Dr350 rebuild

[BBadger]

well the shock is in and set pretty good i think. was hitting the bumps and holes in the road and it felt silky smooth.

Also the shock change has dropped the rear alot so have put the forks through 5mm maybe another 5 after tomorrow big run on it.

anyways decals today!
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1001.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1002.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1003.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1004.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1005.jpg

and on the bike...sits alot lower which is nice and abit more sm'y rather than mx high end.

http://i336.photobucket.com/albums/n344/bbadger101/DSC_1007.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1006.jpg

The tank needs somthing so come monday when ive got some free time again im thinking 2 wedges per side as i ve still got aload of vinal sheet left.

[Owenski]

Mega!
Good work BB

[Skip]

Any updates Mr Badger? Ridden it much?

[BBadger]

erm not alot really put some decals on the tank to break it up but it will need a re spray come ester so will have to wait till then but nothing special.

Came back to uni last weekend so no more riding for 2 months.
but since it got on the road have put about 1500miles on it in about a month and dear god i have never ever had so much fun on a bike.

Not to fast but because it only 350 you ride it hard everywhere and really push it and with tyres that are stickyer than a sticky thing on a hot sticky day i cant complain in the slightest.

also when buggering through london in bloody flooding rain i dont really have to slow down like the any of the bigger bikes as its so light and nimble and only puts down about 35-40hp now.

all i can say is GET A SUPERMOTO NOW PEOPLE OF THE ORG.!!

[Skip]

Hehe - I love my DRZ in Supermoto guise - such great fun 8)

[BBadger]

they are just fun.

although in those 1500miles it drank about 1L of oli...owell ill just have to have it bored and honed 2mm and fit a nice wesco piston (380cc)
And whilst im in there port and polish the heads, repal the valves

sometimes lifes just cruel hu ;):D

[andrewsmith]

they are just fun.

although in those 1500miles it drank about 1L of oli...owell ill just have to have it bored and honed 2mm and fit a nice wesco piston (380cc)
And whilst im in there port and polish the heads, repal the valves

sometimes lifes just cruel hu ;):D

Just re-read this thread, and want one sooo badly

Badger 440 you know it makes sense ;)

http://www.procycle.us/bikepages/dr350.html

[BBadger]

i know im in love!

and tbh it actually isnt that expensive compared to alot of parts.
But no must resist as theres a nice shiny new zx6r that deserves some of my hard earned student loan!

[BBadger]

also forgot to mention made a nice little A frame with braces for the rear fender as it wobbled and flex around like hell.

plan to make one for the front but could be more of a challenge due to its odd shape.

that and a massive strip down and check over come june when its toasty outside.

[BBadger]

its been very quiet on this thread for a while so time for a spruce up.
Might have just ordered this (http://www.ebay.co.uk/itm/Wiseco-Top-End-Piston-Kit-Suzuki-DR350-90-99-83mm-/330439854871?pt=Motorcycles_Parts_Accessories&hash=item4cefc00b17#ht_1348wt_1037)bad boy
So in a month or so when i get some free time i will own a dr385cc along with a bit or porting to match the high comp piston.:mrgreen:

[Skip]

Cool - so that requires boring the barrel rather than a replacement ones like the Athena kits for the 400 which just a little more pricey... :shock:

http://www.ebay.com/itm/SUZUKI-DRZ400-ATHENA-440-BIG-BORE-KIT-BOLT-DRZ-400-/230611153725

[BBadger]

yup, i was a little worried about boring 4mm out but only heard 1 horror story so not to worried if i run it in slowly and keep a good check on things.

Mmmm a new sleve pressed in and bored would be lovely but they are so bloody expensive i couldnt justify it at all.
Cant wait for a good tear down in the summer now.

[Urbanfireblade]

So whats the verdict? If you could only have one bike whould you keep this or the Sv? If most your riding was 30/40/50/60mph roads. I had the CRM250 years ago, 2-stroke, was an exact match when up against my mates XR400(which he still has 12 years on, yet hasn't been on the road for the last 5yrs). Hmm, perhaps i should pester him to sell.......

[Roberrrrt]

So whats the verdict? If you could only have one bike whould you keep this or the Sv? If most your riding was 30/40/50/60mph roads. I had the CRM250 years ago, 2-stroke, was an exact match when up against my mates XR400(which he still has 12 years on, yet hasn't been on the road for the last 5yrs). Hmm, perhaps i should pester him to sell.......

