🔧 DR350S - Solving problem with neutral gear, jammed gearbox and dragging clutch

[@DawidMartasMotoAdventures]

Here is table of context: 0:00 - Intro 0:26 - demounting hardware around engine, draining the oil 3:20 - demounting clutch cover 5:52 - demounting clutch plates 6:58 - problem with the shift drum bolt 👎 8:13 - removing clutch basket 9:08 - problem with the clutch basket spacer and washers 👎 9:30 - problem with shift drum stopper arm 👎 11:04 - new parts arrived 11:12 - cleaning engine threads 11:39 - installation of shift drum stopper arm 13:05 - installation of shift drum bolt 13:50 - test after assembly 14:28 - filing grooves on the clutch basket 15:09 - removing old gasket 15:59 - clutch basket installation 17:31 - clutch plates installation 19:31 - clutch cover installation Parts used in video: 25350-14D01 x1 - shift drum stopper arm 08211-06141 x1 - stopper arm spacer/washer 25312-38A00 x1 - shift drum bolt 09180-20109 x1 - clutch bracket spacer 08211-20363 x2 - clutch bracket spacer washers 09167-20009 x1 - lock washer Have a nice day!

[@eriktruchinskas3747]

The sandpaper on glass trick is awesome, ive watched someone do that with a cylinder head, now they admitted that it was most likely a short term solution but by god it actually worked

[@DawidMartasMotoAdventures]

Glass is a cool trick because it is very flat :) Actually, I'm not sure if you can grind gears made of hard metal easy. It might work a bit like homeopathy :D

[@ftby59mikeD]

Great tutorial! Hard to believe that shift drum bolt didn't cause any damage. Thx.

[@DawidMartasMotoAdventures]

You are welcome :) It looks like it is a smart bolt, because you can find it in oil sump in most of the cases. But unfortunately sometimes it makes some damage :(

[@JR-qe6ro]

I picked up a 1991 DR350S a few months ago as a project and began to experience the same issue. I could not have solved it without this video. Thank you so much!

[@mornemarais4198]

Thank you sooo much!!! I wish there was a channel covering the mecahnics of my bike from front to back and now i have just found this channel thank you so much your the best!!!

[@DawidMartasMotoAdventures]

Welcome on the board :D

[@allwayswest]

Thank you for the informative video. I just completed this repair on my 1999 DR350se.On my motorcycle it was extremely difficult/ almost impossible to shift into neutral, the clutch would drag while in neutral, and shifting was notchy. The parts I used were the 2 metal washers, metal sleeve and cover gasket from Suzuki. My bike has lower miles, so I inspected and reused the clutch. It rides so much better now. Thank you

[@Adventure72Awaits]

Thank you for taking the time to make this video. I had the exact issue with my DR350 and your video helped me diagnose it quickly and fix it quickly. With the use of the video it took me a morning to complete the job. My tensioner was also bent but I just bent it back with the vise.

[@DawidMartasMotoAdventures]

Hi! Nice to hear that! One more DR is happy now :) We bought this tensioner - it was cheap and we were waiting for more parts. But of course you can bent it back without any problems, it is just a piece of metal :D Have fun while riding now!

[@Adventure72Awaits]

@@DawidMartasMotoAdventures thank you again, it's people like you that make it to where I can ride. I can't afford the $7,000 bikes.

[@DawidMartasMotoAdventures]

Anyway you are lucky, you can still buy new "old bike" for 7,000$ in USA. In Europe they needed to update old bikes to EURO emission standards or abandon it. You can't buy here new old style bike with carb and without ABS :( Now you can buy here only "computers" on two wheels, and weight is killing those small bikes. Check new bikes: GS310: 374 lbs Versys-X 300: 386 lbs KTM 390 Adventure: 386 lbs No 21" at front, only Versys got spokes in wheels. Old Africa Twin 750 is only +110 lbs than new "small" bikes :D Look at old bikes: XR400 276 lbs DR350S 286 lbs How it is possible? :D

[@yamama7442]

Just did this to mine today! Thank you so much for the tutorial wouldn’t have been able to do it without you guys!!

