DR350 Clutch or Shift problem ?

C

campaholic

Guest
Hi,

I just bought a used 1993 DR350 with just over 12000km on the odometer. I am not sure if the spedo was hooked up all the time but this is what it says. The motor and tranny seemed fine when I test rode it around the block. Now that I have it home some issues have reared there ugly head.

So heres my question. Most of the time the bike runs and shifts fine. The other five percent of the time I shift and it seems fine for about 10 seconds, then either the clutch slips for a second or the tranny slips. It only slips for a second then grabbs again and is good untill I shift again, or maybe several shifts later. The bike was bought with the lights and mirrors in a box as the owner was just using it on the trails for the last several years. So my real question is, is it a clutch problem or a gear or shift problem?

I have not had a bike since I was a teenager so am just getting back into bikes. My final test for my class 6 in tomorrow, so after that I want to get the problem solved before winter sets in.

Thanks for any advice.

Roger
 
C

campaholic

Guest
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I also forgot to mention that it is a pain in the butt to find neutral wheather the bike is running or not.

Roger
 
Island Hopper

Island Hopper

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Sounds like your clutch may need replacement or your running too slick of oil, most likely the clutch. Brian at the Bikesmith or the local Suzuki shop can order you aftermarket plates and springs {if required} and also the gaskets and maybe a new tab washer. It's not too difficult to change the plates yourself just make sure you soak the new plates in oil for a few hrs before you install so they don't burn up right away. One other thing before you tear into the clutch: make sure your clutch cable is well lubed and sliding smoothly, there is a small chance that if your cable is stiff it may not be releasing the clutch fully after you let go of the lever causing the slippage or if your adjustment at the lever doesn't have enough cable slack.
 
C

campaholic

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I had it into Brian this week and to get some oil and filter. It had a little too much oil from when I bought it, so he thought when I changed oil it may help things. It did not make any change. I was thinking of taking it in to Brian for a new timing chain or maybe doing it myself. I am just trying to get a better idea of what it is so i know what to look for if I tear into it myself. And figure out what is it going to cost me to get it running good.

Roger
 
Island Hopper

Island Hopper

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What is wrong with the timing chain? it shouldn't be worn out with 12000 KM unless like you mentioned the speedo was unhooked. Is your cam chain tensioner working properly
 
C

campaholic

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I wasn't sure how long they last, and while I am driving, every once in a while I hear this click or little slap noise. I am not sure if it is comming from theinsrument pannel or engine. Since the bike is used I just have this worry that the noise could be the timing chain and I do not want to blow the motor because the timing chain is wore out and I have no way of checking it.

Roger
 
C

campaholic

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Can I check my tensioner by pulling it off and what do I look for? How would I know if the chain was wore out?

Thanks for you help and interest.
 
Island Hopper

Island Hopper

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Usually if I buy or pick up a used bike with an unknown history the first thing I do is check the valve clearances and make sure the auto decompression lever has enough slack {so it's not holding a valve open}, The DR probably has bucket and shim valves which are a little more difficult to adjust than conventional tappets and the problem being having a supply of shims on hand if adjustment is needed. I dont know if the DR 350 has an auto cam chain tensioner or a bolt spring locknut combo that you periodically have to crack the locknut and bolt to add tension. Something you should look into just in case. ON some 4 strokes engine clatter is the norm {my KTM 640 for instance} on others it could be worn cam lobes excessive valve clearance or something loose or sloppy in the valve train {worn bearings}. I never owned a DR so I'm not famililar with how much clatter is considered the norm but just by listening to the engine one can usually get an idea of where it's coming from and if it's serious.
 
Island Hopper

Island Hopper

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I wouldn't think the cam chain would be wore out, you can put a lot of miles on those things. Best would be to check for excessive slack when you go to adjust the valves. As for the tensioner , usually there is a spring and plunger affair that puts tension on a boomerang shaped rub block against the chain. Check with Brian on what kind of system the DR uses , probably something simple.
 
C

campaholic

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Thanks for your help. It has a ratcheting cam chain tensioner. I think I may just get Brian to take a peek at it as I want this thing to be reliable for the winter. I may pull the clutch cover first to see if I can find anything wrong there.

Thanks

Roger
 
C

campaholic

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I think I found my problem. I took the clutch side cover off and discovered that the bolt on the end of the shift drum had come loose and fallen out. A new one is ordered so this should solve most of my problems. The clutch looked and measured in perfect condition.

Thanks
 
C

campaholic

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The bolt was a little banged up, but not too bad. I found it in the bottom of the engine by the oil pickup. I ordered a new one. Should be in next week.

My next problem is the main clutch drum nut was not very tight. How do I hold the drum while I tighten the nut? I do not have any old clutch plates or a clutch tool?



Roger
 
Island Hopper

Island Hopper

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Try a strapwrench, I used to make one with a nylon strap twisted around a dowel a couple of times. Did your clutch drum retaining nut have a tab washer on it that you had to bend in order to tighten it?
 
C

campaholic

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The nylon stap sounds like a great idea. I will try it next week when the parts come in.

The clutch drum did have a tab washer. It was the only thing holding the nut from comming off as I could rock the nut back and forth against the tabs, with my fingers. Every thing looks and measures good so I think I got lucky.



Roger
 
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