DR350 Top End Assembly and Engine Install

Finally getting the DR350 back in one piece. It's been apart a long time!
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[@billbright1755]

I have a 92 DR S 350 with 30,000 miles. Runs and operates as new. Never babied but never abused. Genuine Suzuki precision machines.

[@TomsTinkeringandAdventures]

They are good machines, very underrated in my opinion.

[@unclequack5445]

I own a KLR 650 and experienced moto mechanic but I still learn from watching engine build videos never stop learning.

[@TomsTinkeringandAdventures]

Best bet, keep learning because there is a world of knowledge out there. Thanks for watching.

[@yassinmashautymashaury2734]

How are U. Really excited to what you're doing. How if I want some spares of SUZUKI DR 250.Would you be able to supply?.

[@iangriffiths9930]

Love watching these bike repair videos as I learn so much !

[@TomsTinkeringandAdventures]

I like to hear when my videos help other people. Keep learning!

[@john-cc7ul]

another great installment tom! thanks for putting in the effort... very entertaining and informative! best, johnnyg

[@TomsTinkeringandAdventures]

I was just happy to get it back to my buddy, and out of my garage.

[@egoranufriev]

Realy cool detailed videos, man!

[@TomsTinkeringandAdventures]

Hopefully they are helpful for you, thanks for watching.

[@jonsmith3723]

Thanks, You have already saved me much heartache!

[@TomsTinkeringandAdventures]

Make sure you have the manual as well! Glad to help a bit, let me know how the bike turns out.

[@kristofurwilia2340]

I just got my hands on a 96 DR350SE that needed a bunch of work. Your videos have become my bible! Keep sharing and thank you!

[@TomsTinkeringandAdventures]

Glad to be of help, the DR350 videos seem to be pretty popular on my channel. I wish I had more to fix on it, but it's a fairly reliable bike. Thanks for watching.

[@tom535]

Hey great job Tom,, I'm glad it went good for you guy's..

[@TomsTinkeringandAdventures]

It's always great to have it start after being apart for so long. Thanks for watching.

[@ShaneZettelmier]

Looks good and it sounds really good to.

[@TomsTinkeringandAdventures]

Thank you!

[@Pmz604]

Thank you for creating this video and sharing Tom.

[@TomsTinkeringandAdventures]

I hope that it was helpful to you, thanks for watching.

[@Pmz604]

@@TomsTinkeringandAdventures Thank you , its because of the good people like yourself sharing knowledge and experience, I bought my very first dual sport yesterday, 1999 Dr350se . So incase if something happens, I am better equip and certain I can too fix the bike when things needs tinkering with. Thank you again Tom.

[@sebastiangranada8400]

Saludos desde Argentina. Acá hay muchas Dr350 y yo tuve 3

[@TomsTinkeringandAdventures]

Greetings! Interesting to hear that the DR350 is popular there. Great bikes.

[@llawlor]

Trust in Tom! Also, Tom, your patience with Rampage is commendable.

[@TomsTinkeringandAdventures]

Patience is a virtue, they say. Ahh, we know that it's all worth it....good dudes, all of you!

[@benmelloncalfs343]

Some good looking guys there!

[@TomsTinkeringandAdventures]

At least one of them. Not sure which?

[@ftby59mikeD]

It's "DR Deja vu" ...all over again! Thanks Tom, for resurrecting your Bro Justin's bike, where would we be without you! Hey, in the arthritis ad that plays here, not your long lost relative by any chance!?...carry on.

[@TomsTinkeringandAdventures]

Ahhh, you should have got a screen shot of the ad. I don't control which ads get played and I think it changes. I always find it funny when people locate a doppelganger. Thanks for watching.

[@Mudmowerdiesel]

Awesome channel thank you

[@TomsTinkeringandAdventures]

Thanks for watching, appreciate the support.

[@bakerXderek]

This was awesome man

[@TomsTinkeringandAdventures]

Thanks for watching!

[@jackl3384]

Thank you so much this really helped

[@TomsTinkeringandAdventures]

Glad to hear, hope you repairs go well.

[@briansagun2275]

Thank you!!! 🙏

[@TomsTinkeringandAdventures]

You're welcome, hope the video helped.

[@philippemauduit2163]

Thanks a lot

[@TomsTinkeringandAdventures]

Hopefully you get your project together!