[@DawidMartasMotoAdventures]

Glad it helped you and your DR! :)

[@stdjunior]

I had the exact same issue with the bolt coming loose Luckily it just chill in the sump. Would have be nice to have seen this video beforehand but now it's a nice "hey I've done this! " moment

[@abdullahodabasi2139]

Your all videos as an encyclopedia, fault isolation manuel and maintanance manuel for dr350 owners :) Very good job thanks for every thing...

[@DawidMartasMotoAdventures]

There is still missing a lot in this encyclopedia :D

[@abdullahodabasi2139]

By and by You'll complete missing pages 😊

[@TheWaterboarders]

Congratulations on an excellent and clear video. I have shift problems on my DR so I will use this video when I fix it

[@DawidMartasMotoAdventures]

Hi! You're welcome. We hope this video helped and your DR is fine now :) (Just be careful and don't bend this L bracket!)

[@carlandersenlohaitz-itpro9778]

LOS AMO! SIS VIDEOS HACEN QUE LAS MTOS DR350 SIGAN SIENDO LAS MEJORES EN CARRETERA. GRACIAS A USTEDES COMPRE UN DR350SE, Y LO ESTOY ARMANDO PARA CUMPLIR UN SUEÑO QUE TENIA DESDE CHICO Y ERA TENER UNA MOTO DE ESAS. SUS VIDEOS SON FENOMENALES, AON LOS MEJORES! AHORA YA ESTAMOS RESTAURANO 4 DR350(r/s/se). SON LO MEJOR QUE EXISTE! GRACIAS POR COMPARTIR SU CONOCIMIENTO! scientia potentia est !!!

[@Functionovereverything]

Super helpful video! My 96 dr is shifting much better now

[@justme-kw7ww]

Best instructional video on KZbin by far, only wish I had a bike to tear down now! well done!

[@michelhenri6124]

Grand merci pour cette vidéo. Problème récurent sur le 350 Dr (1991)

[@Janchez]

Thanks for a great video with good camera angles and lighting.

[@siTTinLo]

Thank You for making these videos Marta! They have helped me greatly with my 92 DR350. 🙏

[@jamesmasanja1963]

From Tanzania 🇹🇿, thank you for updates,, MRS DR

[@ibrazish]

Thank you for all this great information! It is really helpful to all of us preparing our bikes for adventures! So much detail and good explanation with technical info! Great job!!

[@DawidMartasMotoAdventures]

Hi! Thanks for nice comment, it is nice to know those videos are helpful! See you on the road during motorcycle adventures :)

[@ibrazish]

Dawid&Marta's Moto Adventures My pleasure! Do you remember what grain of abrasive paper you used for the clutch basket clearance?

[@billbright1755]

My 91 DR 350 has 30,000 miles. They love Suzuki Ecstar 9000 synthetic oil. Two quart oil in frame system. Suzuki builds incredibly well built and designed motorcycles. That kick lever return spring spacer must be installed with notch over spring and proper side out. Be careful when handling that clutch basket. The edges are near razor sharp. Be sure the release bearing has rollers to release pin and smooth side to clutch inner basket. I use Pirelli Rally Cross tires on my DR for off road with reasonable on road performance.

[@DawidMartasMotoAdventures]

We also run full synthetic oil and it works great! At first attempt we had problem with this cover because of this kick starter lever return spring :) We use Mitas E09 tires. Pirelli MT21 is very expensive in Poland :( Have a nice day!

[@jamesg5059]

I bought a 1990 DR350s cheap. Had a bottom end rattle and would occasional jump out of gear. Opened it up to find the same thing. Shift drum bolt rattling around in the bottom of the case. replaced it but had to tear everything back apart because my L bracket was bent as well. Replaced that and I have had many trouble free miles since.

