Dr350 rebuild

[BBadger]

hello.
I finally got the Dr i had been looking at the other week.
http://i336.photobucket.com/albums/n344/bbadger101/B0iTq8gEGkKGrHqUOKicEfgFcRkBMuh5yT-Q_12.jpg
Now it arrived abit tattier than the pic and required new bolts for the header and rear mc but after a strip down and removal of everything and a imaculate clean up it should look good.

atm:
its in peices in the garage and the frame is off being powder coated a gun metal grey.
I have a set of 17" wheels on there way that i got dirt cheap.
other ods and sod like shorter mx fenders front and rear
carb jet kit and a big hole in my airbox.

Really just waiting on the frame and ive only had it a week.
More pics to follow as its no longer dirty and i can touch my camera.

[warrenhewitt10]

very nice, could be a nice project! do you intend to use it afterwards?

[Paul the 6th]

woo I'll be following this one closely :)

[yorkie_chris]

I had one of these years ago, careful with short fender, if you loose much off the front when you're trying to get forward and weight the bars at any speed it will shoot clay up the front of your lid!

[BBadger]

im keeping the long one but have a nice short acerbis one now ( thankyou mr postman )
also the 17" rims turned up today some some piccys will be in order later.

[Owenski]

ohhh muchy likey

[BBadger]

looks like the powder coating is taking longer......as usual](*,). so no frame for a few more days grrrr.

in the mean time though
17" wheels
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0716.jpg

New braided oil lines
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0711.jpg

chucking the crappy plastic pistons and some nice stainless ones are going in!!!! woo :D and some other bits and bobs from wemoto.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0706.jpg

nice acerbis front fender
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0710-1.jpg

goodrich braided lines front and rear.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0708.jpg

hi flow oil and air filter (just need to open up the airbox abit 1st!)
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0707.jpg

nice little mx tail tidy
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0709.jpg

going to pick up the fmf pipe today at 4 (£10 on ebay ) so bargin!
then new needle and jet kit should arrive with my mx rear fender and the bike is ready to go back together and hunt down some nice little led indies.

and heres the rest of the junk
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0715.jpg
only 2 boxes the rest if vfr stuff
and btw the cat litter....good at soaking up oil spills.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0717.jpg

and i havent yet decided if i want the caliper vapour blasted or not to make it nice and shiny or just sand it down the grime and be cheap.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0714.jpg

[robh539]

I have been looking for one of these. nice job will be watching intently :)

[Skip]

What are the 17" wheels from? Did they do a road biased DR350?

[sv4me]

Looking good so far :thumbsup: will be interested to see how it turns out

Slight derail but how hard is it to modify 1 of these to a supermoto? I've been hankering after a small SM for a while and the DRZ400-SM took my fancy but ain't got that kind of dough

[BBadger]

The wheels are the standard hubs that come with the bike laced to morad rims.
they didnt ever do an actual road dr i dont think just waked some road tyres on the huge front wheel.


and flebay no: 200518998298 is the can and link pipe which ill grab some good pics of tomorrow when i dismantle it down.

[BBadger]

Looking good so far :thumbsup: will be interested to see how it turns out

Slight derail but how hard is it to modify 1 of these to a supermoto? I've been hankering after a small SM for a while and the DRZ400-SM took my fancy but ain't got that kind of dough

wheels are the biggest input really.
i think i new set of rims spokes all laced up to the wheels would cost just over £300 brand new....or seen some that have gs500 wheels on them and they look pretty cool...and you get the bigger brake, also dirt cheap you only need spacers made up.

Front brake is a wee bit small. think 250mm? there are 270 ones with a braket for mounting the caliper out there but limited by the fact the earlier models 90-97 only have 4 bolt holes where as the 98-00 have 6. but theres a whole list of changes from 97-98.

[BBadger]

ok so rebuilt front brake but the rear dust seal doesnt want to sit right....and the piston was pushing it out and will start destroying it....but the old and the new are the same size so im abit stumped. help anyone?

stripped down and painted the oil line connections in hammerite smooth black and they have turned out pretty good.

also got the frame back
will grab pics tomorrow but £80 in a gun metal grey and its absolutely brilliant. Now just a matter of putting things back together and cleaning up the engine and forks.

[Specialone]

Out of interest, how much can you pick these up for?

[squirrel_hunter]

Those braided oil lines... Where did you get them from looks interesting?