Owenski has a DRZ-400 and rates it. I can vouch for it being highly amusing to ride ;)

[Skip]

If you could only have one bike whould you keep this or the Sv?
For the riding I personally do I would have the DRZ over the SV anyday - but having both is the best compromise as the DRZ doesn't lend itself to long distances easily.

[Owenski]

For the riding I personally do I would have the DRZ over the SV anyday - but having both is the best compromise as the DRZ doesn't lend itself to long distances easily.

Perfect summary. I can't see me ever selling my main Drz but if I started taking in touring id pick up something else but it wouldn't be an SV though I'd maybe go grandad and buy a GS.

[BBadger]

Best of both worlds with two bikes now ( sv has gone and now have a zx6r 55 plate ) so long distance and those fun fast blasts on a sunday to annoying the ss600 riders on a 350 supermoto in the twisties by buggering off into the distance. Sm's are the best.

And for the long distance bit owenkis and skip buy some berik leathers, i have leg and **** padding so the dr is comfortable for hours on end. That and the dads gs1200 is silent ish with a remus can but after 200miles is still better than an car. tops out at 150 not that i would know =p.

[Owenski]

Its not a physical comfort concern for me it's a mental concern based on mechanical sympathy. In honesty I got more saddle sore on both SV's than I ever have on the Drz, the aches from riding the SV used to set in little beyond 60miles but on picking up the Drz I rode 130+ miles to get it home and didn't feel a thing.
Like I said the mental worry is that by riding a motorway at constant top end revs I'm over stressing the motor and wouldn't fancy doing 300+ miles for more than a couple of days in a row hence no serious touring AR or GM are about as much as I'd brave 400+miles in 2 days last AR weekend no problem with me or the bike.

Logically thinking the motor should actually prefer the constant revs over been hammered with WOT-Closed all the time as its the less stressing option but it just seems wrong. Sort of like when you see a scooter riding past and your minds ear is waiting for the gear change that never comes. And here in lies the major problem identified by most Drz riders in that the z is geared badly for its motor, it has the guts for another gear but not the all important cog lol. Most riders combat this by going up a tooth on the front AND down a couple on the back... And they still wheelie in 2nd off the power.

[BBadger]

I know that feeling when buggering along at 70/80 just thinking "dont go bang pleaseeeee" but im running 14/43 and it seems to be okay so far but most of my riding on it is always wot or on the breaks its a supermoto is there any other way to ride it?

[Urbanfireblade]

If it wasn't for my consideration towards neighbours :( (i go to work at 5.30am 5 days a week), i'd most probably consider a DRZ as my next bike, i've no reason to travel more than 10miles any direction unless on a jolly.
Can anyone comment on the noise levels DRZ vs SV(both standard)? Starting up and riding off as quietly as poss type of comparison?

[Skip]

DRZ with the standard can on is easily "neighbour friendly" - I just fitted an 'E' model header to mine to increase gas flow but left the can on to keep the noise down :)

Now have a Leo Vince x3 can on it as I felt guilty not letting that thumper noise free 8) (Definitely not 5:30am friendly!)

[BBadger]

standard its quiet quiet like the sv.
But like skip says you cant keep them all sedate, its a sm squeeze every pony out of it and they are the funnest bikes to ride!

[BBadger]

forgot about all of this with my crazy revision schedule.
Went for a 82mm piston in the end which will leave the sleeve another mm thicker, so im more happy in mind its not going to put lumps of metal somewhere important in the case, but still 377cc with 10.5:1 rather than the 9:1 it came with.
Anyways it arrived and is sitting quietly at home waiting to be put in once i get back from the AR next weeknd.
Will be porting/polishing and new valve guide seals along with a valve relap to get it all snug inside. have to check out the cam chain aswell as i really dont know what condition its in.

Id love to get the cams done but i think money should be spent on a disc for the front first.
Give it a week and 2 days then there will be some pics.

[Owenski]

How much is the porting and lapping gonna cost you squire?

[BBadger]

as much as a new tube of grinding paste costs.
Have many drills and different grade sanding tips/grinding tips/ polishing tips and every type of polish under the sun, so i really want to attempt it myself. Read so much and watched alot of videos so i feel competent, and if i get abit stuck one of my best friends dads builds engines for lotus 7s as a hobby and has some impressive tools and knowledge.

