looking forward to hearing you light her up


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: BillyGoat4130 on Mar 05, 2017, 08:56:33
Nice work on bushing in that cam and machining the journals. I started a project like that 10 years ago on a Honda but never finished it!

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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 06, 2017, 18:35:40
Finally, rockers came in...

(https://uploads.tapatalk-cdn.com/20170306/a9a2168f647a87901c67929a636ecc30.jpg)


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Title: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 07, 2017, 03:20:47
Got the head put together, plus i machined a cap to replace the stock rubber jawn...

(https://uploads.tapatalk-cdn.com/20170307/6480b41863b97fb9c8bd5a1fe0f1933c.jpg)

Viton valve seals. Valves are within spec, so a lap and re-install.

(https://uploads.tapatalk-cdn.com/20170307/6b85b95bf29d3be602c58b9e6f027c1c.jpg)

New rockers

(https://uploads.tapatalk-cdn.com/20170307/3dd264cf008fb4680ac52d10a6f7778c.jpg)

(https://uploads.tapatalk-cdn.com/20170307/c07b40cc24e82649defe7111deec99e9.jpg)


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: cxman on Mar 07, 2017, 07:07:01
very nice

when can you do my xl350 head???
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: Tune-A-Fishİ on Mar 07, 2017, 12:51:00
All you pretty boys and your lathes!......man I wish I had one.

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And when you get one, I hope to be your friend lol


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: canyoncarver on Mar 07, 2017, 16:08:00
Got the head put together, plus i machined a cap to replace the stock rubber jawn...


(https://uploads.tapatalk-cdn.com/20170307/c07b40cc24e82649defe7111deec99e9.jpg)





You knocked that shit out of the park quick.  Don't stop now!



Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 07, 2017, 20:11:49
Ha.  Thanks, Kelly.  This is assuming it will actually run.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 08, 2017, 00:16:53
Cleaned Mikuni...

(https://uploads.tapatalk-cdn.com/20170308/71c4fa180213803769ba3db0596ec232.jpg)


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: cxman on Mar 08, 2017, 08:40:47
does it run yet??

looks close
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 08, 2017, 09:00:47
It's close.  Got the tappets adjusted and the carb installed last night.  I plan to get to the oil filter next, change the oil, then get the Supertrapp hooked up to the end of the header.   Should be good to go after that.  I also need to figure out why there is no clutch.  I hope it's just an issue with the lever mechanism. 
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 12, 2017, 20:48:49
Since Augusta, GA is the land of "not in stock," I'm waiting on shipment of throttles cables, an oil filter, and a chain.  Most Autozones carry a Fram oil filter that fit these, but not here.  For the most part, it's all put together. Side covers are still off to be able to get to the carb. 

Exhaust is complete, with the Supertrapp welded on...

(https://uploads.tapatalk-cdn.com/20170312/41a80ad19d15ef636c93e86311f2d381.jpg)

... with dual sport tires back and front...

(https://uploads.tapatalk-cdn.com/20170312/b3cce0fda82525a818436a7e418ebee2.jpg)

(https://uploads.tapatalk-cdn.com/20170312/f0227fe47a24e01b97a64b8624145a8b.jpg)

(https://uploads.tapatalk-cdn.com/20170312/e048fff2bbf4e1c31237180bb207847a.jpg)

(https://uploads.tapatalk-cdn.com/20170312/e5122545396b65842cb0546dfda06fb0.jpg)


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: canyoncarver on Mar 13, 2017, 00:11:09
You'll be poppin wheelies in no time.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 19, 2017, 02:14:04
Looks like we're in for a change of pace.  I'm struggling to find compression.  It's in the valve train, as one of the intake valves just won't seal up.  Multiple laps, to no avail.  So, I ordered new valves and we'll send the head out to get recut.  And while we're at it, I ordered a 441cc big bore kit.  As soon as the piston and valves comes in, I'll send the jug out to Mototech and the head to DWMS... 

... pause for station identification...

(https://i.ytimg.com/vi/GMDGCMH8_1g/hqdefault.jpg)

Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 22, 2017, 18:50:16
441cc big bore piston kit is in the house...