[@DawidMartasMotoAdventures]

Nice to hear that it solves the problem permanently. We also hope for trouble free miles now :)

[@paul8158]

your videos are awesome, makes oneself confident to fix the most!

[@nvmcrider8475]

very well done video. Too bad Suzuki has a history of small bolts coming loose in their engines. Your repair is very professional.

[@DawidMartasMotoAdventures]

Thanks :) It is 27 years old bike with just a "small" problem with just one bolt. Some modern bikes got problems at end of production line :D

[@wtfnetown5049]

Great video. Jeez that frame looks immaculate. Sweet bike.

[@gardener6196]

Thank you do much guys!! I have to do this to my DR350 as we speak and this video has helped heaps!!

[@DawidMartasMotoAdventures]

Let's hope shift drum bolt just unscrewed and fell off. Sometimes it may break in half and then you got a much bigger problem. Good luck!

[@gardener6196]

@@DawidMartasMotoAdventures definitely broken in half 😕 wish me luck!

[@DawidMartasMotoAdventures]

🤞 Fingers crossed for successful repair 🤞

[@MegaFafa91]

Dobrze że to rozebraliscie mialem kiedys tam dr 350 i nie wiedzialem wlasnie o tym ze ta śruba sie luzuje i mnie spotkalo wlasnie to ze sie wykrecila i wleciala miedzy tryby - rozwalilo skrzynie i karter ;/ duze koszta byly niestety ;/ Pozdrawiam dobra robota ! DR 350 super sprzet chetnie bym zakupil jako 2 moto ;d do latania po polach !

[@DawidMartasMotoAdventures]

A ludzie często mówią, że ten tym tam ma i ciężko znaleźć luz :D Taki kawał śruby fruwającej w silniku to bomba z opóźnionym zapłonem, kawałek do tyłu i w górę są własnie tryby skrzyni biegów - miałeś pecha że tam trafiła :( I pełna zgoda - DR to fajny motorek :)

[@chuchitohab4389]

Thank you very much! Very helpful Video!

[@1227-b8d]

THanks for such detailed video

[@DawidMartasMotoAdventures]

We are happy to help :) Somehow we like making this kind of videos :D

[@martinvonderemde2513]

Super detailed Video. Very helpful. Thank you.

[@DawidMartasMotoAdventures]

You are welcome :)

[@MrTravis789]

Your clutch release bearing was in there backwards initially. I hope you did not put it back in there like you found it. The bearing side should face the back of the pressure plate. Thank you making this video

[@dannyaustin84]

I would like to know a bit about how the bike feels/performs after the repair. I really enjoyed watching your methodical work. Thanks.

[@luke0b708]

Love this. Thank you!!

[@DawidMartasMotoAdventures]

You are welcome :D

[@berlum1]

This is great thanks. I have same bike same year. I’m part way through stripping the clutch etc. I also noticed that The clutch lever pinion shaft/clutch release lever shaft (fitted in the casing) was loose. I can pull it up by about 5mm. Looks like oil seal broken. How do I remove the pinion shaft from the casing to service it? I can’t find anything in the manual. Any help would be appreciated.

[@IDontWantAHandle101]

Great vid. Hope mine doesn't do that, but i'll know how to fix it. Thanks for taking the time :)

[@DawidMartasMotoAdventures]

You are welcome :) I hope your DR will work without any problems, it is great bike! :) Cheers!

[@IDontWantAHandle101]

@@DawidMartasMotoAdventures Hi, yes it's so good I just bought another :)

[@edenilsonlopes8025]

parabéns pelo vídeo aqui no Brasil tem pocas de 350 esta fichando difícil pecas tenho uma 95 partida elétrica a minha está com a engrenagem dura e tá um pouco ruim pra engatar acho que vou ter que trocar a embreagem e este vídeo me ajudou parabéns

[@dunemaster3179]

Really nice video. Your bike looks super clean compared to mine.