[yorkie_chris]

ok so rebuilt front brake but the rear dust seal doesnt want to sit right....and the piston was pushing it out and will start destroying it....but the old and the new are the same size so im abit stumped. help anyone?
.

Are they a seal which is not square in section? If so try it other way up. Also did you use a bit of grease?

[BBadger]

about £1k seems to be the average going price.

and squirrel i got them at a place in isle-worth called "think automotive" only cost me £12.50 for all 3 lengths cut to the right size.

ill flip the seal over and try again but it really only seems to be the dust seal thats causing me the issue.

[BBadger]

As promised some new pics of the frame...although i forgot to take any of the fmf can. Was getting abit dismayed with only having a frame and cleaning things so i decided to put it back together to give me some insperation.

1st things 1st though.
Thanks to spannerman and a lil trick with superglue the carb went back together with a 140main jet ( from 128 ) and a new longer tapered and multi step needle. Had a good blast with the carb cleaner and is squeeky clean inside.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0718.jpg

Shiny Shiny frame ( cost £80 for shot blast hot coat and powdercoat yey )
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0719-1.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0720.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0721.jpg

forks still need to be stripped and then polished and other bits cleaned and then all torqued up and done!
Shame most of the old bits are so tatty compared to the frame.

[robh539]

Looking good, the frame is mint, I maybe asking for there phone number at some point in the future.

keep the updates coming :)

[BBadger]

This is the lot i used.

http://www.microblastservices.co.uk/

tbh updates are going to dry up now as my uni course is moving me to nottingham so no major work till christmas as i just wont have the time as i leave tomorrow :(

shame really as its just sitting waiting to go back together bar a few little things that need greasing and cleaning.

[Speaky69]

Looking good mate, Ive currently got 2 Dr600's that im going to be making into a winter hack for my old man, and then got a second set of wheels/tyres for the odd Green lane/offroad blast!
be good to see the finished article!

[BBadger]

Wooo new swing arm and shock all in for £35.
both are a dam sight better than mine, as it has a huge gauge from the kick stand and general all round crappy condition, and the shock well its buggered but this one at least seems serviceable.

pics to follow in December.

[Richie]

loving this rebuild :0) keep the pic coming BBadger...

[BBadger]

Im itching to get home and do it but being in nottingham for uni and bike back in surrey just makes me a sad badger =[

[mjc]

You should take the bits up with you and build it in your house. My SV lived in the kitchen for a few weeks last year when it was poorly, only one of my housemates complained. Tough sh*t Ian!

Your DR is looking good, if youve got any horrible battered and rusty but functional parts you want rid of I can use them on mine, see here- http://forums.sv650.org/showthread.php?t=158795:thumright:

[BBadger]

Up to the 4th floor without a lift could be a challenge!

Erm i have bits but most are fubar
front caliper
rear shock
old air filter
Depending on how much off-roading i actually do maybe a set of wheels with tyres and discs and sprocket, but not till next year.

Acerbis front fender ....big offroad one thats in ok nic, bit scratched as expected and the original rear fender and break light.
the original indies aswell.

[Edit]
also a swing arm but got a nice big scratch out of it from the stand, can slightly make it out in the pics.

[Richie]

I hope your going to renew those Jubliee clips on the rear shock reservoir :0)
and clean up that spring.

[mjc]

What would you want for the indies mate? Im trying to bodge my bike back into road trim.

[BBadger]

erm not a clue atm as there still all attached to the loom, and couldnt send them till the beginning of december.
make me a fair offer and their yours.

[rob13]

Interesting thread... will keep watching with anticipation

[BBadger]

Updates coming friday.

Engine mounted
cush drive arrived
Started to polish forks
airbox opened up and all fitted with carb

All thats left to do is wiring back in and respray the tank then im finished but that can wait till it get warmer.

[BBadger]

Ok this time its for real.

updates update updates!!!!

engine is mounted and some nice shiny bits after a good scrub sand and what not.
carb and airbox all in
loom is in and plugged up apart from lights ect.
Breaks got vapour blated and sprayed so look the part now aswell with their shiny stainless pistons.
spacers finally came so got the sm wheels on and a nice wavy disk for the rear ( front one coming soon )

pics will be up tomorrow for those nosey lot of you.:rolleyes:

[Amplimator]

Ok this time its for real.

updates update updates!!!!

engine is mounted and some nice shiny bits after a good scrub sand and what not.
carb and airbox all in
loom is in and plugged up apart from lights ect.
Breaks got vapour blated and sprayed so look the part now aswell with their shiny stainless pistons.
spacers finally came so got the sm wheels on and a nice wavy disk for the rear ( front one coming soon )

pics will be up tomorrow for those nosey lot of you.:rolleyes:

Yay! About blurry time. :p

Lookin forward to the finished product, good work so far fella!