[@stevec-b6214]

watching this makes me realise im not as crap a mechanic as i thought ;)

[@TomsTinkeringandAdventures]

I have never implied that I am a professional by any means! I hope that most people see that if I can do it, they can do it. Have a great day and good luck working on your bike.

[@KowboyUSA]

Mine has noise that sounds top-end and possibly timing chain related. Got a feeling I'll be doing this soon.

[@TomsTinkeringandAdventures]

Just check everything first. Maybe you'll get lucky and won't have to take it all apart. Let me know what you find.

[@timetable620]

Read the manual: 1700 for oil change w/o filter 1800 for oil change with filter 1900 for oil change with engine build

[@TomsTinkeringandAdventures]

Good call, RTFM. Thanks for watching.

[@timetable620]

@@TomsTinkeringandAdventures I love my 92 Suzuki DR 350 s

[@Trytocookthis]

👍

[@TomsTinkeringandAdventures]

Thanks for watching!

[@alexbbeta1113]

Hola no entiendo su idioma pero esta bueno el video yo tengo una moto que trae ese motor pero es una tipo Chopper marca beta motor Suzuki 350cc me salió muy buena es 2002 y estamos en el 2020!! Mexico 🇲🇽🇲🇽Saludos y gracias👍!! por el video!!👍

[@TomsTinkeringandAdventures]

Gracias, andar en moto con seguridad

[@julianlarocca5191]

Excelente trabajo loco!!!!yo tengo que desarmar para ver porque me hace ruido el engranaje de la 5ta y 6ta cambio gear box!!!!😬😭😭😭

[@TomsTinkeringandAdventures]

Good luck, transmission issues can sometimes be tricky. Thanks for watching.

[@ralphderkapitaen9875]

nice video, thanks. A question - what manual do you use? is it the original Suzuki Service Manual? or some other one? Would be nice to have some very detailed manual for everything..:-)..Thanks

[@TomsTinkeringandAdventures]

I have both a Clymer manual and the Suzuki factory manual. If you can only have one, I recommend the Suzuki one. A bit of internet searching can find one to download for free of a small fee. It's well worth it, it's difficult to cover everything in a video unless it's a few hours long!

[@germancavicchio]

Hi, im from Argentina, first: Excellent explanation, I have been watching the video several times to fully understand how this engine works, I thank you Second: I have a DR350, and my crank spring broke.. I have the service manual that I download from the Internet and I do not quite understand how it is placed, It was just one of the parts you cut in the video 🤣🤣🤣 the problem is that the images in the manual look blurry and I don't quite understand what shape the spring is placed and what are the right steps to place it (my technical English is not so good)..Should I put the tip of the spring that goes into the shaft first or the one that goes in the crankcase first? Also note that there is an alignment between thr pawl and the shaft.. That's all? Or it has some other alignment regarding the other gears? Could you try to explain? I'll be in your debt. Saludos desde América latina! A seguir rodando!

[@TomsTinkeringandAdventures]

Your English is much better than my Spanish. I'm sorry, but I don't understand which spring you are talking about. The one for the kick starter maybe?

[@dariusbucas5509]

Hi, i like yours videos. I would like to know where to get this big bore kit 87mm piston and what is the process. Thanks

[@TomsTinkeringandAdventures]

There used to be a few places that made the big bore kits, but I don't know if they still do. Check "Thumper Racing", they are one that I remember.

[@danmac0]

The stand is cutting the arm when not in use. You can already see it cut some material. I had the same problem with my DR.

[@TomsTinkeringandAdventures]

Are you talking about the side stand hitting the swingarm? Very common issue on the DR350. Just takes a little bit of adjustment on the mount tab to make sure it doesn't happen anymore.

[@danmac0]

@@TomsTinkeringandAdventures yes.

[@KowboyUSA]

Mine also has the big bore kit and is running lean. Wouldn't happen to know which carb jets yours is running would you?

[@TomsTinkeringandAdventures]

This bike had the TM33 pumper carb on it for a long time, but it was getting worn out. We actually installed a CVK from a DRZ400S on it and it runs great. I can't remember the jetting setup, though.

[@stephend9821]

Hey what camshaft did you use with the built in decomposition? I must know!! Thanks

[@TomsTinkeringandAdventures]

It was from Webb Cams. I don't know if it's on their site, you probably have to call them.

