Suzuki DR350 Engine Disassembly And Diagnosis

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My buddy and I take apart his DR350 engine to figure out why it's making noise.
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Опубликовано:

28 авг 2019

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Комментарии : 112

@doccops 6 месяцев назад

Thanks for these videos - Interesting to see the infamous counter-balance pin caught on camera, so lucky the motor did not get destroyed.

@TomsTinkeringandAdventures 6 месяцев назад

I can’t believe how lucky my buddy got. He’s still riding this bike! Thanks for watching

@hanktapia2016 3 года назад

So cool you put all this on video thanks guys oh, much appreciated. I have a 1997 DR 350 I really enjoyed this video

@TomsTinkeringandAdventures 3 года назад

Thanks for watching, have a few more DR350 videos as well

@forresttaylor3025 3 года назад

Nice work guys! Vid was a big help.

@TomsTinkeringandAdventures 3 года назад

I'm hoping that you didn't have the same issue and are just doing a rebuild. I have an assembly video here as well when it comes to putting it back together, best of luck.

@cornholius 4 года назад

Thanks for the straight forward knowledge-driven video without the annoying excessive brain fart pauses of other youtube mechanics.

@TomsTinkeringandAdventures 4 года назад

Jesse N haha, thanks... I have been accused of such annoyances by other commenters. Guess it depends on your point of view! Thanks for watching.

@LassesFoodAndBarbecue 4 года назад

LIked this, well found

@TomsTinkeringandAdventures 4 года назад

Lasse's Food and Barbecue we got lucky that it was easy and also didn’t cause major damage.

@SheriffBo 4 года назад

That is crazy, i have the same bike making the same noise. Im not turning it back on until i tear down the motor. If you rev it to a higher rpm you can definitely hear it ticking louder. Thanks so much for posting !

@TomsTinkeringandAdventures 4 года назад

Bo Gnar Garage dude, if it’s the same issue I would be amazed! Hopefully it hasn’t caused damage. Get back to me, I would love to hear how it turns out.

@SheriffBo 4 года назад

Tom's Tinkering and Adventures I’ll be using this vid as a reference. And even better i’ll make a vid of tearing it down. So you can see the carnage (hopefully its not bad) lol

@santiagoduranona5553 4 года назад

@@SheriffBo so what about your bike, dude? any vid?

@SheriffBo 4 года назад

Santiago Durañona i tore it down just haven’t gotten it back in the bike. I been busy as a mother fucker with work. It wasn’t this problem though. My motor actually seemed perfectly fine. I guess these bikes just like to make some racket. Im actually selling it after i finally finish it. I have too many other toys

@johnr4459 4 года назад

oh that problem, ive read about that some years ago, and stories about counter balance having big arguement with crank and resulting with counter balance escaping out of the front of the block and therefore total destruction, engine goodnight vienna. the one i had was a '95 electric start, i had it for 8 years, the only issue i had with it was primary drive nut came loose from time to time. i replaced it with a 2003 xt600e, the motors on those out live the cycle parts, apart from 5th gear issue on the older ones. i like the xt its nothing fancy, its a good bike if you have arthritis in the knees like i have.

@TomsTinkeringandAdventures 4 года назад

John R I have always been interested in the XT600 but never got one.

@trevorjameson3213 4 года назад

I had a '91 DR350 that did the same thing. But it was making a distinct knocking sound that was pretty loud. I bought the bike new in '91, and the problem arose in '95, only four years old and around 5,000 miles on it. I split the cases and discovered similar damage to yours, but slightly worse gouging on the counterbalancer, in the same spot as yours. The solution was exactly what you did, simply had that pin welded into place, then put the engine back together. After that, I rode it until 2001, and sold it. The problem never came up again, but I didn't really trust Suzuki after that, and have ridden Honda's ever since, well, except for my Sportster.

@TomsTinkeringandAdventures 4 года назад

Trevor Jameson we found out it was fairly common. DR650 is likely a different setup, never split one of those engines yet.

@marcoveltre3014 2 года назад

Your DR350 videos have been a life saver to me. I have to pull my bottom end apart as I found some crud down there during a piston replacement. What all would you recommend replacing while I'm in there? I was thinking crank bearings but is there anything else I should look at?