[BBadger]

life got in the way but only a day late :p

the bike atm. You can just about see the nice shiny engine mounts
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0725.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0722.jpg

its finally taking shape since parts have come and there really isnt much left to do mechanically now just abit of wiring, sorting out the exhaust and then plastics and its away!

Nice oversized hole in the airbox to match the up jetting
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0724.jpg


forgot to take pics of the brakes but they look just like the sprocket carrier in the pics...clean and silver after a vapour blast and spray.

next is the forks me thinks.

[kiggles]

nice tip about the cat litter, bare that one in mind.

otherwise nice project you got here

[speedplay]

'Bout bloody time too!!!



Looking good there:cool:

[BBadger]

just little things today.

cleaned and mounted the tank airfilter and seat along with rebuilding the brakes.
so its looking more bike like with my barny the dinosour seat on it.

[BBadger]

Bit of a bummer now im back at uni so cant get anything done for a few months again.

But everything is ready to go before i left.
Brake all fitted just got to put lines on
waiting on the new rear sprocket to arrive
New exhaust for £90 instead on 120 (http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=170562645004&ssPageName=STRK:MEWNX:IT#ht_5025wt_1002) as the fmf was knakered when i took it apart but only £10 so not a killer.

Mock fitted all the plastics and it looked good.
all thats left is main light switch gear to ride it.
In time revamp of all the suspension and itll be a hooligan machine:smt066

Looking at a very cheap acerbis 4 gallon tank atm aswell which would be lovely and finish the bike off i think.

[BBadger]

Been a while folks.

the odd bits been done here and there but its essentially ready for the plastics to wack on a take for a spin.
So as of next weekend a full exhaust system. fully wired bar headlight all breaks working and everything where it should be.

Over Easter and to stop myself from becoming a complete swat of a student i should hopefully get it into one finished piece bar suspension work that will start in june, that ill do some nice pics and write up for you all which includes a full rear shock strip down and re-gas which im quiet excited about myself.

[Bluefish]

pics man pics, lol ;)

[BBadger]

dun dun dunnnn as promised to you lot.

Got it running today so im bloody happy.
Few issues which is why theres a drip pan underneath but thats the internal diameter of the oil piper so it leaks £10 for new lines to sort then i can start on the suspension rebuild and general spraying up of bits.


one beautiful motorcycle.
Side panels scrub up quite nicely after a light polish with a drill.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0732-2.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0733.jpg

shiny stuff and a well soaked chain that is now free of all stiff links and good as new!
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0731.jpg
nice and clean, actually bits look better than new after being blasted and sprayed.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0730.jpg
nice rear brake which has the same treatment and braided line.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0729-1.jpg

Now for the exhaust. £90 off ebay and it sounds amazing even with the baffle in.
Also header and link piped sprayed with exhaust paint but bits bubbled so may need redoing, you can see small specks near the front its a pain :(

notice the nice home made brackets aswell for the link pipe and hanger and nice new clamps :D
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0728.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0727.jpg

ill see if i can get a vid posted for you all to be jealous of soon.

[Treacle]

Looking great Mista.

[BBadger]

more issues but that life.

trying to get the front brake to fully bled is hell and im stumped after trying all methods known to man.
slight weep from one of the oil lines.
and

blowling from the link pipe/header joint but black rap is a very good discovery (thick black foil for those of you who dont known) that seems to sort the problem with about of cutting and tightening .

video soon to follow people!

[Edit]
fueling also sorted with the high flow air filter in. so running lean caused the heat which melted the exhaust paint but no perminent damage it would seem

[Specialone]

I wouldn't expect too much from the exhaust paint tbh, it's gonna come off at some point.

Good work though, looking forward to see the finished result.

[BBadger]

tbh i think the paint going was due to it running very lean as the entire bike got red hot.

still stumped on the dammed front break though as it just wont fully bleed!
started back bleeding from the bottom and then normal bleeding followed by mouting the mc above the bike so the line was perfectly straight but still spongy and lacking any real power or force. ( using gold fren pads btw )

[BBadger]

I know i know ....no pics again but im not going to be at home for at least another month or so.

but finally got news of a very shiny pair of forks all ready to go back together.
all seals and oil have turned up
few new spokes and spoke heads aswell.

so hopefully the wheel will be back together and trued up upon my return then it is just forks and abit of plastic polishing until its finished.

watch this space people. Not long now.