(https://uploads.tapatalk-cdn.com/20170322/e8906bb7cb53102ab556bea048f24f15.jpg)


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: Hurco550 on Mar 23, 2017, 16:30:13
441cc big bore piston kit is in the house...

(https://uploads.tapatalk-cdn.com/20170322/e8906bb7cb53102ab556bea048f24f15.jpg)


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headed to mototech?
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 23, 2017, 16:34:08
headed to mototech?
I have to call Chris and see if he does sleeves.  441 kit needs a re-sleeve. I'll hone this stock jug, run a Wiseco stock sized piston, then buy another jug for the big bore.


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: Hurco550 on Mar 23, 2017, 16:39:37
I have to call Chris and see if he does sleeves.  441 kit needs a re-sleeve. I'll hone this stock jug, run a Wiseco stock sized piston, then buy another jug for the big bore.


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He does (or at least did). Last time I was over there he was putting in a sleeve that he had made from scratch as it was no longer available.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 23, 2017, 23:03:37
Not sure if this sleeve is available either.  There might be a cross reference, but I haven't found it yet.  There are some places that sell kits that include the cylinder sleeve, but I just need the cylinder sleeve.  In the meantime, the head is off to Mototech to get the valve seats recut.  I have new valves to replace the old ones. 
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: cxman on Mar 24, 2017, 08:18:43
eric

i have done sleeves in those 2 times once back to standard \

and used

LA Sleeve Sleeve Suzuki DR350 90-99 CI FL-5112

they make the one you need to but its 100

the next time it was overbore to achieve a 480 my guy did it and i cant get a hold of doug to ask him yet

but i know he found one from mellings he was able to cut down in length and use it was about 30 canadian at the time

since you have the final size of what you need and the barrel measure it up and give them a call they know what they are doing

they have helped me out for years and years in auto and marine

http://www.mellingcylindersleeves.com/

Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Mar 24, 2017, 09:10:17
Thanks Murray.  I'm still not finding anything on LA Sleeve.  They show DRZ, but no DR.  Melling may be the ticket.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: cxman on Mar 24, 2017, 10:35:57
e mail them maybe they still have one kicking around
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Apr 01, 2017, 20:02:13
I may have found a top end swap. The LTF 400/Eiger 400 and Arctic Cat 400 all look swappable with enough meat for a big bore.

First test was to buy an $11 base gasket to match against the DR base gasket...

(https://uploads.tapatalk-cdn.com/20170401/88392b31524d0e655801c20e74764a2c.jpg)

(https://uploads.tapatalk-cdn.com/20170401/5b0a5abafb9b2bbf44e6d6ab8a5718aa.jpg)


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Apr 06, 2017, 10:16:13
(https://uploads.tapatalk-cdn.com/20170406/79e71cf7da4cd555e4d9eb323087d23d.jpg)

Sooooooo pretty... valve seats recut with new valves and seals installed. Hopefully, we'll have this together and firing up today.


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: JustinLonghorn on Apr 06, 2017, 10:22:18
Will you be bringing both this and the airhead?
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Apr 06, 2017, 10:31:29
This is absolutely, without a doubt, coming to Thaw.
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: testaccount1 on Apr 06, 2017, 10:48:16
Awesome!!


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: SONIC. on Apr 06, 2017, 11:09:06
Purdy
Does it run yet?  ;D
Title: 1990 Suzuki DR350 Moonbat Hellride
Post by: irk miller on Apr 06, 2017, 23:08:26
Purdy
Does it run yet?  ;D

This is the first start. No adjustments. It ran about 20 seconds at a high idle, then settled right in. Smoke is just burn off.