[@DawidMartasMotoAdventures]

Thanks :) It was super clean after rebuild :D After vacation trip it was dirty, but now after big cleaning (before winter) it is clean and it waits to be dirty again :D

[@philippemauduit2163]

Very useful , thanks

[@DawidMartasMotoAdventures]

You are welcome :)

[@jamilakontena9160]

Thanks so much coz also my motorbike as this problems i will salve after watching this video

[@DawidMartasMotoAdventures]

This is common problem with DR. Good luck and keep riding! :)

[@uguryvz]

Perfect job. Wonderfull detailled explaination. All the details.. İ stuck watch ing your videos last days. '). Your info enlightining me like i was in dark... And your infos videos lighting me as hps(high pressure sodium) Millions thanks. Marta&david.. Dr 800 have some similarities but i know there are sharp differnces as well.. İ still have dr 800 ignition problem. İ bellieve i ll solve w your precious infos

[@marcoab]

Excelente video muy prolijo todo, como corresponde!!!

[@Reids-Rides]

Great video, thanks for taking the time to share all the work you have done. I have just bought a really nice 98 DR350 SE and it was really hard to find neutral the other day but now seems better. Watching your vid has made me think I'd be wise to take clutch cover off and check that bolt. Are there any other symptons to check for before I open the engine?

[@maxredchannel]

Very very good! 👍

[@TAULBEE]

nice man. i have a 1999 dr 350 project bike. killing me right now

[@DawidMartasMotoAdventures]

It will be fine ... you need only time and money :D

[@TAULBEE]

@@DawidMartasMotoAdventures lol I know

[@pawemynarski8066]

Bravo👌

[@varieze117pj7]

Nice DR.

[@DawidMartasMotoAdventures]

Thanks ( ͡° ͜ʖ ͡°)

[@johnnyrebellion8672]

Hello, the clutch plate actuator arm on the outside of the case moves freely by hand. No spring tension? Any idea of what may have broken before I take the cover off?

[@thedirtdominators]

hey you guy, love your videos and the detail you go into! Making myself feel good about working on my own 350! I'm super interested in your selfmade stand you put the bike on for doing all that work. Would you mind sending some detailed pictures? I'd like to build my own similar to yours :) cheers from germany

[@DawidMartasMotoAdventures]

Hi! You are welcome. Working with own bike is nice. You care about it in garage and bike cares about you on the trail :) Here is stand from the video kzbin.info/www/bejne/kGHSd5umgceGmJo (actually it is first video on the channel) Also check out this one: kzbin.info/www/bejne/pIPFl4SdpsZjsKc Last time I build similar one for light trial bike and it also works fine. But it is less stable of course.

[@mareks8682]

Super robota

[@DawidMartasMotoAdventures]

Dzięki :) Nawet daje radę, przejechało do tej pory 4kkm i się jeszcze nie rozpadło :D

[@cornholius]

Is there a video where you cover the clutch cable installation? I can't remember...

[@DawidMartasMotoAdventures]

We don't have clutch cable replacement video yet :)

[@cheba4786]

🔥🔥🔥🔥🔥

[@matiasshanahan5164]

Hello, where do You get the drawings of the components and how they mount in the motor? And where do You Buy the original component? Congratulations from argentina.

[@DawidMartasMotoAdventures]

Hi! Check this site for drawings and parts numbers: landdsuzuki.dealerspikeparts.com/oemparts/c/suzuki_motorcycle/parts I'm buying parts in Poland in offroad motorcycle aftermarkets store, but they can delivery almost all OEM parts. The prices are nice, for parts from this video I spend about 40$. There is also store "IMPEX JAPAN - online new genuine spare parts shop" (google it) and a lot of people in Poland buy there. Prices are better, but you need wait a little more. Also you can look at ebay for specific part number.

[@mt1885]

What COLOR of BLUE PAINT did yall use on the bike frame?

[@Tdori61692]

When you tightened the second washer for the inner clutch and bolt, was the bike in gear or was the bike in neutral

[@DawidMartasMotoAdventures]

The bike was in gear. At 16:54 you can see Dawid is holding rear wheel because it spins during torquing the nut.