[BBadger]

dun dun dun dunnnn!
after a few months chocked up on its stand ive spent the last 2 days running around getting it all sorted.

Shiny shiny forks and nicely balanced up wheel, not to hard once you get the hang of it so i think its all straight and true. Also some nice fork socks to keep it all clean underneather.
New seals and bushes all round with hangon springs aswell.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0740.jpg

brake fitted with braided line, blasted and sprayed calliper just need shiny bolts next.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0741.jpg

No headlight because someone who i wont name put the brackets on the wrong side:(
No side panels either as they need some good polishing to make them shine like new.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0742.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0743.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0744.jpg

Im in love with the rear fender and tail unit as the brake light being LED and clear is blindingly bright.

New gear change to
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0745.jpg

Forks are going to get dropped through a bit more soon.
Engine casing off tomorrow hopefully for a strip down and spray up over the week and a 1 of the oil hoses needs replacing.
whilst im in there have new thrust washer on the way so i can do the basket clearance and create end shake. makes it smoother and stops the wear on the washers and bearing.

not far off at all and it runs like a gem atm just waiting for the new throttle tube to turn up then handguards and grips can go on to:p

expect more pics to follow over the next few days people.

[Skip]

Looks fantastic and I can tell you right now its going to be a proper hoot to ride :twisted:

[BBadger]

Todays efforts are brought to you by paint stripper and how its removed suzuki engine paint quicker than my skin....yes its that thin and bad.

casings off and prepped for a painting.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0750.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0753.jpg

1st coat to final coat, think its come up quite nice if a little lighter that i wanted.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0751.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0752-1.jpg
its there because i like taking pics :)
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0755-1.jpg

flys....just why it was so nice and now even if you dont see it ill know its there!
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0754-1.jpg


this then left me with time between spray and running outside to save wet paint from the constant shower to fiddle around with the rest of the bike.

1 clutch! await new thrust washers and need to do a basket clearance tomorrow before it all goes back together, and i think it will work this time as i dont plan on doing the main nut up finger tight but actually use a torque wrench which was half the problem with the thing not working properly.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0746.jpg

new throttle tube arrived which has a open end and allows me to fit hand guards. just a quick fit but you get the jist of how its going to look.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0747.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0748.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0749.jpg

Tomorrow it should all go back together if i have enough time, new clutch cable can go in then a little test ride around the garden:p might even wack out the rear plastics as it will look finished and give me some inspiration to get a move on.

[BBadger]

Clutch has new thrust washers and clearance done, oil is in the bike with a new filter, casings are all on with new gaskets everything tight and a new clutch cable

But the bloody new gear change lever doesnt fit....miffed is an understatement!

i was hopping for a little run around the garden but nope!! dam you flebay!

[BBadger]

Well the slight creep i had with the clutch in has turned to a full lerch and stall so im even more annoyed now!

any one got any idea's on possible issues, maybe clutch hub nut, pressure plate bolts to tight ect? going to tear it all down later and get you some nice pics ofc but im stumped as the problem has only got worse and its not un-rideable

[Owenski]

cant help with the clutch but loving the time/effort your putting into the whole thing.

BRavo!

[BBadger]

haha progress and what not after a busy week of doing bugger all, god being a jobless student is bliss!
anyways after a few odds and sods with gear levers clutch adjustment and a new oil hose i can finally get back to moving on with the bike properly.

indicators and rear light
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0913.jpg

full handguards and mirrors
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0912.jpg

Engine casings are on after i had to the alternator side due to "misshaps" also did the front sprocket cover to match it all up.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0911.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0910.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0909.jpg

Working on the wiring atm, bit of a mess and one the things i should have done was check the fuses 1st as they are a mess but thats now sorted so just trying to get all the indicators working then onto plastics tyres and a nice mot to round it all off, give it a few weeks and it will be better than new.

[Skip]

I like the rear light indicator combination thing - what make is that? My enduro one has no indicators which is annoying.

[BBadger]

They are hein gerick ones, bit pricey around £12 a side but ive had a set on the sv for 3 years now and they still work a treat.

Wait until you see the front indicators ive got on the way skip, will blow your mind!

