What I Did Last Summer

While attending the 2008 Seattle Supercross my father and I got to talking about getting him back into riding. He agreed to bring his bike down for me to work on.

The bike is a 1990 Suzuki DR350, which my father purchased new, from Aurora Suzuki in Seattle. The DR served as a trail bike, race bike, a spare bike for myself, and a loaner bike for all of my friends. I shudder to think how many miles were accumulated, a testament to its reliability. Ironically, all of the abuse we subjected this motorcycle to while riding it, was not what finally killed it. We will get to what did, but first a little more background.

In 1997 I started college, and between going to school full-time and working, there was no time for riding. I was my fathers riding partner, and while he made some attempts at riding, soon lost interest and last rode in 1999. After college, I got married, purchased a house and started a family. Needless to say, there was some time, but now with bills, no money to go riding. Fast forward to 2008. My financial situation had improved to the point that I was able to buy my son Taylor, a used motorcycle and we began riding. While telling my father how much fun Taylor and I had on our rides, I could tell he wanted to get back in the saddle, which lead to our discussion at the 2008 Supercross. So now that you know some of the history of this bike, some simple math will tell you that this thing had been sitting for nine years, exposed to the elements.

Toward the end of April my father delivered the DR to my home. Seeing the bike for the first time in a number years left me shocked. Pictured above is the before, but the photo does not do how bad the bikes condition was justice. Both tires were flat and so rotten they were ready to fall off, metal items were very corroded, and the plastic had sun rot. At this point most people would have just written it off, and parted it out. But, I'm not like most people.

I started the restoration by cleaning the bike with a pressure washer. It was very amusing watching all of the creatures scurry off the bike and run for cover. Even washed the bike did not look any better. Wherever my father last rode it had some pretty acidic soil, it etched into the paint and metallic surfaces. I began disassembly, and started a long list of items that needed replacement. I knew the cradle of the frame below the engine, had received a lot of abuse. Upon removing the engine the frame sprung, distorting the cradle area, which would make it impossible to reinstall the engine. Even if I was able to reinstall the engine, it would be placing great stress on the aluminum engine cases. Searching eBay, I was able to locate a seller parting out a DR. I contacted him and as luck would have it he had the frame, but had not listed it yet. We agreed on a price, and it was on its way.

Upon uncrating the frame I immediately inspected it and found a few minor problems. There were a couple of stripped bolt holes, and one of the number plate mounting brackets was cracked. Bolt holes repaired and bracket welded, I dropped it off with the powder coater for sand blasting and powder coating.

Now that the frame was squared away, I had a solid foundation to build on. Disassembly of the engine revealed no major problems. I had the cylinder bored, installed new piston, rings, bearings, seals and clutch kit. Before assembly I bead blasted the engine castings and painted it two-tone to give it a more modern look. With the engine bolted into the frame, I moved onto the suspension. All of the rear suspensions swingarm and linkage bearings were worn out. Installed new bearings and seals, and bolted it onto the frame. Attention now moved to the front forks. Both forks were leaking, and there was surface rust on the upper tubes. Once disassembled I found that the right fork leg was pretty much scrap metal. The entire dampening rod assembly was damaged beyond use. Unfortunately with all of the other parts this bike needed I could not afford replacement forks. I polished the upper tubes, installed new guides, seals and called it good. I figured I would just run heavier oil in the bad fork and it would be fine for now. I know this is a hack repair, but it actually does not work to bad. As of this writing there is a set of 1992 RMX250 inverted forks sitting in the garage, waiting to be fabbed on. Yet another eBay score.

With the suspension sorted out I turned my attention to the wheels, tires, and brakes. Suzuki, like other manufacturers, left the aluminum hub and brake castings bare. Years of riding in the dirt have stained them a brown patina. I put the castings in my bead blaster and they came out looking better than new. I painted the pieces and used the same two-tone technique on the brake castings that I used on the engine. I stuffed the front rotor, in a motocross race back in 1993, after tangling with another rider, leaving it usable but warped nonetheless. I thought it time to replace it. I laced up a set of new black Pro-Wheel rims, using new OEM spokes. I think the black wheels are striking. Spooning on a set of Kenda "Millville" tires wrapped up the wheel assemblies.

The bottom of the fuel tank was hopelessly lined with a thick coat of nine year old fuel. Persistent flushing made it usable again. The carburetor was clogged with the same spooge as the fuel tank. Soaking the disassembled mess in carburetor cleaner for a week returned the parts to service.

Restoring the plastic proved very time consuming. The front fender was so sun rotted the it broke when I accidentally dropped it to the floor from waist height. I put a new unit from a RMZ450 on in white. The late model fender definitely updates the look of the front end. Headlight, side panels, tank and rear fender were wet sanded and then polished to restore them to like new condition. CEET supplied the gripper seat cover, replacing the hopelessly cracked old cover.

To protect my frame investment, a Moose skid plate was installed. It is much thicker and provides better coverage than the stock unit. Wrapping up the project, was the polishing the collection of now obsolete aluminum Devol guards.



Since the above photo was taken, I have made a few changes. The White Brothers disc-type megaphone muffler, I felt, was to loud. During the overhaul process I dissembled, repacked, and ran it with minimal discs, but it was still too loud. I was able to dig out the original muffler from my mothers garage. Installing it made the bike quiet. Unfortunately it also made the engine anemic. I cut the stock muffler apart, and found extremely restrictive baffles inside. I modified the baffles for improved flow and installed a larger outlet tube. The modifications really woke up the power and only minutely increased sound output.

My father absolutely loves the way his bike now looks. Unfortunately he is not in love with the way it feels. He is starting to come to the realization that he is not getting any younger. Couple that with the fact that he is also vertically challenged, and your making a recipe for disaster. I mean lets face it, the DR350 is a tank. We are now looking into shorter, lighter options with electric start for him. If we find another bike for him, I'll make sure the DR stays in the family. I may even make it street legal and use it commute to work, and enter dual sport events.