@TomsTinkeringandAdventures 2 года назад

Glad to hear the videos are helpful, that’s why I make them. The bottom end of these engines are pretty stout. For sure check the pin that came out on this one. Bearings are a good idea while you’re in there. If you research a bit, some people swap gears from the DR250 model because it has a wider gear spread or something. Best of luck!

@marcoveltre3014 2 года назад

@@TomsTinkeringandAdventures thanks for the help. I actually had the pin slip out on my previous motor! Caused catastrophic damage when the crank smashed the counterbalancer out of the front of the engine. The JB weld plug was the first thing I did when I swapped bottom ends.

@anthonygonzalez7488 3 года назад

Good video

@TomsTinkeringandAdventures 3 года назад

Thank you for watching!

@anthonygonzalez7488 3 года назад

@@TomsTinkeringandAdventures your welcome

@santiagoduranona5553 4 года назад

What you should do, in order to be feel secure is to first of all replace all the four bearings. Then replace the pin using a press to perfectly fit it in and may be use a bit of 'thread adhesive just to be sure and then also replace the pin that holds the balancer. Sorry if I miss translated. But anyway. The 3 items should be taken special attention. The two pins and the bearings. And if you want the bike to last enough you should take a look to the entire oil pump. Clean it, replace if needed and then clean all the way to the cilinder head because lack of oil there is frequent . Do not forget to clean the oil filter that is on the frame!

@TomsTinkeringandAdventures 4 года назад

Santiago Durañona it’s my buddy’s bike, he won’t be spending much money. Just getting it back together. I’m considering using epoxy on the back side of the hole.

@santiagoduranona5553 4 года назад

@@TomsTinkeringandAdventures yeah it may work. But do not use any electric weld or hot weld. It may change steel properties and turn it weak. Good luck dude and good video! If you happen to replace bearings use those dessigned for high rpm. I think they have a c3 code or something

@mtnmotoadv 4 года назад

How long did it take to get to the head gasket? Is it pretty easy job? I recently bought a dr350se and I've an oil leak from the head gasket on the front side that I would like to fix. I've never dug into a motor before but your video makes it seem rather straight forward. Is it something that can be done in a couple hours, or is it more like a day long + project? How many things can I screw up with it? Do I have to redo the timing when reassembling?

@TomsTinkeringandAdventures 4 года назад

Frankenscuzz if you have a manual and watch a few videos, along with having the confidence to go forth with the job.... you can do it! The cam timing will need to be set, the head bolts need to be properly torqued, those are the most important aspects of it. If I were close I would help ya out. Good luck, let me know how it goes.

@ftby59mikeD 4 года назад

Tom (or others) correct me if I'm wrong, but the DR250 doesn't have this problem. It's counter balancer & shaft are basically a one piece design using a "Woodrow" key..lmao "Hoo-yah"

@TomsTinkeringandAdventures 4 года назад

FTBY59 Mike D I would assume (you know what that means) that the DR250 has the same counter balancer. I don’t recall what years it was in production, but from what I have read this issue only happens on later model DR350’s...maybe 96+? Earlier ones didn’t have the hole drilled all the way through on the crankshaft.

@Dafi-mx6fz 4 года назад

does the balancer shaft have any points. how so how to set it up.Do you have some engine diagrams because I put together from scratch for quite a long time

@TomsTinkeringandAdventures 4 года назад

Dafi1771 there’s a couple dots you have to line up. I have a manual.

@TimMutton317 4 года назад

Originally suzuki drilled a small hole all the way through, then drilled a hole the size of the pin part way through, which would make it impossible for the pin to work its way through. At some point they just started drilling it the same size the whole way, leading to this issue. Most people dont realise this until the engine grenades. Some have fixed it with JB weld, some have welded it, some have press fit a second pin the counter balancer

@TomsTinkeringandAdventures 4 года назад

Tim Mutton exactly what I have heard. It’s a small thing that can lead to big problems

@santiagoduranona5553 4 года назад

This issue is since 93' models. Older versions or at least 90 to 92 has the half drilled hole. And it is better, as you said.