[@berlum1]

I am replacing the shift stopper arm. same bike same year. I am a bit stuck. Do I actually need to remove the shift drum bolt to replace the shift stopper arm? Can I not just replace the arm independently? I don’t want to undo the shift drum bolt because it turns the whole mechanism when I put a socket on and I have back wheel and swing arm removed so can’t hold the wheel. Not sure how to remove it as it is now.

[@berlum1]

I know, sad replying to my own message but the shift stopper arm can be removed independently. Just need to pull the gear shifter shaft out a bit and turn it out of the way.

[@Micscience]

I have never seen oil come out of a motorcycle frame before.

[@MotorcycleParody]

nice job, pretty nice! why did you used new clutch springs?

[@DawidMartasMotoAdventures]

Don't ask :D We bought complete clutch repair kit in one box (clutch plates + metal plates + springs) so we put all new parts in. This springs at wideo are much stronger than OEM ones. After new springs installation clutch lever (with new clutch cable) was so hard to use, so after 2 days we took off clutch cover once again to switch back to OEM ones... :D

[@MotorcycleParody]

@@DawidMartasMotoAdventures eheh ok, I Just got my dr350 se a few days ago. Clutch is Hard as hell. I Will have a ton of work to do on it :/ Also have to take like 10 minutes of hell to get it on neutral :/ I Will also upload the rebuild proccess. Subscribed!

[@DawidMartasMotoAdventures]

We spent more than 6 months with this DR. Weekends + a little time everyday after work. Unfortunately it takes a lot of time. Have a fun while rebuilding this :D

[@MotorcycleParody]

@@DawidMartasMotoAdventures ive seen lots of 'only good' opinions about these engines. But I also have seen some problems with things Just falling apart inside the engine O.o

[@jamilakontena9160]

Can assist me to get spears part for my motorbike Suzuki dr350 example celindarhead complete and how much coast until derived i am in Tanzanian?

[@DawidMartasMotoAdventures]

Hi! DR350's cylinder head in good condition is very difficult to buy... additional there is a problem with shipment even inside EU due virus :(

[@wrobelwbutach4981]

18:02 na zdrowie :) Dokręcać nakrętkę sprzęgła na biegu aby się nie obracał?

[@DawidMartasMotoAdventures]

Dzieki :) W 16:55 trzymam koło, a Marta kręci kluczem :D Bieg wrzucasz najlepiej jakiś większy a nie 1. Czasami ludzie wrzucają jakiś kawałek alu między tryby aby się zablokowało i dokręcają.

[@jackkight7771]

What tourqe metter is that I can't find them anywhere

[@arielbrites6794]

Hola cambie los discos de embrague, pero al desembragar y poner la primer marcha . La moto sale andando.

[@DawidMartasMotoAdventures]

Hola! Puedo responder español simple con el traductor de Google, pero este es complicado: D No tengo idea de por qué la bicicleta está avanzando ... el juego libre del cable del embrague, el juego libre de la cesta del embrague (espaciador y arandelas) son normalmente el problema principal. Buena suerte!

[@unclequack5445]

You did not check the engine when you had it out?

[@DawidMartasMotoAdventures]

We only started it one time in middle of rebuild ... also we checked camshaft condition because it is common problem in DR350. Engine started without any bigger problem and it was working fine, so there was no need to rebuild it :D But during first ride I noticed problem with gearbox ... ehm.

[@swassige]

What is your preferred oil for this bike?

[@DawidMartasMotoAdventures]

We use Valvoline SynPower 4T 10W40 in XR and DR. Any full synthetic oil 10w40 or 10w50 will be fine :)

[@officialGFguitars]

Mine was in the exact same place.... The problem is that mine as a piece of broken screw thread still inside the case thread :s

[@DawidMartasMotoAdventures]

Ehm... that's bad. You can use screw extractor, but during drilling be careful. I think you can use some thick grease during drilling to stick some metal shavings to drill bit. Probably the best solution is putting it apart... .