The exhaust port is actually smaller than the header so just a nice bit of boring and a polish then same to the inlet but keep it rough for the fuel atomisation and were away.

And to improve throttle response cut a coil or so off the spring inside the card and enlarge the hole in the slider a very very small amount. It wont be a pumper but has had very positive results on the forums.

Im having the bore done at Sutton bore, they offer to do everything from valves seats and guides and they are a good price with a good rep ( lots of local dealers and race teams use them ) but like i said, for what im doing i cant do any damage as ill be going at it carefully and methodically.

Ill try my best to make a vid for you owenski, just need the tools to get the valves out and then it should be about a week to get it all together and running as long as i dont hit any problems.

[BBadger]

HELLPPPPP

2 hours in and everything is stripped off oil lines bolts ect, but the head isnt coming off. At all. Its stuck. It no budge. now i can move the whole head and barrel but dont want to get half way and find out it will get stuck in the frame.

Any one got some tips or tricks im missing?
Already been going at it with a rubber mallet and scrapped off the excess gasket and tried abit of leverage but with fins i dont want any to snap.

so as before HELP!

[Owenski]

What you done so far?
Remove head cover, remove cams and unhook cam chain, undo external retainaing bolts, undo internal long head bolts from within cam wells, slid head off top of the barrel, undone the other external retainers and now you're trying to separate the barrel and case at the base gasket?

[BBadger]

rocker cover is off
cams / cam chain out
Bolts all out apart from the external ones for the barrel so i can separate it from the head.
Dont really want to have to drop the engine out unless i really really really have to.

head isnt held down by anything apart from the the gasket which has welded it'self to the barrel basically the force is strong with this one.

[Owenski]

heat?
brake cleaner?
although not at the same time lol

[BBadger]

To the head gun i go.

[BBadger]

So after faffing around trying to get the head off the barrel i gave in and handed it to someone in the know how.

anyways what it looks like atm.
keep the dust out
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1095.jpg


only took about 2 hours to get to this point...rest of the time was spent ****ing around with bolts.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1096.jpg

looks tidy but the bore although looking ok had the odd bad spot in it, and some heavy carbon build up on the exhaust ports, one quite bad so will be going ahead with the re-lapping of the valves.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1098.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1098.jpg

How to stop the engine turning over without proper tools :cool:
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1100.jpg

and whats going to be fitted once the engine is back in and wheels/forks have had a good polish.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1099.jpg

tomorrow will be...clutch basket end float and getting rid of the notches in the fingers for a smooth gear change.


also abit of my time between polishing the fork brace was spent finishing the tail tidy on the zx6r.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1093.jpg
home made with a total cost under £20 when a good one will cost £70 and up off ebay or in shops...got to have abit of aimless plugging really.:thumbsup:

[BBadger]

forgot to mention the fork brace is off a old slab side 750 gsxr. bit of a flap wheel on the inside to get it just right and a nice polish and tada perfect fit.

also mr wiseco was nice enough to drop this off the other day.
Every imaginable seal and gasket for the engine
new pin
new cir clips
new rings
Forged 82mm piston (378cc from 348cc) 10.5:1 compression ( std is 9:1 )
and it comes with STICKERSSSS and its own little draw bag

http://i336.photobucket.com/albums/n344/bbadger101/DSC_1103.jpg

[BBadger]

So got the valves out today and started the clean up, port/polish job so it can go back together later this week once i get the bore barrel back.
Anyways as the cleaning goes on......the carbon is really really inground on the exhaust side but its getting there.

http://i336.photobucket.com/albums/n344/bbadger101/DSC_1104.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1105-2.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1108.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1109.jpg

Went a little further with the cleaning but gave up taking pics

http://i336.photobucket.com/albums/n344/bbadger101/DSC_1106.jpg
More burnt on muck but its inside and doesnt effect anything so it can stay there.

Exhaust valves are fine but the inlets are well ...
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1110.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1111.jpg

it looks like i let the gf bbq in there.

Started cleaning up the rough patches and casting marks on the inlet and hacking away at the exhaust port but ill show you those tomorrow when i get abit further with it.

Also clutch got all fingers de-notched and abit more clearance added from the back so the new friction plates will be snug and work for once.