@TomsTinkeringandAdventures 4 года назад

Santiago Durañona I just got the gaskets to put this back together. Not sure which solution to do to prevent this from happening again.

@iangriffiths9930 4 года назад

Heat build up by the bearing with the discoloured oil on it probably expanded that sprocket hole where the pin was and allowed the pin to work lose. Just my thoughts?

@TomsTinkeringandAdventures 4 года назад

Ian Griffiths I did some research, DR350 engines from about 1996-1999 had that hole in the crankshaft drilled through, early models had a blind hole. Over 20 years of use, the locating dowel probably just works it’s way in which causes the gear to be disengaged. I believe the discolored bearing is due to the gear and bearing not rotating together. That’s my theory, at least.

@iangriffiths9930 4 года назад

I love your videos as I’m learning so much! I’m still looking to buy an XR but man they hold there value well here in the UK

@TomsTinkeringandAdventures 4 года назад

Ian Griffiths I’ve heard that some bikes are crazy expensive there. DR650 guys say those bikes are insane as well.

@maurialcorentin9296 Год назад

how did you unscrew the Phillips screws from the retaining plate and the oil pump?

@TomsTinkeringandAdventures Год назад

I usually use a speed handle with a JIS bit. Best way to get full torque on those to get them loose without stripping them out

@danielbazan7547 Год назад

Hey man my dr350 seized due to it not having oil the gears still shift and I can roll it in neutral do you think it’s just a new piston head and resurface the cylinder walls or what else would you recommend replacing as well as the gaskets of course

@TomsTinkeringandAdventures Год назад

Take a look at the timing chain and guides. They usually are good, but that's a great time to replace them. If you ran low on oil, chances are that the top end starved first and your cam, followers and cam bearing surfaces took lots of abuse. It won't take long to determine that, just remove the cam cover and inspect the followers and the cam lobes, then remove the cam caps and check the bearing surfaces. I wish you good luck!

@hooptydx 4 года назад

nice video

@TomsTinkeringandAdventures 4 года назад

Gabriel thanks for watching.

@philbrookman3126 4 года назад

have u got a vid showing assembly ive stripped mine down put it backtogether and gears dont work ,

@TomsTinkeringandAdventures 4 года назад

Phil Brookman actually working on it right now.

@MrH3lper 3 года назад

Great video. I'm down under in New Zealand. I believe I have the exact same problem. Similar markings in the same area. But it destroyed my oil pump drive gear. Trying to get another. I have a concern about other parts I had to loctite to stop them unscrewing. Now I need them to to split case. Do you need to pull cover of fly wheel bolts go right through? And gear shifter assembly selecter does it need to come off. I have those two screws loctite.

@TomsTinkeringandAdventures 3 года назад

The gear selector has to come off I’m pretty sure. Are you asking about the stator cover?

@MrH3lper 3 года назад

Yes does it have to come off?

@TomsTinkeringandAdventures 3 года назад

@@MrH3lper I can’t recall if any of those bolts go through the case. I guess you can try to split it without removing the cover and see?

@MrH3lper 3 года назад

My bad typing messages on a phone it is hard enough to see let alone type with one finger. This is my first time stripping down a motorbike motor. I was wondering do you think it is worth replacing the sleeve with only 7000ks on the clock at 60bucks idk. 120 for piston.

@TomsTinkeringandAdventures 3 года назад

@@MrH3lper my suggestion is to measure it in accordance with the manual, if it’s in specification then save the money.

@lucasgutierrezm3998 7 месяцев назад

Hi ! I just need to replace the valve cover gasket, do you think I can do it without having to take the engine out of the bike ? If anyone knows I would really appreciate the help !

@TomsTinkeringandAdventures 7 месяцев назад

You 100% can. If you search DR350 in my channel I have one on replacing the camshaft. It was all done in frame.

@teamground0229 2 года назад

Two weeks - that's what I tell IT clients also. Its a moving two weeks, day by day 14 days out.

@TomsTinkeringandAdventures 2 года назад

My buddy has had the two weeks joke going for a while…he set himself up for it!