[@officialGFguitars]

@@DawidMartasMotoAdventures already removed it. I must say it was not easy O.o Are you inside europe? I never bought parts for this bike, whats the best site you recomend? My stoper arm was also bend like yours, but i got that spacer in its place.. weird

[@DawidMartasMotoAdventures]

Good job! :D We are from Poland/Europe. You can buy parts in local Honda dealer. I always buy parts in the internet, it is a little cheaper. But this site is only in polish language... You can bend this stoper arm back - it should work :)

[@officialGFguitars]

@@DawidMartasMotoAdventures its not only bent, the "little bearing" at the tip is completely grooved O.o it like a square now ahaha looking forward to new episodes from you guys :)

[@DawidMartasMotoAdventures]

It was bent for a long time :D Last time we are working on repair kit for Africa Twin 750 rear shock (o-rings, main seal, new rod, air can modification and new air can cap ...) because we are members of Polish Africa Twin community. Also we are thinking about about small shock service point ... haha :) Next projects are: lowering link for DR350, new luggage rear rack for XR and DR, DR shock rebuild kit. Also it would be nice to make small windshield for XR and DR... but it is hard to work on those stuff after "real" work and make new episodes at once. But we are trying :D Ride safe and keep making guitars! :)

[@Dafi-mx6fz]

Posiadasz jakas serwisowke gdzie ładnie rozrysowane są schematy silnika wraz z momentem doręcania śrub. Składam silnik od podstaw i potrzebuje. Dzięki za pomoc

[@DawidMartasMotoAdventures]

Jedynie serwisówka co wyskakuje pierwsza po szukaniu w google "dr350 service manual". Są jeszcze dostępne fiszki, ale tam są tylko numery części, bez momentów. Wszystko do pobrania na stronce thisoldtractor. Jak potrzebujesz to mogę poszukać i wysłać linki :)

[@Dafi-mx6fz]

Mam problem taki że automat raz zmienia biegi raz nie zmienia. Czasem poluzowanie środkowej śrubki pomaga A raz praktycznie nic nie zmienia. Wiesz może czego to może być wina ?

[@DawidMartasMotoAdventures]

@@Dafi-mx6fz u nas zacinało się chyba na 2gim lub 3 biegu i to była wina krzywej dźwigienki co blokuje położenie bębenka zmiany biegów. Tylko to mi przychodzi do głowy. Oczywiście czasami bieg nie chce wejść bo zębatki nie są spasowane i trzeba delikatnje ruszyć wałem kosza sprzęgłowego. To chyba jest normalne.

[@1227-b8d]

Seen two other dr350 engines with the same issue, its common

[@LosVRC]

yup. i was replacing cam chain, and opened the cover. then noticed a bolt hiding at the bottom of the case.

[@DawidMartasMotoAdventures]

Suzuki didn't expect that this bike will run 26 years :D We hope there is no more surprises. At this friday (13) we are starting our 2,5k+ miles trip to Montenegro. It should be our lucky day :D

[@1227-b8d]

@@DawidMartasMotoAdventures haha thats true! well also appreciate what you mentioned about clutch basket washers.. my shifting has been a little crunchy so im in the process of replacing those washers and filing the worn spots from clutch plates. hopefully its just wouldnt disengage properly because i took care of the drum bolt already. Good luck with your trip! Greetings to Marta from Florida!

[@DawidMartasMotoAdventures]

Thanks! Fix all problems with DR and keep it rolling! :D

[@jorgeybalo6003]

Necesito este video al casrellano

[@DawidMartasMotoAdventures]

Hola! A veces la gente de España agrega subtítulos propios a nuestros videos. Solo podemos hablar inglés y polaco, por lo que agregamos subtítulos solo en EN y PL :D (traductor de Google)

[@osmarjose4345]

🇧🇷🇧🇷🇧🇷

[@DawidMartasMotoAdventures]

🇵🇱 :)