.https://youtu.be/zZRgHRTXwOU


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Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: Hurco550 on Apr 06, 2017, 23:37:42
Nice
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: JustinLonghorn on Apr 07, 2017, 07:24:10
Fucking Rad!
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: cxman on Apr 07, 2017, 07:39:50
nice
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: WhyNot on Apr 07, 2017, 08:15:09
dayyyyum......wtg..
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: Maritime on Apr 07, 2017, 09:23:30
Good Job Irk!
Title: Re: 1990 Suzuki DR350 Moonbat Hellride
Post by: iatethepeach on Apr 07, 2017, 09:39:07
Next stop, Mondo Enduro.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: SONIC. on Apr 07, 2017, 10:38:12
Yezzir!
want to come put my 250 back together?  8)
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Apr 07, 2017, 10:39:18
hahaha.  Bring it on. 

We'll run this one through the paces to see how durable and reliable it can be.

(http://img.pandawhale.com/94275-Jason-Sudeikis-Satan-YEAH-gif-GitI.gif)
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: SONIC. on Apr 07, 2017, 10:40:50
You ride it yet?
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Apr 07, 2017, 10:44:04
You ride it yet?
Not yet.  I got it running about 10pm last night.  The last time I test rode a dirt bike that late the cops drove by.  I was doing laps in the back yard, drunk and raising hell, so no surprise there.  Haha.  I plan to ride it today- just need to clean the tank.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: advCo on Apr 07, 2017, 11:17:08
I need to get a supertrapp for the XL...

In other news when do we start converting all the old XLs and 360s to needle bearings?


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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Apr 07, 2017, 11:43:51

In other news when do we start converting all the old XLs and 360s to needle bearings?



I've already bought the bearings and material to convert the 360(378).  I'll be taking it apart to do the work once I get the DR and BMW finished. I also have two XL motors (a 175 and 250) that will get the test.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: cxman on Apr 07, 2017, 12:24:20
i have a 250 head waiting
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: JAGspeed on Apr 10, 2017, 23:30:15
Great bike, like what you did with the head. I've got a 99 DR350 Dirt model but made it street legal. I did tons of mods to mine, DRZ400 piston big bore (453cc). Keintech airbox, 37mm FCR carb. porting. DR350SE stator and CDI. My bike rips now.
The reason I built my motor was my original motor had a catastrophic failure. These bikes are notorious for the pin in the counterbalance gear to come loose and push trough the hole in the crankshaft that lines it up. This causes the crankshaft and counterbalance to hit and blows it through the cases. Jesse at Keintech Engineering has a fix for it but you need to send him the counterbalance gear and crankshaft. There are plenty of DR's that never have this issue but it SUCKS when they do. If you ever tear it down you should definitely get it done.
Good luck with your build.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Apr 10, 2017, 23:53:57
Great bike, like what you did with the head. I've got a 99 DR350 Dirt model but made it street legal. I did tons of mods to mine, DRZ400 piston big bore (453cc). Keintech airbox, 37mm FCR carb. porting. DR350SE stator and CDI. My bike rips now.
The reason I built my motor was my original motor had a catastrophic failure. These bikes are notorious for the pin in the counterbalance gear to come loose and push trough the hole in the crankshaft that lines it up. This causes the crankshaft and counterbalance to hit and blows it through the cases. Jesse at Keintech Engineering has a fix for it but you need to send him the counterbalance gear and crankshaft. There are plenty of DR's that never have this issue but it SUCKS when they do. If you ever tear it down you should definitely get it done.
Good luck with your build.

I haven't read about the counterbalance issue, yet. Thanks for the warning. The plan is to street this one too. On that DRZ swap:  Was it a DRZ sleeve or one from LA Sleeve? I have an 89mm piston to do a 441, but no sleeve. I hoped the Eiger 400 would give me enough meat, but they don't. I found a DR350 jug at a salvage that happened to be re-sleeved and bored to 86mm. I have no idea what piston they used for 86mm. Unfortunately, they turned the base of the sleeve down to 89mm, so now I search for another. It's been suggested that an XR400 big bore sleeve, which utilizes an 89mm piston might work.


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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: JAGspeed on Apr 11, 2017, 13:02:45
I haven't read about the counterbalance issue, yet. Thanks for the warning. The plan is to street this one too. On that DRZ swap:  Was it a DRZ sleeve or one from LA Sleeve? I have an 89mm piston to do a 441, but no sleeve. I hoped the Eiger 400 would give me enough meat, but they don't. I found a DR350 jug at a salvage that happened to be re-sleeved and bored to 86mm. I have no idea what piston they used for 86mm. Unfortunately, they turned the base of the sleeve down to 89mm, so now I search for another. It's been suggested that an XR400 big bore sleeve, which utilizes an 89mm piston might work.


