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Old 02-06-2011, 08:04 PM   #136
Pablo83 OP
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There's a pin that aligns the cam gear to the cam shaft. I assume it's supposed to be a permanently pressed in place, but it is slipping out of the 250's cam gear. Is that supposed to happen?
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Old 02-06-2011, 09:37 PM   #137
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There's a pin that aligns the cam gear to the cam shaft. I assume it's supposed to be a permanently pressed in place, but it is slipping out of the 250's cam gear. Is that supposed to happen?
I don't know if it's supposed to, but I've got 4 or 5 350 cam's and it's loose on all of them. The C shaped lock washer for the cam sprocket bolts keeps the pin in on one side, but the only thing stopping the pin on the other was the rocker cover (although there was no indication that the pin ever touched the rocker cover).
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Old 02-06-2011, 10:18 PM   #138
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I saw someone's comment that they had installed a DR250 CDI on their 350. Is there any advantage to that?

I believe the 250 has more timing advance...
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Old 02-07-2011, 06:15 AM   #139
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Quote:
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I don't know if it's supposed to, but I've got 4 or 5 350 cam's and it's loose on all of them. The C shaped lock washer for the cam sprocket bolts keeps the pin in on one side, but the only thing stopping the pin on the other was the rocker cover (although there was no indication that the pin ever touched the rocker cover).
Thanks. That's what I was afraid of. Now I have to remove the cover on the other bike to make sure the clip is covering the pin.
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Old 02-07-2011, 10:43 AM   #140
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When I started this project I bought two DR350 engine gasket kits. Since I ended up with a 250 and a 440, I had two 350 head gaskets left over. I could only find one last night. After a lot of searching I found the 250 head gasket (uh oh). So last night I took apart the DR250 so I could remove the 350 head gasket that I had installed and replace it with the proper size one. It turns out that there is a noticeable compression difference with the proper size head gasket.
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Old 02-07-2011, 11:49 AM   #141
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removing the kickstand switch

I hate kickstand switches. Removing it is easy. Unplug and unbolt the switch; throw it away. Follow the two switch wires (one green, one black w/ white) up through the wiring harness as far as you want to take them. Cut and solder them together. A butt connector would work to, but if it ever came loose you would have a very difficult time trying to find out why your engine dies when you put it in gear, so I suggest soldering and shrink tube.


Pablo83 screwed with this post 04-24-2011 at 02:10 PM
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Old 02-08-2011, 09:50 AM   #142
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mounted skidplate

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Old 02-08-2011, 09:52 AM   #143
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The DR350 has a larger rod on the end of the shift pawl than the DR250S. I'm guessing the smaller rod was digging into the case so Suzuki made it larger.

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Old 02-08-2011, 09:54 AM   #144
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The 250 is running! It still has some clutch drag so it will have to come back in some time, but I had to make room in the shop for other projects so right now it sits on the back porch.

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Old 02-08-2011, 10:03 AM   #145
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What's next?
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Old 02-10-2011, 12:08 PM   #146
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That skid plate looks awesome!

I need to learn to weld!
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Old 02-10-2011, 12:28 PM   #147
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Love this thread!
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Old 02-10-2011, 12:43 PM   #148
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I believe the 250 has more timing advance...
And a higher rev limit (though the 350 should get stiffer valve springs and ti retainers before you try and rev it that high imho).
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Old 02-10-2011, 02:50 PM   #149
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And a higher rev limit (though the 350 should get stiffer valve springs and ti retainers before you try and rev it that high imho).
That's good to know. I'll be retaining the RPM gauge from the 250 which shows redline at 9500. Do you know what RPM the rev limiter activates for the 250 and 350?
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Old 02-17-2011, 04:23 PM   #150
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I need a longer clutch cable. Any ideas?
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