[vardypeeps]

This conversion and build is brilliant to look at. Hope it's just as nice to ride mate!

[BBadger]

skip your going to love this next development with the indies i think.

1st of all got 5m of a fibre wrap for the loom that cost a total of £2 from ebay...brilliant stuff and with abit of soldering and fixing old corroded wires everything works as it should.

sorry for the bad quality taken off my phone in the dark.

now the new front indies...made from very soft malleable plastic which i can only describe as being abit like silicone so they are ultimately flexible.
http://i336.photobucket.com/albums/n344/bbadger101/DSC00090.jpg

now where their going to be mounted
http://i336.photobucket.com/albums/n344/bbadger101/DSC00091.jpg
nice and bright to.

just need to sort out why the rears work but both front come on no matter which way i throw the switch and none of them blink ....:confused:

[Amplimator]

Your not really gonna stick them on the hand guards are ya? Its a supermoto now you dont need indies! No one will be behind you anyways as ya'll be blattin around in true loony fashion. Rip the indies off and get your hand signals going. The front ones will be in the air and the rears will be pointing at the floor so no-one will see them ;)

Same goes for the mirrors, they are no use when all you can see is tarmac, sky, tarmac, sky. :cool:

[BBadger]

you make a strong point sir! but im a tart as is the bike so i want it to look nice...either way they can be removed and stuck back on in a matter of seconds if my hooning needs require, that and i hate london drivers so the more lights the better even if the front wheel comes up in 1st just on the throttle and thats in about 10m of garden path:riding:

once i sort out why the stupid new relay isnt working it is a matter of plastics and getting a numero plate as i have some continental sm tyres on order as we speak.

[BBadger]

Really getting there people.
later today i will bring you new pics of the fairings all shined up and the secret behind it all along with the make shift gear lever thats a work in progress.
Getting so close now i can almost smell the mot

[Skip]

Looking great Mr Badger - you are going to love riding it 8)

[BBadger]

Have been neglecting the little dr the last few weeks but mot time on monday or tuseday soooo.

ill show you some pics tomorrow of the wiring ive been slowly beating with a hammer ( it now all works i think )
tank needs a light sand and final top coat
new tyres
rear end complete plate and all
headlight in place and all in.
frame guards sprayed and on.

so a few good pics for you all tomorrow.

think its going to raf odiham on the 4th aswell muhaha!

[BBadger]

here were are then.

painting the side tank panels to match the tank otherwise it might look abit stupid. Rear panels may get done aswell but they will be easy to take off as and when.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0972.jpg

Meet the anger radiator....shoot it, hit it with a hammer, angle grinder ect....useful tool to have around when things dont work and you get frustrated.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0973.jpg

back to the bike.
home made gear lever with vfr rubber to help shift.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0975.jpg

frame protectors are sprayed and on to stop boots rubbing on my nice frame.
Oh and a nice little extra mud guard i made up just below the shock res to keep more crap off and out the frame.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0976.jpg

rear end in finished plate and all.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0977.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0978.jpg
diddy number plate lights
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0980.jpg

tank needs a wet and dry to get rid of one or two runs then a final coat and its rear to roll.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0981.jpg

front end is all in place.
the headlight cover is abit ugly but it does its job.
running light on.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0982.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0984.jpg
ditched the other indies and went for these HG one as there down to £10 now. nice and bright.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0983.jpg

http://i336.photobucket.com/albums/n344/bbadger101/DSC_0985.jpg

[Owenski]

Thats looking the bo11ocks now pal!
Top Draw!

[-Ralph-]

That Sir, is looking very very smart! Mucho respecto!

[Skip]

Just awesome - love it :D Are you going to do something about the seat or some accents elsewhere to make the seat stand out less?

[yorkie_chris]

I like this bike.

You watched mondo enduro yet?

[ImplodedHamster]

very nice :D where are the indicators from? got a link?

[BBadger]

I like this bike.

You watched mondo enduro yet?

I have. love it.


Quick question people of the org ( that means you yorkie )

on firing my mighty beast up today :mrgreen: all is well but the reg/rec has gone as theres no change in voltage across the battery so need to get a new one asap!

but the revs drop to 0 once in gear and the needle even tries to move the other way ?? but is fine in neutral rises and falls as it should.

but here in is my question...when putting the pick ups back in the alternator there are 2.(single magnet on each )...i believe to have put them back as they come out but they only pick up on some raised timing marks. Could this have screwed everything up is they were not in the right place as one is raised for one mark the other low for the other mark ??

help me please as i hate electrics with a passion and am stumped!