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My cylinder was an LA sleeve modification. The DRZ piston is 90mm and did require me to machine the head some to keep the compression down so I could run pump gas.
If you look a Kientech's website there is some info on the counterbalance pin. Jesse is the DR guru there. He is an older guy with tons of info. and likes to talk. He told me that he ad an aluminium sleeve for  the big bore kit that ran a little cooler. I know he has the big bore gaskets also.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Apr 20, 2017, 21:42:37
Just a seat cover...

(https://uploads.tapatalk-cdn.com/20170421/85dfbab0788df38ec01366cf35a0a8e4.jpg)


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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on May 02, 2017, 01:29:17
The bike was bought with stock hardware missing for the side covers so I machined some washers out of delrin...

(https://uploads.tapatalk-cdn.com/20170502/9e0bd716ca00dc0b17919a8fab46dce3.jpg)

The plastics are actually in decent shape except for yellowing on the tank and oxidation on the fenders and side covers. How I like to restore it is wet sand with 1000 grit paper and soapy water. In this case, Clorox cleanup for white plastic. Then polish with Meguiers Ultimate Black plastic restorer. More on the tank later...

(https://uploads.tapatalk-cdn.com/20170502/b6e1b38fcfba75e7de144c2973585c30.jpg)
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: Mr.E on May 11, 2017, 19:51:46
I'm late to this party but I'll have some pretzels
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: Hurco550 on May 11, 2017, 19:59:09
I'm late to this party but I'll have some pretzels

No pretzels for E....
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: Mr.E on May 11, 2017, 21:47:56
No pretzels for E....

Fine I'll eat the busted cashews everyone leaves in the bowl
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: SONIC. on May 12, 2017, 16:35:15
I rescind the offer to let you rebuild my 250. I prefer my cams in one piece  ;D
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on May 12, 2017, 16:48:46
I rescind the offer to let you rebuild my 250. I prefer my cams in one piece  ;D
Goddamn it.   :-\

Version 2 will work better.  I promise.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jun 27, 2017, 11:13:24
We're back on the road. I was lucky enough to find a spare jug at a yard near me that was re-sleeved and bored to 86mm. Sent it out to Mototech USA to bore to 89mm. Installed JE piston and .032" copper gasket.

I also ordered a proper parting tool and machined a new cam to 18mm on all three journals, plus an oil groove on the middle journals. With a dial indicator, I insured the shaft was true within .001", which was my biggest mistake not doing before. Basically, my first cam had a twist between the three journals that caused it to corkscrew. This is one thing that caused the middle bearing to spin.  The top half of that bearing was thinner on top then bottom. I did that to seat the cam better and it was dumb.   I ordered two 18mm ID x 24mm OD and one 18mm ID x 25mm OD oil bronze bearings. I split the middle bearing and installed it with a roll pin to keep it from spinning.

(https://uploads.tapatalk-cdn.com/20170627/14dfcac0a94d5812d558accd96a1523b.jpg)

(https://uploads.tapatalk-cdn.com/20170627/5a8c594ef2f905bbcc420ca1a68677d2.jpg)

(https://uploads.tapatalk-cdn.com/20170627/9402930afec148332cf7e988ad002244.jpg)

This should last a lot longer.


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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jun 27, 2017, 11:32:57
The next project will be to convert to the TM33 to oval bore.  So, essentially it will be running a TM33 at the bottom of the bore and TM34.5 at the top of the bore.  This pic illustrates the mod for a TM40 to TM44, but the concept is the same:

(http://thunderproducts.com/wp-content/uploads/2013/07/Carb-Bore.jpg)

The idea is to keep the torque and power at the bottom end, while also maximizing power at the top end.  With a straight bore, you sacrifice bottom end for top end.  Beings I still want it to be a mountain goat, I don't want to lose bottom end.  One obvious difference since I bored it to 440 with the TM33 is it has a significant torque gain.