[BBadger]

today the "clean up/port" is complete.
Some bits are just to dam hard to get to fully but almost all the carbon has gone or is very very thin in the odd place.

inlet is all smoothed up but still has enough rough area.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1112.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1114.jpg

The pics make the exhaust look alot worse than they are, but trust me they are clean and sooth apart from the odd bit around the valve guide that i cant get to...and dont fancy removing them either.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1115.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1116.jpg
A fair amount of metal has been removed but talking in 0.xx of a mm, might get back in there just to clean and smooth it up a little more but not sure yet.

valves are as good as they are going to get on the face, as the carbon is tougher than the metal, but need a little work on the stem side to get them perfect.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1118.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1119.jpg

clutch although looks abit notchy is smooth on all the fingers after a file and wet & dry.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1120.jpg

carb is squeeky clean inside and out.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1122.jpg

engine oil lines got a strip and re-spray in black.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1117.jpg

various bits waiting to get cleaned fully, header needs another go.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1121.jpg

now i dont want to hear anything about the porting being wrong or messing up my engine unless you can give me the full derivation of Bernoullis equation and Reynolds number to determine flow rates, head pressure and head loss which actually only apply to liquids thus making it almost impossible to determine the flow rate and whether its laminar or turbulent without proper gas flow equipment ( sorry just alot of know it alls on other forums :smt063 )

[Skip]

All looks good Badger - I ported the heads on my GX160 Prokart engines in a similar way - my thoughts were - smoother tracts must be good and as long as they are still rough we are all good.

[Owenski]

Brock when you gonna stop messing about and buy a drz?

[BBadger]

My thoughts exactly, slightly larger area for the increased capacity but just cleaning up the horrible rough casting marks. As for the exhaust its just been sanded with flap wheels of various grit, so smooth but couldnt be arsed to polish it as im sure the carbon will be back soon, and is a fair bit bigger ( well relative to what it was ) Did a little more and have the exhaust ports sparkly apart from right by the valve guides.

Owenski ill get one when they release a model that is better than my super machine. Also its retro which makes it so much cooler.

[BBadger]

Sorry owenski but i did my valves last night at spannermans and forgot a camera as he let me use his diamond cutting paste but ill give you some nice pics and a write up on it later today once the main engine has gone back together.

[BBadger]

**** **** *******ING BOLTS!!!!!managed to snap the head on one of the clutch basket bolts when putting it all back together....everyone seems to have done it but now i have to spend a few hours sorting it all out and waiting till monday to get replacement ones grrrrrrrrrrrrr:smt097[/SIZE]

everything else went a treat though, getting the timing right was easy as was everything else.
the bore is beautiful and perfectly cross hatched and for £60 is a bargin.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1125.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1123.jpg

forgot to take pics of the head and valves but they were shiny by the time i was done with them and lapped them in.

new piston is place
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1127.jpg

barrel took abit of fetterling to get over the rings but lots of oil later it all went on nice as did the head.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1128.jpg

the bolts that caused all the hassle of getting the head off were just as hard to get back in due to how close the studs are to the barrel and fins.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1129.jpg
but old spanner and a quick grind got it down to size.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1131.jpg
tewght ash a tiwger now

new friction plates getting a good soaking and got everything sorted oiled and in place then snap.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1126.jpg


new fork brace...isnt it pretty

http://i336.photobucket.com/albums/n344/bbadger101/DSC_1134.jpg

anyways im fed up, ****ed off and just eugh as i was hoping to fire it up tomorrow and maybe a little test ride but no my suzuki had other plans to ruin my day, off to get absolutely plastered so dont expect any updates for a few days.

[BBadger]

Turns out the original bolts are real 20 year old cheeseium and snap with bugger all force.
Got the old one out fairly easy and replaced with A4 steel cap heads using all the original washers.
Got abit carried away getting back together so no pics as of yet but ill explain all later on.
Clutch in casing on with oil line, starter motor and cam chain tensioner.
Rocker cover carb and the rest of it later so it should be running by lunch time wooooo.

[Owenski]

Hmmm tempting to remove my big bore from the for sale section....
Looking good badge, gonna be a true thumper soon enough.

[BBadger]

it runs, like a dream.
deeper tone out the now completely sealed exhaust system.
No oil leaks
no odd noises ( cam chains a little noisy but its getting less every min so putting it down to being dry and what not. )
starts 1st time every time.


ill get a load of pics tomorrow, maybe a vid and show how real men polish forks and wheels. then the laborious 500 mile run in begins.


also owenski keep it, dont sell, more cc's makes more sense.