[BBadger]

Testing shows its the reg thats gone. meh!

new one is on its way.

gives me time to replace the 4 studs in the front as one or two are looking abit grim, so this is where my spare forks come in handy as their in good nick apart from the oil seals being jammed tight.

everything else torqued up.
panels sprayed on the rear

Really just waiting for the reg/rec to turn up then finally mot and its all done!

panels will go on tomorrow and youll see a nice finished bike bar whats under the seat.

[yorkie_chris]

Rev counter should work same in gear and neutral even with reg rec gone, I think there is some bad earth there involving the neutral light.

[DarrenSV650S]

Have you ridden it with those mirrors yet? I got some of them and they are very wobbly

[hindle8907]

Have you ridden it with those mirrors yet? I got some of them and they are very wobbly

+1

I had some on my naked sv and they was bloody awful I had to put the standard ones back.


Bike is Looking good though mate !

[BBadger]

looking around at earths atm but it was fine before the reg went so im going to wait until thats sorted.

and i have they wobbled a little but tightened them up on the rear to stop mirror movement and arlydite on the stem to the bar thread and they seem fine...then again we all know the dr is just a far superior bike than an sv;)

and i think were all use to seeing sod all out of sv mirrors anyway its either elbows or so viby i see 3 of everything.

[BBadger]

DONE!!!!!!:D

Just waiting on the reg/rec then decal hunting and the ever elusive 300 or 320mm disc!
Maybe drop the forks through abit later and a shock rebuild over christmas otherwise going to get the big tank on ( 4 gallon ) and put some miles down. Also itll be going to raf odiham on the 4th if anyone else is there.

http://i336.photobucket.com/albums/n344/bbadger101/DSC_0986.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0987.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0988.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0989.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0990.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0991.jpg

next time its on here will be me setting off for its 1st ride and to show up those power rangers at box hill on sunday!

[hindle8907]

Good job mate. looks excellent.

[Owenski]

It really does look the nuts mate, good job!

[Skip]

Fantastic - love it! 8)

[BBadger]

oh you wouldnt love it atm!

ive gone from a reg that didnt work at all to one that massively over charges the bike and and in turn blow all the dash bulbs and the headlight bulbs aswell.....someone is going to be getting a very very angry email and a brick with a reg attached through their window!

[Owenski]

Would it be a dumb idea to attach a fuse between the reg/rec and the battery, easier to replace fuses than it is to replace all that lot.

[BBadger]

already done... connected the reg/rec direct to the battery through the fuse afterwards and poof!
also multi meter reading shows almost 17v across the batt when at 5000 rpm should be 14.somthing

[Owenski]

Assuming the 350 is a 3phase alt then I have a spare* drz400 r/r which I can vouch is funcitoning 100% if you're interested in that, see if it can at least point you in the right direction.

*spare in the sense Im not using it at the moment so you can borrow it, if it works fine for you then I may be inclined to sell it.

[BBadger]

well i did just retest it with a digital multi meter and its putting out 24 dcv at tick over through that reg, and 150 acv....through a reg/rec into a battery and rest of system!!!!!!!!! :smt067:rant:](*,):smt022 i could go all day with these.

yep is a 3 phase, 3 yellows in live and earth out. but ive found a company that makes them bike specific so and only £35 so not a big hit but thankyou owenski.

[Owenski]

£35 thats a bloody good find, I wouldnt have sold mine for that lol.

[BBadger]

china is my saviour! good reviews about them all over the place and more fins so hopefully it wont get warm.

now ive found all my troubles to be diode related.

a 2 pin that appears to be working and a 3 pin ( power from either side into the middle one ).

now this has blow on one side so i can either have lights or ignition but the bike wont start without seeing the neutral light come on.
there is no sign of one in the wiring diagram or micro fische.

suzuki dont really have a clue.

i believe it to be a zener type diode but cant see to find any....anyone got a clue where to look apart from get 2 separate ones and then tape it up, although id prefer to have a seal unit.