[@DrTusker74]

Could I ask, did you do something to the suspension to raise the bike? Looks taller than the stock DR350? THank you

[@TomsTinkeringandAdventures]

The suspension on this motorcycle has been revalved and sprung for the weight of the rider, so it may seem a bit taller?

[@cc3775]

How did you mount up the DRZ speedometer and headlight?

[@TomsTinkeringandAdventures]

The headlight shroud fits over the DR350 headlight just fine from what I remember, no mods needed. The speedometer bolted directly to the triple clamp, exact same as the stock speedometer. The wiring connections were completely different, but the wire colors were the same as a stock DR350 speedometer. I cut and spliced the connections from the DR350 to the DRZ speedometer and everything works. Thanks for watching!

[@h4mst3rtube]

Great Video, i'm about top do a rebuild on my '93. how do you feel with the 430cc kit? it's good also with long transfer between one trail and another, or not? ok more power/torque for sure, but rpm wise ? thanks a lot.

[@TomsTinkeringandAdventures]

I have had two bikes with the big bore kit like this. It's definitely more torquey but it feels like it revs a bit slower and loses a bit of top end power? So if you're a person that likes to rev the bike you probably don't want this, but if you like low RPM power it's great.

[@h4mst3rtube]

@@TomsTinkeringandAdventures thanks a lot, Just the way i suspect, so maybe Better for the off-road, but not so for the Road, i'm thinking about a 380 borse cylinder with an 82 wiseco piston... Otherwise Just a new piston with a proper cylinder job. Still not sure.

[@tylerbequette121]

at 14:36 there is one bolt in the top of the valve cover. mine is missing and i cant find it in the manual anywhere, do you know what size it is? or have a parts number? thanks!

[@tylerbequette121]

the one labeled " in head" on the cardboard

[@TomsTinkeringandAdventures]

I watched the video again but don't know which bolt you're referring to. I suggest doing an internet search for "Suzuki Microfiche" which should bring you to any number of online parts diagrams. Good luck and thanks for watching.

[@abdullahodabasi2139]

Hello i have a 97 model electric start dr350 and it has extremely worn camshaft. I found a cam which is 95 kick start with auto decomp model just like yours is that fits my 97 electric start? So It has auto decomp also

[@TomsTinkeringandAdventures]

Yes, the cam from any 94-99 DR350 will work in any of those models.

[@abdullahodabasi2139]

Thank you so much friend. Keep going I’m fallow from Turkey 🇹🇷 love your videos

[@joseluissanchez963]

Hola buenas noches cómo estás . Los felicito por el armado de la moto DR 350 suzuki. Soy de la argentina y yo también estoy arreglando un DR 350 arme todo el motos puse a punto cómo estedes pero no tengo el manual . Pero tengo un problema q no enciende la chispa de la bujía es muy pobre . Le quisiera pedir si me pueden ayudar gracias por acer los vídeos son de mucha ayuda para les mando un abrazo Jose Luis de cordoba capital

[@joseluissanchez963]

Me encantaría poder tener ese manual de taller q tienen

[@TomsTinkeringandAdventures]

I used Google translate, so hopefully I got this right. It looks like you're having an issue with spark? I have had a few failed stators on the DR350's in the past. There are test parameters in the manual. The coil and the CDI are usually pretty reliable but worth checking if you can. If you take some time searching online, you can probably find a manual to download for free or cheap. Best of luck, I hope that my reply has been helpful.

[@LosVRC]

Anyone reading this I assume is a Dr350 owner.....has anyone had any issues reading oil level?..the oil drains back down soon as I shut it off...I've googled forums but nobody ever has a solution....also not one video of the "oil valve check" that these DRs come with... they're on the inside of the clutch cover...

[@TomsTinkeringandAdventures]

From my memory, you are supposed to run the engine for a while (a few minutes), shut it off and then check the oil right after shutting it off. If you let it sit too long, you will get an incorrect level. As for your second point, I am not sure what you are talking about? Oil valve check? There is a bolt on the clutch cover that you can remove to do a cursory oil check if you want to ensure oil is in the bottom of the engine before starting, if that's what you're referring to.