@troudecul69 2 года назад

hey tom ! I cannot believe I have the oil caramelisation(burned oil deposit) on the crankshaft near the big bearing. Did you invistagate further to know what cause that ? I opened the clutch case to change the cam chain and the clutch... I was wondering if I should split the crankcase open to investigate... I also have a very small oil leak at the front of the engine on the 2 halves joint. I dont know if im ready to attack a job that big lol

@TomsTinkeringandAdventures 2 года назад

If you have a lot of burned looking oil on the big bearing it could be from overheating? Definitely check the bearings closely. Splitting the cases isn’t that bad of a job. Take your time and you can do it!

@troudecul69 2 года назад

@@TomsTinkeringandAdventures Thanks tom for the fast response. you are a great youtuber ! also thanks for all the encouragements. Last question, do you need a press to fit that big bearing or to remove it ?

@TomsTinkeringandAdventures 2 года назад

@@troudecul69 you are probably going to need a press or come up with a solution. I have heated the bearing with a heat gun to remove it from the crank, still needed a bearing puller but it worked easily. Also have heated up the cases when installing bearings. You can hit the bearings with a can of compressed air to chill them a bit. Just need to think it out a bit, lots of ways to get stuff done. 😀

@troudecul69 2 года назад

@@TomsTinkeringandAdventures Cool, very logical. like putting the half case in a oven at 300 f to remove it or putting the bearing in a freezer for 24h for installing it.

@TomsTinkeringandAdventures 2 года назад

@@troudecul69 yes. If you’re married, do it while your spouse is away…they tend to frown upon engine parts in the kitchen I have found out.

@dyldawg6691 2 года назад

Hi there! i got my engine apart as much as i need to and i have so question if you don’t mind i posted another video, thanks so much

@TomsTinkeringandAdventures 2 года назад

Let me know when it posts, I didn’t see it…

@dyldawg6691 2 года назад

@@TomsTinkeringandAdventures i believe it is posted

@matlowsex6219 4 года назад

I will need some help rebuilding my Dr soon ....if ur available I'd like your input

@TomsTinkeringandAdventures 4 года назад

Matlow Sex I will do my best to assist, let me know.

@stevetkocz 4 года назад

Thanks for another great video I'm gonna start building my spare engine soon About 2 weeks 😂

@TomsTinkeringandAdventures 4 года назад

Steven Tkocz ahhh, jokes! 😂. I’m still waiting on my buddy to get the parts to put this one back together.

@ordinaryguy8113 4 года назад

I am looking at buying a 99 DRZ 350 with a cracked crank case from a broke crank case pin. Where do you get your parts from?

@TomsTinkeringandAdventures 4 года назад

Stan Paszkiewicz it depends on the parts needed. OEM stuff I get online from RMATV.com and some stuff I get from eBay or Amazon. Broken case? Might be better to get a donor engine.

@ordinaryguy8113 4 года назад

@@TomsTinkeringandAdventures Do you think a $600 is a fair price for a 99 DRZ considering I would likely need a new case, rebuild? bike had 13k miles but seems to be good otherwise.

@TomsTinkeringandAdventures 4 года назад

Stan Paszkiewicz 99 was a good year, better suspension than the earlier models. You should research used engine prices, with case damage you will be spending a lot on parts. 94-99 engines are the same, I suppose this is the electric start model?

@dyldawg6691 2 года назад

Hi! i did get a manual and there is just one question i have still if you wouldn’t mind i posted a video on my channel thanks so much

@TomsTinkeringandAdventures 2 года назад

I will check it out!

@chrisromo9291 Год назад

Hey I have Dr 350 aswell Wich I took to a shop down in Baja,I got a transmission swap because the transmission before broke on me,Bike runs and shifts through all Gears smoothly expect for 2nd gear wich is hard shifting it.Any suggestions???

@TomsTinkeringandAdventures Год назад

Could be a shift fork, shift drum, gear dogs….so much stuff needs to work together in a motorcycle transmission.

@chrisromo9291 Год назад

@@TomsTinkeringandAdventures Thanks!Motorcycle shops in Cali don't really work on these bikes anymore,So I had to do it down in Baja thoe motorcycle shops there aren't that trustworthy.Had the bike in the shop for 6 months and when I received it and took it to my fams house I realized it was missing some screws,so there assemble was trash.Dint wanna deal with them anymore "Lesson learned"This time took it to a recommended shop see how it goes.