[Owenski]

I do WANT to I just cant justify it just now, its supposed to be a commuter tool not a toy. I'd be livid if the Bigbiore becomes a reliability issue.

[BBadger]

hmmm duno if reliability would be compromised. Theres got to be a fiar few people on thumper talk or supermoto forum that have done it.
Also the run in is painful only done 11 miles and keep having to tell myself "no easy on the throttle" when all i want to do is see how much power there is.
But a good run in and oil changes at 250 and 500 miles will mean that the engine should be good forever really as something else will go like the big end before the barrel does.

anyways.

Where im going i dont need wheels ( 6:30 was maybe to early to wake up and work on bikes )
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1135.jpg

some polishing before and after of the front rim.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1136.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1137.jpg

it got better though.
Everything got teacut, polish, a proper wax and acf50 so it gleems in the sun also fork brace fitted and clamped down.

http://i336.photobucket.com/albums/n344/bbadger101/DSC_1138.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1139.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1141.jpg

didnt put as much effort into the rear wheel as it was so grimy and i wanted to ride it so was quick but still came up nice.

http://i336.photobucket.com/albums/n344/bbadger101/DSC_1142.jpg

Ready to go
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1140.jpg

the tank will be coming off for a re-spray in the next few weeks and a new tail light is needed as one for two of the LED's have blown so its not great but not far off finished.

More thump and less pinging sound from the exhaust, more power there for sure aswell even though i was being gentle and giving it nothing theres a huge difference.
clutch still wont shift properly once hot and at a stand still but works a treat on the move with no slipping or dragging.
so finally

ALL DONE!!

[Owenski]

Its the cold winter starts that I've been advised against, those in the states who live at altitude have found problems with the fuel.

There is a method of running an engine in, its well known I just cant think of the name but it actually means thrashing it as oppsoed to bimbling, its been proven to work much much better. Google it

[BBadger]

but then there's the treat it easy for the first few hundred miles argument.

TBH the people who bored it said take it easy for 500 miles and drop the oil at 250.
So take it easy till 250 just lots of gear changes going up and down the revs but no big load on the engine, let the clutch bed in, oil change and then start building more and more load and high revs onto the engine.
Just need a whole days worth of riding and i can get the first 250 done easy.

As for the fuel part on the big bore, i couldnt see it being an issue with the english climate and altitude but then again drz is a whole different bike but im sure could be sorted with the proper fuelling.

[BBadger]

Well am now 180miles into the run in.
most of which was spent running around so tighter than tight country lanes and then beggars lane ( gravely green lane near me)....who needs knobly tyres when youve got a supermoto. No slipping or spinning up even going up a bloody steep hill although i did collect alot of wildlife and camouflage

[rictus01]

I presume you mean the beggers lane at Gomshall? interesting road.

Cheers Mark.

[BBadger]

the very one.
nice hot dry day meant no mud just the loose gravel which the tyres can handle.

[Owenski]

pah! you dont wanna be taking it near mud! you'll get it dirty lol.
The "inbetweener" drz gets an E model engine in it this weekend :)

[BBadger]

it was a dry day, although i thought the electrics were shorting as i kept hearing lots of odd buzzing sounds....turned out to be a lot of half alive bugs trying to pry themselves from the bike.

also does that include a pumper??

[Owenski]

Unfortunately not, the 440barrel is still for sale. Just can't justify it at the moment seems nuts but selling it makes sneae

[BBadger]

You may remember my rear tail light
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0980.jpg

Well it started to play up and half the LED's wernt going to full brightness
So i replaced it the other day with this bad boy
http://www.racing-planet.de/ruecklicht-led-mini-mit-kennzeichenbeleuchtung-p-248850-1.html?sessID=791f2e092ab8379e84229cada62fb9ab

much brighter and all round a better unit, but after a 10mile ride to the GF's last night it has packed in....any ideas on cause?
and owenski what are you using as i just need a working rear light so i can ride the bugger!

[Owenski]

Edge light unit dude, cant fault it.

Bolts on the plate holder :)
FYI - Big bore is sold :(

[BBadger]

I know i saw on the drz forum.
Owell youll just have to rag it a little harder in that case.

Hmm well on taking the new unit apart i found a blown resistor so im off to maplin when home to try repair myself, but if that dont work they sent me another one that will get rubber mounted, and if all else fails im on to a edge light.

[BBadger]

So 300 miles in.

