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Suzuki DR350 Supermoto Project

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at106
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Joined: 16 Jul 2011
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PostPosted: 12:48 - 23 Feb 2013    Post subject: Suzuki DR350 Supermoto Project Reply with quote
I bought a DR350 after getting my 33HP licence, as i wanted to do a bit of green laning. However i also need a road bike as knobbly tyres on the road aren't much fun.

The bike,

https://i448.photobucket.com/albums/qq202/at106/Picture002_zps536baa7d.jpg
https://i448.photobucket.com/albums/qq202/at106/Picture003_zpsab5d4141.jpg

GS500 wheels, disks, sprocket and speedo drive,

https://i448.photobucket.com/albums/qq202/at106/Picture004_zpsbc308307.jpg

The front wheel fits perfectly, however the speedo drive doesn't as it is too wide so i'll just use a bicycle speedo.

https://i448.photobucket.com/albums/qq202/at106/Picture006_zps0f27ee8f.jpg
https://i448.photobucket.com/albums/qq202/at106/Picture008_zpsa4b11ff3.jpg

There's just enough clearance between the disk and forks,

https://i448.photobucket.com/albums/qq202/at106/Picture010_zpsc7a6fee6.jpg

I made up a couple of spacers out of copper pipe to see how it looked (i'll get proper spacers made next week),

https://i448.photobucket.com/albums/qq202/at106/Picture011_zps80304bb0.jpg
https://i448.photobucket.com/albums/qq202/at106/Picture012_zpsc93e5220.jpg
https://i448.photobucket.com/albums/qq202/at106/Picture013_zpsa1d8d5c4.jpg

The next job is to see how the rear wheel fits, and make an adaptor for the front caliper.
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Irn-Bru
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PostPosted: 13:08 - 23 Feb 2013    Post subject: Reply with quote
Cool project, bro.

What is the white tubing for?
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at106
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Joined: 16 Jul 2011
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PostPosted: 13:39 - 23 Feb 2013    Post subject: Reply with quote
Irn-Bru wrote:
Cool project, bro.

What is the white tubing for?


I knew someone would ask Laughing The previous owner fitted it to hold spray paint cans which he used for marking out horse events (i think) but i've left it on as it makes a good drinks holder!
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waffles
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PostPosted: 16:18 - 23 Feb 2013    Post subject: Reply with quote
I like a good supermoto project Smile

What are your plans for it? Basic clean and wheels or are you going for a bit more of a tart up?
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at106
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PostPosted: 16:31 - 23 Feb 2013    Post subject: Reply with quote
waffles wrote:
I like a good supermoto project Smile

What are your plans for it? Basic clean and wheels or are you going for a bit more of a tart up?


The plan is to fit the wheels, modify the exhaust (basically just removing the baffles and fitting a larger outlet pipe) and ive got an acerbis long range tank to fit. The bike will still be used off road so there's not a lot of point making it look good as i regularly fall off Laughing
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suzukirider19...
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PostPosted: 16:33 - 23 Feb 2013    Post subject: Reply with quote
nice project, did a very simlar wheel conversion on my TS except i used kawi gpz 500 wheels

got a nice brand new mini acerbis enduro rear light kit for sale. they look so much better than std ones
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mysterious_rider
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PostPosted: 17:13 - 23 Feb 2013    Post subject: Reply with quote
You should opt for a larger rear wheel, personally I'd ditch the 130 and run something with a 160, such as a bandit rear.

Good job on it so far though, you'll be having fun making the brakes fit. Laughing
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suzukirider19...
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PostPosted: 17:40 - 23 Feb 2013    Post subject: Reply with quote
mysterious_rider wrote:
Good job on it so far though, you'll be having fun making the brakes fit. Laughing



when i did mine thats the first thing that worried me but when it came to it small bracket on front and very small amount of machining the rear disc and all fit on together very easy.
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TUG
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PostPosted: 17:53 - 23 Feb 2013    Post subject: Reply with quote
I was just wondering, how do you make sure that the rim is dead on center and that the fork legs don't bend when tightening? If that question is a bit confusing I'll drum up some pics on what I mean.
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at106
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Joined: 16 Jul 2011
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PostPosted: 17:55 - 23 Feb 2013    Post subject: Reply with quote
I'm happy with the wheels as there are quite a few people who have done this conversion so i know it works. The brakes shouldn't be an issue, for the front i'll make a bracket because the gs500 disk is a lot bigger. The rear disk will be turned down to make it the same diameter as the standard dr350 disk.
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suzukirider19...
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PostPosted: 18:00 - 23 Feb 2013    Post subject: Reply with quote
TUG wrote:
I was just wondering, how do you make sure that the rim is dead on center and that the fork legs don't bend when tightening? If that question is a bit confusing I'll drum up some pics on what I mean.