[@LosVRC]

@@TomsTinkeringandAdventures very few information on the oil check valve..it slows the drain back oil from frame...it was suzuki fix for the owners having incorrect oil readings...some drs have them others don't...it's below the bolt on the clutch cover..it's a spring then ball. Then a rubber plug...in the manual it's reference as Seat oil valve check....not much info online on servicing those components or replacing......I just finished rebuilding my Dr350...your videos helped out a lot. Thank you

[@TomsTinkeringandAdventures]

@@LosVRC I had heard there is an oil check valve in the system but didn't know where it was. Interesting. Glad to hear you got your bike back together. Thanks for watching!

[@tumbleweed6612]

Did you fit in a fresh new cam? Where did you get it?

[@TomsTinkeringandAdventures]

This bike did get a new cam, but it was just prior to this work. It was custom ordered through Webb Cams. I don't think it's listed on their site, but you can contact them and they will help you out. Good customer service

[@tumbleweed6612]

@@TomsTinkeringandAdventures thanks m8! Good to know.

[@twedipops]

Are the later models using the same barrel as the earlier bikes?

[@TomsTinkeringandAdventures]

I guess I need to research it, I thought all the cylinders were the same but it's been so long since I bought any parts that I can't remember.

[@twedipops]

@@TomsTinkeringandAdventures I realise its a old video but thanks for taking the time to reply sir, much appreciated

[@TomsTinkeringandAdventures]

@@twedipops These DR350 videos get a lot of views and questions. My buddy still has this bike, I've been involved with it for over ten years. I keep saying that if he sells it I want first chance at it again but it's just hard to make room and time for so many bikes. I have plenty already!!

[@teamground0229]

I have a 1999 Dr350se with 3000 miles. How many miles do people get before needing to do a top end?

[@TomsTinkeringandAdventures]

There's really no way to answer that, it all depends on maintenance and use but I can tell you that if you have 3000 miles and it's been taken care of you have plenty of life left in that engine. I have seen them with over ten times that mileage.

[@FPSHungary1337]

@@TomsTinkeringandAdventures This right here! As long as you keep the oil clean these things will run for a very long time. My 91 DR250 has 29k miles and 95 DR350 has 16k miles and the only time the engine has been opened up is to put in a Barnett clutch upgrade. Both bikes were purchased new and have the original top ends.

[@antarcticmoongiant2691]

Clean oil is optimal but oil in it is key. Put fuel in it check the oil. I have seen bikes with 700 miles on them that got ran with almost zero oil & cam floated around in channel & bottom end bearings felt like a bike that had been ran into ground. Lube is our friend

[@johnw9874]

Not using the compression release for starting?

[@TomsTinkeringandAdventures]

The 94-99 models have an automatic compression release. You can still use the lever if you want to, but it's not really necessary.

[@johnw9874]

@@TomsTinkeringandAdventures thanks didn't know that. My 1991 DR350S is manual. Learned something new. 😊

[@TomsTinkeringandAdventures]

@@johnw9874 It's definitely required on the first generation models (90-93) and it's still included on the 94-99 kick start models but not really needed. The 94+ electric start ones use the same automatic decompression cam and don't have a release. A few other minor changes, otherwise mostly the same engine. Enjoy!

[@patrickkitchens3363]

How much would yall charge to put one back together

[@TomsTinkeringandAdventures]

It really depends on what has to be done. No two jobs are the same.

[@patrickkitchens3363]

@@TomsTinkeringandAdventureswhere are yall located

[@unclequack5445]

You didn't show how you fixed the counter balancer pin did you have it welded? and Trim that scroungy ass beard Sir Aaha hajaha......

[@TomsTinkeringandAdventures]

You would have to watch the lower end assembly to see the sketchy repair on the counter balancer. The scroungy beard stays, thank you very much! LMAO!

[@unclequack5445]

@@TomsTinkeringandAdventures So Tom did you just epoxy it in place? or burn it in-Tig Weld? You say this motor is kitted out with 450cc Big Bore?

[@unclequack5445]

Thumbs up #42...…..

[@TomsTinkeringandAdventures]

@@unclequack5445 I used the epoxy (JB Weld) to close off the back of the hole, then used some permanent loctite to hold the pin in place. It really can't go anywhere with the back of the hold being closed off. Yes, that engine has a 435cc big bore kit. Nice for low end torque but it seems like it revs a bit slower and loses steam on the top end. Probably should have bigger valves?