14/41 gearing changed so i can finally use the extra power without it over revving
Go's like stink
Handles beautifully
spent more time in the mud than on roads so ive had to wash it everyday so far and this downpour isn't helping things.

This week i might dig out the big knobly wheels

[BBadger]

So its almost run in fully, although ive been treating it a little harsher for the last 100 miles ( now on 400 )

But its getting a face lift, thinking
Polisport halo headlight in white
Want to recover the seat, itll be grippyer but still have the cool yellow bits http://pictures.kyozou.com/pictures/_3/2721/2720413.jpg

And when recovering the seat it will get abit of a "remodel" to remove the god awful dip that you slide into every time you even look at the breaks.
So new foam and a flatter profiled seat.

The 2nd swing arm is well on its way to looking clean and shiny so that can go on soon

The the big acerbis 4.5gallon tank can get a look in at fitting and re-spray and re design on the std tank.
ill get some pics up soon hopefully.

[BBadger]

im not very good with this picture taking thing am i.

Owell tomorrow ill have some nice pics of the new headlight and tank preparation to wow you all with.
Seat covers on order but will take its sweet time from america before abit of cutting and glueing of some old foam from another seat to get a nice flat area for my ****!

[BBadger]

i lied mwhahaha!
but tomorrow headlight and brackets, the new seat cover has arrived and the big tank is almost ready....so maybe a mock up. still need to measure and cut foam for a better ride height and style ( needs to be flatter ) but hopefully ill get this done next weekend.

[BBadger]

well its been a while but meh. back at uni so there will be little progress on the bike until christmas.

but one tank ready to go.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0058.jpg
one new headlight with 55w bulb rather than the 35 it came with and not even a hint of excess heat or melting plastic.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0057.jpg

the new seat cover.
got around to cutting the spare foam to the right shape so it has a flatter profile and should be even more comfy now!
just need to dig the stapler out and get some adhesive mounting spray and its good to go.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0056.jpg

nothing new till christmas really. but there is the possibility of either new fancy speedo unit or a big disc on the front before the year is out.

[Teme]

Hello, found this thread at max suz and thought ill register here too :D Man thats a clean bike!
I got a DR too and its almost at the same state as yours. Bought it last Feb and rode it maybe 1000km during the summer. Was hard to start hot and clutch was crap so I did some rebuilding. Replaced the cam chain and clutch disks/springs and sanded the basket. Ive thought of going SM but its so expensive and I want to keep the knobbies. I dont like the old look so I got RMZ 450 plastic kit and installed front fender and rear fender + side panels are going on too, they just needs brackets. Headlight will probably be Halo or from Husaberg if I can find one. I also got a new seat cover and its waiting to go back. I reshaped the foam a bit too, it looked so old and blocky. So same point as yours. What exhaust is that? How much were the sm wheels?

[BBadger]

Hey teme. Get to it...makes for a whole new bike and even though it will never be a drz or rm its always fun.
looks like we are in the same sort of place just a few final bits to get sorted but if your like me it will never be finished and there will always be something more you want to do, half the fun i think.
The wheels i found online for £200 ish delivered which was quiet a good deal i think but they are hard to come by.
Morad rims ( which i have ) seem to be dam good quality so i wouldnt bother forking out for excel ones and re lacing is a doddle. Had never done it before and after a few reads and the odd vid on utube took me a few hours to get both wheels true and tight with new tyres.
Good luck and get to it before the bad weather sets in...not that it seems to affect the dr.

[BBadger]

its been a while, but university and the fact id rather get out on the bike than spend days in the garage means not alot has happened until now.

ignore the wonky headlight its not mounted so i can get to the loom.

new seat cover , and flattened it out as well not to bad for a home job i think and some bar risers that were a steal on ebay.

http://i336.photobucket.com/albums/n344/bbadger101/DSC_1321.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1326.jpg

new mirrors and dash with home made bracket for dash and ignition barrel.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1322.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1323.jpg

looking alot sleeker finally.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1325.jpg

and just finishing up mounting the speedo sender.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1324.jpg


final things to do come summer.

re-spray the tank
raise the rear slightly and swap in the polished un marked swing arm
new brackets for front indies
possibly a larger front disc if the budget stretches ( or the gf lets me dip into the holiday fund )

[rb8989]

Love it, read the whole thread. Really like my SM and couldn't be without one!

[BBadger]

Thanks RB. I know what you mean given the choice ill take the dr over the zxr any day its just more fun all the time.