pretty easy to do when the std wheels are on just meassure inside to inside on the fork legs and repeat with the new rims. with spacer made to suit. i couldn't run a speedo on mine either as not enough space. the dr and ts used simlar parts and are roughly same size so will be easy to do
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TUG
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PostPosted: 18:07 - 23 Feb 2013    Post subject: Reply with quote
suzukirider1987 wrote:


pretty easy to do when the std wheels are on just meassure inside to inside on the fork legs and repeat with the new rims. with spacer made to suit. i couldn't run a speedo on mine either as not enough space. the dr and ts used simlar parts and are roughly same size so will be easy to do


Ahhh I see, also for the speedo, would it not be possible to machine it down? Or even replace it for a narrow one from another suzuki? or is it just not possible due to limited space?
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suzukirider19...
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PostPosted: 18:10 - 23 Feb 2013    Post subject: Reply with quote
TUG wrote:
suzukirider1987 wrote:


pretty easy to do when the std wheels are on just meassure inside to inside on the fork legs and repeat with the new rims. with spacer made to suit. i couldn't run a speedo on mine either as not enough space. the dr and ts used simlar parts and are roughly same size so will be easy to do


Ahhh I see, also for the speedo, would it not be possible to machine it down? Or even replace it for a narrow one from another suzuki? or is it just not possible due to limited space?


just purely limited space. i went with a sat nav to replace my speedo. looks cool and is useful and probs more accurate
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TUG
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PostPosted: 18:17 - 23 Feb 2013    Post subject: Reply with quote
suzukirider1987 wrote:



just purely limited space. i went with a sat nav to replace my speedo. looks cool and is useful and probs more accurate

Ahh right I see, yea your probably right there.
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suzukirider19...
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PostPosted: 18:26 - 23 Feb 2013    Post subject: Reply with quote
TUG wrote:
suzukirider1987 wrote:



just purely limited space. i went with a sat nav to replace my speedo. looks cool and is useful and probs more accurate

Ahh right I see, yea your probably right there.


this is what mine looks like and only cost arouns £20 for the satnav and the waterproof case

https://i1341.photobucket.com/albums/o743/pitbiker1987/735015_10151349493568363_1737419430_n1_zps0a2231a6.jpg
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mysterious_rider
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PostPosted: 18:26 - 23 Feb 2013    Post subject: Reply with quote
TUG wrote:
suzukirider1987 wrote:



just purely limited space. i went with a sat nav to replace my speedo. looks cool and is useful and probs more accurate

Ahh right I see, yea your probably right there.


illegal. highly suggest a koso speedo, i have one
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at106
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Joined: 16 Jul 2011
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PostPosted: 19:16 - 23 Feb 2013    Post subject: Reply with quote
To get the wheels centred i just made sure that there was an equal distance either side of the rim, however from what i've read it's more important that the wheels are aligned with each other.

The GPS speedo may be illegal but it is only short term, i hope to be able to machine the gs500 speedo to fit although i want to get the wheels fitted properly first.

This afternoon (in the freezing weather) i attempted to fit the rear wheel. The rear wheel isn't as easy as the front because it needs bigger bearings and it is slightly too wide.

I started by removing the rear caliper and then measuring the distance between the sprocket and swingarm of the dr350 wheel so i could get an idea of the sprocket alignment.

https://i448.photobucket.com/albums/qq202/at106/Picture015_zps3502d25f.jpg
https://i448.photobucket.com/albums/qq202/at106/Picture014_zps4dec6a76.jpg

Next i removed the bolts which hold the brake disk on as they need replacing for countersunk ones due to clearance issues.

https://i448.photobucket.com/albums/qq202/at106/Picture017_zpsb8031aa8.jpg

I got the wheel fitted, made up a 13mm spacer and the chain aligned perfectly Smile

https://i448.photobucket.com/albums/qq202/at106/Picture018_zps889f0c59.jpg
https://i448.photobucket.com/albums/qq202/at106/Picture019_zps8478eade.jpg