[BBadger]

after my diode hassle i fixded it up well good mr!
a bodge but a dam good one none the less, all taped up now and tided away.

http://i336.photobucket.com/albums/n344/bbadger101/DSC_0992.jpg

and as i never showed it the stuff i got to wrap the loom. 10m for about £3, semi water proof and basically wraps itself, works a treat and most of the wiring is getting done in it.

http://i336.photobucket.com/albums/n344/bbadger101/DSC_0994.jpg

everything working ( i think, final testing tomorrow ) then back together she goes!
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0993.jpg

show you a pick of the damage the overpowered reg/reg did tomorrow its bad but only effected the number plate lights, sent me 2 new ones free of charge :p

[BBadger]

well its back to how it use to look now.

Mot tomorrow and i dont think it can fail at all....heres hoping!

next on the agenda i need help from those of you who are good at photo shop to help design the rear panels.
thinkings suzuki along the bottom edge and then a wedge of some sort along the top with a nice curve finishing about 3/4 of the way down.

maybe a go faster stripe and pin stripes on this tank aswell as im a tart!


also got rid of 2 links in the chain so its now tight and not flopping around like 80year old tits, which has solved the massive lerch into gear

[davepreston]

right now its basicly done i'll give you £270 for it so i can use it on the p2p charity ride
cash or cheque :)

[BBadger]

never! i have not finished tarting quiet yet and your not getting your hands on it preston its got to stay shiny side up :p

[BBadger]

OHHH MYYYY GOD!!!!

it is just so much fun to ride i love this bike i could stay on it all day.

brakes arnt to bad if you use both and apart from that only had a rattle from the chain slider on the bottom of the swing arm which i forgot to tighten.

it will be going down to raf odiham on the 4th so might get abit of racings on it.

im like a kid in a sweet shop this thing is just amazing to ride.

[BBadger]

MUWHAHAHA its a "wheelie good time on this bike" pun intended!

the more miles i put on it the more fun it becomes.
keep tuned for some good pics next sunday.

[Electro]

http://i930.photobucket.com/albums/ad147/Mountain_01/Stuff%20for%20sale/stuff036.jpg (http://i930.photobucket.com/albums/ad147/Mountain_01/Stuff%20for%20sale/stuff036.jpg)

After Dave gets his mitts on it :)

[BBadger]

The poor poor bike!

got a set of acerbis fork and disc protectors in dirty white if your interested.
also what mileage do you get out of the big tank as i still need to fit mine/ make the fittings through the frame.

[Electro]

Its not mine mate, just what yours would look like after DP modded it for the P2P run lol. I found the pic on a forum :)

[BBadger]

ahhh knew a few people on here had dr's but not sure who. and DP aint getting near it.

there is a pic somewhere of 2 big green bins strapped to one.

[Owenski]

so c'mon then wheres all the completed pics?

[BBadger]

errrr its in pieces ...again....i decided it was a good time to rebuild the rear shock which ill get pics of tomorrow and also move the needle up a notch as its running just a teeny tiny bit on the lean side atm.

hopefully that should be oiled and gassed with decals to suit on sat ready for abit of track action on sunday.

[Owenski]

I dont know if its the same on the dr350 but z400 has a 160paj iirc and thats due to emmisions regs in europe but the bike and carb is actually designed to run off a 135paj so all our bikes run a little bit too lean until you make that change. General opinion on the drz forum is it makes a notable differnece to the ride/performance.

[BBadger]

would make sense tbh.
either way big 145 main jet 3x3 airbox with high flow filter and it was just just just lean so needle up a notch should solve this i hope or could tape up the airbox slightly.
Runs and pulls well though.

garage apart from being a bomb site the shock is waiting to be gassed but steve jodran have buggered off racing with the nitrogen till monday!
pics will be added later on today.

[BBadger]

here we go people!
1 bike minus the esential bits ( theres really nothing to this bike )
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0998.jpg
the trail of destruction
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0999.jpg

spraying up certain bits and cleaning of all metal parts on the shock.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0995.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0996.jpg
http://i336.photobucket.com/albums/n344/bbadger101/DSC_0997.jpg
As you can see the lower bracket in the pic above and below is slightly shorter than the street shock ( had a dirt one on standby as most things on this bike were unmoveable and fubar! ) But this should lower by about 1/2" which should get the ride hight bang on and stop the front end being so twitchy.

All oiled and gassed with the new braided line made by think automotive for £7.
Now this has new ohlins oil and is gased to (142psi comapired to the big fat 0 it use to )
so setting up tomorrow with the new compression screw on the res so less spring and more shock working.
http://i336.photobucket.com/albums/n344/bbadger101/DSC_1000.jpg

got the spring on and all together but im sleepy so it can wait till tomorrow.