My 1994 Suzuki DR350SE

XS

Sahara Sean all up in you
This is Bazuki, my first motorcycle. I bought Bazuki a couple years ago because I have wanted a motorcycle since I could remember and had the means to do so. I picked her up during my lunch break at work and rode her back to the shop I work at. While talking out back, the subject of bazookas came up, and in a caffeine fueled frenzy the words 'bazooka' and 'Suzuki' collided in my brain, hence the name Bazuki. And it's here to stay.

So anyways, I've ridden this bike for a couple of years now. A lot of street duty and what ever dirt road I could find, which wasn't many since I've never looked for such things and knew where none of them were. But I've gone on a couple trips and learned enough to know that I don't have a clue about what I'm doing on dirt. That only makes in more fun.

The day I got her.



First trip in to the North Cascade mountain range. The little DR200 is no more. Suffered a quick, yet horrible death in a rock quarry.



And then her second.



Ok, kidding. We drove a Jeep there and stayed the night. Screwed around all day and got a killer sunset. So enjoy the damn picture.

This was her last trip before snow descended upon the Cascades. Packed up and rode 50 miles out side of town. Spent two nights in a little hunting cabin my buddy built and the days exploring. This was taken on the last day just before eating lunch and heading home. This is the trip that made me fall madly in love with Bazuki. I chose to keep the old Suzuki over getting a new KTM or Yamaha. Will that turn out to be a good idea? We'll see.



We did get a little rowdy on that trip.



Then someone gave me a gorram GoPro Hero 3 Black. There is no riding in this video, but a couple curse words, and an idiot. Note, this was shot before I replaced the rear tire with a Michelin T63, which I had on trip in the above photo.

https://www.youtube.com/watch?v=R9J8Dact0_w
 

XS

Sahara Sean all up in you
That brings us to today. Time for some maintenance and repairs.

I decided to get some work done on the bike before the rainy season is over and riding season gets in to full swing. So I pulled Bazuki in and stripped her plastics off and pressure washed her.



I need to have the seat recovered. There is a guy down the street that does all the work for one of the local race shops, so I'm going to have him do it with black neoprene. Probably not going to do anything with the plastics except slowly replace them with stuff that isn't so old and beat up. The skid plate it in great shape, though.



I'm not even going to try to save this piece of crap. Going to pick up a Twin Air foam filter to replace it. I still have to cut out more of the air box.



Cleaning an lubricating my levers and I notice the clutch pivot hole is a nice oval. Add that to the parts list.



The clutch perch seems to be in good shape. All the holes are still round and there are no visible cracks. Don't know if I'm going to keep the factory mirrors.



While I'm in there I might as well get rid of the pesky clutch safety switch. Suzuki made this easy by wiring it in with bullet connectors so no splicing required.



I am to the point where I need to drain the fuel tank to pull it off. The front fender is getting replaced. Not sure what I'm going to do with the rear. An MX rear would look cool but I would need a new tail light with built in turn signals. And I don't know about strapping luggage back there. Modify the stock one?

I've inspected the entire frame and found zero cracks. The spark plug has less than 500 miles on it and looks great. I have everything to change the oil. I even splurged for synthetic. Lets see if I get any leaks.

Rear brake pads have 800 miles on them, rotors are fine. Front pads have 200 miles on them, rotors are fine. Front and rear fluid was flushed 200 miles ago.

I should pull the clutch basket while I have it drained. There are a couple ridges I need to file down which make neutral hard to find when hot.

Airbox is out so I can take it to work to modify. The Matco 1/4" impact rules.

 

XS

Sahara Sean all up in you
I really wish I had an exhaust system in the budget right now.

Anyways. Picked up this electronic timer for my turn signal. Gets rid of the annoying relay and allows me to put any kind of lights on it without using resistors.



You know, since I've already drained the oil, I should fix that clutch drag issue. So off comes the clutch cover.



And I'm stuck. I have no idea where my 19mm socket is to get the clutch basket off. I'll just go watch dirt bike videos now.



It's been years since I've had a project vehicle of any kind. Last one was an FD RX7. It was fun but an absolute nightmare to maintain. This, on the other hand, is fun. And compared to RX7 prices, cheap as dirt.
 

XS

Sahara Sean all up in you
I'm stupid and can't count. So I found my 19, but that isn't a 19, and I don't have anything bigger at the house. So I'll move on to the next thing.



But that turned out to be a waste of time. I found one piece of dirt in there. But now I know for sure.







So now I'm just waiting for parts.
 

XS

Sahara Sean all up in you
While I just poke around I'll show you the exact reason I am starting to have issues with a sticky clutch. This is the basket that holds the friction plates. The grooves aren't allowing them to move away from the steel plates when I pull the clutch lever effectively creating pressure between them. I'm just going to use a mill file to take them down until they are smooth again and it should feel almost new. Almost. I just don't want to fork over $300 for new ones.



Speaking of new, these are the original machining marks on the steels. There are almost no rotational markings on them. The frictions look brand new, as well. Either this bike has been babied it's entire life or they were replaced right before I bought it. What do you think?

 

XS

Sahara Sean all up in you
An air saw made quick work of the airbox. I still have to work on it with an Xacto to make it look good.

 

XS

Sahara Sean all up in you
The plastic actually melts at a pretty low temp, so a Dremel would be more hassle than it's worth.

The clutch basket has had all the grooves filed down and is reinstalled on the bike. Waiting on the cover gasket to arrive at the dealer, which should be today or tomorrow. I'm hoping to have it all back together by this weekend.
 

Dr. Satan

Sacred Cow Tipper
That bike wasn't babied. The frictions, if not the steels too, were replaced. The grooves only happen when you hammer the hell out of the clutch.

It looks like a real good setup. Everything I know about dual sports and dirt bikes is that unless you literally are a pro-racer or high end rider, "newness" won't make it any better and will probably just cost you more in the long run.

Any plans on a bigger tank?
 

XS

Sahara Sean all up in you
I don't have any pictures, but I got the jets installed. The thing will now edge out the DRZ400 in a drag race. A new seat and bigger tank are in the plans but I'm not 100% certain on what I will go with on either.

For the seat I would love to get a Seat Concepts kit for it. But I could save over $100 if I just recovered this one. The foam is still in perfect shape.

For tanks, I have to decide between Clarke and Acerbis. There isn't much price or capacity difference between the two so I will just have to see which one I think looks better. They both have great reviews.

I've also started commuting with it on a regular basis. Again, this thing is being a freak and getting almost 70 mpg putting to and from work. When I'm railing on it on twisties or mountain roads, I'm getting 54-56 mpg. It's crazy.
 

XS

Sahara Sean all up in you
Yeah, that was my bad. I just threw the Gopro in the case and forgot to check the mount screws. I hit the camera early in the ride and didn't notice until it was too late.
 

NIGHTSHADE

Well-Known Member
Was that private land or public? Id venture off a little bit, set up the hammock and camp out there. looks nice and peaceful
 

XS

Sahara Sean all up in you
It's a mixture of private and public. It's really not a great place to camp. Too close to town.
 
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