@TomsTinkeringandAdventures Год назад

@@chrisromo9291 just gotta find people like me!

@chrisromo9291 Год назад

@@TomsTinkeringandAdventures Yes indeed,I like the way you put efforts on diz bikes 👍 One Last question,The owner of the shop Wich did the transmission swap told me that the bike needs some use that's why it's hard shifting it to 2nd gear?wich I think is BS,your thoughts?? Thanks

@TomsTinkeringandAdventures Год назад

@@chrisromo9291 new bikes don’t shift like that, so yeah…BS.

@ppaha 4 года назад

nice work! i think wrong counter balance timing.

@TomsTinkeringandAdventures 4 года назад

TV garage papillon yeah, the locating dowel slid through....poor design.

@billycheeseman9795 7 месяцев назад

I would of just peened the pin but what you did is definitely better

@TomsTinkeringandAdventures 7 месяцев назад

Lots of ways to get it done. Taking it all the way apart and welding it is probably ideal, but it’s still working to this day so I think it’s good.

@dyldawg6691 2 года назад

Hey, i’m taking apart the exact same engine right now and can’t get the very top plate of. any ideas?

@TomsTinkeringandAdventures 2 года назад

Top plate? Do you have a manual?

@dyldawg6691 2 года назад

@@TomsTinkeringandAdventures I don’t

@dyldawg6691 2 года назад

@@TomsTinkeringandAdventures it’s the first thing you took of and I was gonna see how you did it but it didn’t show you do it

@TomsTinkeringandAdventures 2 года назад

@@dyldawg6691 you need to get a manual . Some time on an internet search will likely find one to download. You probably are talking about the valve cover.

@dyldawg6691 2 года назад

@@TomsTinkeringandAdventures ok! thank you so much for taking the time to respond that’s super cool👍🏽

@MrN0bady 3 года назад

Where you order parts for dr350?? Working on my engine

@TomsTinkeringandAdventures 3 года назад

MrN0body Rocky Mountain MC website, OEM parts section.

@MrN0bady 3 года назад

Tom's Tinkering and Adventures thank you so much

@jacobhighland4742 4 года назад

It's actually called a *gudgeon pin* not a wrist pin or piston pin if you wanna be technical.

@TomsTinkeringandAdventures 4 года назад

Does Wayne Bradey in England!

@brucemckelvy9920 2 года назад

Put the darn camera on a tripod or something so the images are not jumping around all over the place while you are trying to work. Makes the video very hard to watch.

@TomsTinkeringandAdventures 2 года назад

Thanks for the input. It’s not easy to work and make videos either. Maybe you could be my cameraman? Thanks for watching, even if it was very hard! 😀

@brucemckelvy9920 2 года назад

I have done a lot of camera work and still do. If I lived closer I would be happy to participate and try to improve on your videography skills. That said, I don't know if you just posted this as a casual thing, or if you hope to monetize your efforts, but if you are trying to do that, you will need to invest more effort into the filming and editing to produce quality videos that will drive subscribers and maybe even Patrons. That said if was just a casual post then so be it. I have a DR350 and will be rebuilding the motor this winter so any content is of interest to me.

@TomsTinkeringandAdventures 2 года назад

@@brucemckelvy9920 I do my best with the equipment I have. My channel has been monetized for quite a while, but this isn’t something I do to make money. I like to help people, and lots of people have appreciated my attempts to do so. It took a long time before I considered making videos and it’s still not something that I really enjoy but I do like the feeling I get when people say that my video helped them to do a job they didn’t think they could do. Best of luck with your rebuild. You can always email me for help, as well.

@brucemckelvy9920 2 года назад

@@TomsTinkeringandAdventures No problem Tom. I did enjoy the content and I think there is a market for this kind of stuff. Glad you are giving it a go. Heck, if Bus Grease Monkey can make a living working and filming working on old Detroits, surely someone can do it working on vintage dual sports. :-). Thanks again and keep producing videos as best you can.