 
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: SONIC. on Jun 27, 2017, 13:12:28
So how do you go about that?
Grind it out to shape?
Title: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jun 27, 2017, 13:31:44
Yep. A dremel with an assortment of mounted blue stones, white stones, sanding drums, cratex, and bayflex bits.  Or take it to someone with a mill. I'll do it by hand, tho.


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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jul 10, 2017, 20:40:08
I decided to go with a 37mm FCR, which was just ordered. I scoured Mid-O for a carb and came up empty. 

Also, took a couple 70s Suzuki racks, cut them up and made a rack for this thing. I'll blast it and powder coat it...

(https://uploads.tapatalk-cdn.com/20170710/c2e62f6bc7849ae7b9f04a75f15b5144.jpg)


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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: Maritime on Jul 11, 2017, 08:24:31
Nice rack       ;D !
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: JustinLonghorn on Jul 11, 2017, 09:38:00
Will it hold a pony keg?
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jul 11, 2017, 10:03:01
Will it hold a pony keg?
Damn right it will.  A rack isn't a rack if it doesn't at least hold a pony keg.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: canyoncarver on Jul 11, 2017, 11:49:40
Damn right it will.  A rack isn't a rack if it doesn't at least hold a pony keg.

That I gotta see.  Oh...and nice rack....
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jul 11, 2017, 14:23:43
I picked up an old rashed EX500 or ZX6R can at Mid-O for cheap. Cut about 6 inches off, cleaned it up fit it to the DR. The Supertrapp was too restrictive. I was blowing the end off...

(https://uploads.tapatalk-cdn.com/20170711/1ba79f515a4920a8bc15d4d3791acd97.jpg)

(https://uploads.tapatalk-cdn.com/20170711/ab07de458910908853c66e2a6f4ddb4b.jpg)

(https://uploads.tapatalk-cdn.com/20170711/23e94215149c653a671130f930de1c2a.jpg)


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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: Mr.E on Jul 12, 2017, 13:45:41
Nice can
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: sealedwithakay on Jul 12, 2017, 14:11:48
Nice can

Mr.E - Nice photo - aka Paddington Bear, still cracking me up. :D
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: advCo on Jul 12, 2017, 14:41:42
I picked up an old rashed EX500 or ZX6R can at Mid-O for cheap. Cut about 6 inches off, cleaned it up fit it to the DR. The Supertrapp was too restrictive. I was blowing the end off...

Is that the one I had at our booth?

Watcha doin with the supertrapp?  ;)
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jul 12, 2017, 14:50:04
Is that the one I had at our booth?

Watcha doin with the supertrapp?  ;)
No, this isn't yours.  Yours was oval and half the length this one started out as.  This one is round and I bought it on the first day.  The Supertrapp will get saved for the 250 motor or another contraption.  I never dump Supertrapps or any other can for that matter.  I've put the same can on three different bikes before. 
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: advCo on Jul 12, 2017, 15:16:56
No, this isn't yours.  Yours was oval and half the length this one started out as.  This one is round and I bought it on the first day.  The Supertrapp will get saved for the 250 motor or another contraption.  I never dump Supertrapps or any other can for that matter.  I've put the same can on three different bikes before.

Ahh yeah I see it now. Looked similar at a quick glance. I figured you'd keep the Supertrapp. Kicking myself for not picking up the one at the swap meet on Saturday.

Can looks good on there.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jul 12, 2017, 15:25:56
Ahh yeah I see it now. Looked similar at a quick glance. I figured you'd keep the Supertrapp. Kicking myself for not picking up the one at the swap meet on Saturday.

Can looks good on there.
Thanks man.  What's worse, I had one in my hand too.  We both stepped out on a decent deal. 
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: Hurco550 on Jul 14, 2017, 15:35:38
Is that the one I had at our booth?

Watcha doin with the supertrapp?  ;)
Lol I owe ya $2 for yours. I sold it while you were out walking around and forgot to hand you all the mad cash for it

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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jul 14, 2017, 22:18:10
$2?!?!?!  Fuck.  I should've bought that one.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: advCo on Jul 15, 2017, 11:54:55
Man I would've traded you straight up for those handlebars


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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: Hurco550 on Jul 15, 2017, 16:15:37
That's what was written on it right?

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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jul 15, 2017, 19:48:42
(https://uploads.tapatalk-cdn.com/20170715/c0ca671d6320c204367dd0d0e38a76e7.jpg)

37mm FCR.  Love you long time.


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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: Hurco550 on Jul 15, 2017, 23:55:19
(https://uploads.tapatalk-cdn.com/20170715/c0ca671d6320c204367dd0d0e38a76e7.jpg)

37mm FCR.  Love you long time.


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Ahh yess. What's your plan for the pumper carb that your pulling off?

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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jul 16, 2017, 10:34:18
A major altering of the intake spigot to fit the FCR. The question now is whether to port a taper in the head or to machine a taper to install in the spigot or a little of both.

(https://uploads.tapatalk-cdn.com/20170716/5200389ac956d3b75a1b3cc7f69f2cde.jpg)

(https://uploads.tapatalk-cdn.com/20170716/911914f0e519515cb93e2797af16d456.jpg)


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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: JAGspeed on Jul 16, 2017, 12:27:32
I used that same carb on my DR. It works really well. I used a intake manifold from Sudco and machined a spacer to match the carb and fit into the manifold. I then ported the head to match. I'm sure you can make what you have work but you will probably have to do some porting to the head to match it.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jul 16, 2017, 13:12:37
I used that same carb on my DR. It works really well. I used a intake manifold from Sudco and machined a spacer to match the carb and fit into the manifold. I then ported the head to match. I'm sure you can make what you have work but you will probably have to do some porting to the head to match it.
Thanks for this.  I wasn't thinking very well not to order a flange that fits. 

Ordered a Mikuni HS42/018-45k. 

(https://i.ebayimg.com/images/g/XP4AAOSw8w1X5Za-/s-l500.jpg)

Nice thing about this flange is it saves 10-15mm of length which will keep the carb off the rear shock reservoir line and the back of the tank. 
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jul 19, 2017, 23:46:00
Flange came in, so I machined the spacer and ported the head.

(https://uploads.tapatalk-cdn.com/20170720/7efd53082e625017ade27d1cfd3edd90.jpg)


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Title: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jul 20, 2017, 10:38:37
TPS delete with a very thinly machined delrin sleeve...

(https://uploads.tapatalk-cdn.com/20170720/73fb4734e693692efec8eaa0131396f8.jpg)


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(https://uploads.tapatalk-cdn.com/20170720/954b39aa949e5c9caf39f782af922b9e.jpg)
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Jul 31, 2017, 12:15:43
The site won't let me post an image from my phone for some reason, so I hope this works.

I've been reluctant to change much on this bike as far as customizing, but then a guy near my mom's house decided to part out a Ruckus.  So now we have to make a desert bike.   

(https://scontent-iad3-1.cdninstagram.com/t51.2885-15/e35/18723727_217441242117676_3719515002017677312_n.jpg)
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: SONIC. on Jul 31, 2017, 13:16:32
Yes.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: JustinLonghorn on Jul 31, 2017, 14:08:24
Perfect.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: Maritime on Jul 31, 2017, 14:43:55
Yep, those work well.
Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: dakine_surf on Aug 01, 2017, 05:08:14
I concur, looks fantastic


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Title: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: irk miller on Dec 13, 2017, 20:13:44
I’ve been messing with port matching the intake, mostly to get good transition from the offset FCR spigot. I’ve heard two camps as to how much or how little polish there should be.

(https://uploads.tapatalk-cdn.com/20171214/c65f52c7936810a474966ef52a713a9d.jpg)

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Title: Re: 1990 Suzuki DR350 Medusa Transducer Hellride
Post by: cxman on Dec 14, 2017, 10:57:06
no camps less is better on the intake side

or all of nascar drag racing and marine is wrong