Now onto the brake side Sad With the caliper fitted the wheel wouldn't slide in because it's too wide. To overcome this i removed the disk so i could measure how much material needs to be removed.

https://i448.photobucket.com/albums/qq202/at106/Picture020_zps8c76d93d.jpg
https://i448.photobucket.com/albums/qq202/at106/Picture022_zpse506b950.jpg
https://i448.photobucket.com/albums/qq202/at106/Picture023_zpsd8157bbe.jpg

It needs about 5mm removing, i can either remove it from the brake side of the wheel, or the sprocket carrier but it depends on how the front and rear wheels align. So next week i'll get the correct bearings ordered and some proper spacers made up.
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evoboy
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PostPosted: 19:37 - 23 Feb 2013    Post subject: Reply with quote
mysterious_rider wrote:

illegal. highly suggest a koso speedo, i have one


How? Speedo's arent required for an MOT.


OP, i guess youll have to do some calculations to sort out the final drive gearing? GS rear sprocket looks tiny!
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at106
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Joined: 16 Jul 2011
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PostPosted: 19:44 - 23 Feb 2013    Post subject: Reply with quote
evoboy wrote:
mysterious_rider wrote:

illegal. highly suggest a koso speedo, i have one


How? Speedo's arent required for an MOT.


OP, i guess youll have to do some calculations to sort out the final drive gearing? GS rear sprocket looks tiny!


Yeah using this website https://www.gearingcommander.com/ it should be quite easy. I was thinking of gearing it for a theoretical speed of 130 ish and seeing how it runs.
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mysterious_rider
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PostPosted: 19:52 - 23 Feb 2013    Post subject: Reply with quote
evoboy wrote:
mysterious_rider wrote:

illegal. highly suggest a koso speedo, i have one


How? Speedo's arent required for an MOT.


OP, i guess youll have to do some calculations to sort out the final drive gearing? GS rear sprocket looks tiny!



Road requirement though. So if pulled by plod they might notice and do you for it.
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suzukirider19...
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PostPosted: 20:01 - 23 Feb 2013    Post subject: Reply with quote
if you get stuck mate you message me and will take some pics of mine. you are facing the same problems of what i had. i had to machine the wheel on mine to get the sprocket carrier to sit more into the wheel hub. i cut the nut tops off on the sprocket carrier as was hitting the swing arm. also you might have to macine the rear disc to get it to sit in the caliper and also the caliper carrier had to be ground to give enough clearence. would you like to see pictures of mine. as for gearing i went with 1 less tooth on the rear as that what came with my wheels. getting good accel and plenty on top
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Irn-Bru
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PostPosted: 20:06 - 23 Feb 2013    Post subject: Reply with quote
at106 wrote:
Yeah using this website https://www.gearingcommander.com/ it should be quite easy. I was thinking of gearing it for a theoretical speed of 130 ish and seeing how it runs.


Probably will accelerate like a ped going for such a high top end, 100 is as high as you need really, not exactly a powerful bike is it Razz My old 690 did 120 (on private land etc.) and it's no fun on a supermoto.

Usually 15T front & 44T rear is a good start on DRZ 400's not sure about the 350...
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at106
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Joined: 16 Jul 2011
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PostPosted: 20:29 - 23 Feb 2013    Post subject: Reply with quote
Irn-Bru wrote:
at106 wrote:
Yeah using this website https://www.gearingcommander.com/ it should be quite easy. I was thinking of gearing it for a theoretical speed of 130 ish and seeing how it runs.


Probably will accelerate like a ped going for such a high top end, 100 is as high as you need really, not exactly a powerful bike is it Razz My old 690 did 120 (on private land etc.) and it's no fun on a supermoto.

Usually 15T front & 44T rear is a good start on DRZ 400's not sure about the 350...


That's true but i think the site is slightly optimistic with the top speeds Laughing
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at106
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PostPosted: 20:31 - 23 Feb 2013    Post subject: Reply with quote
suzukirider1987 wrote:
if you get stuck mate you message me and will take some pics of mine. you are facing the same problems of what i had. i had to machine the wheel on mine to get the sprocket carrier to sit more into the wheel hub. i cut the nut tops off on the sprocket carrier as was hitting the swing arm. also you might have to macine the rear disc to get it to sit in the caliper and also the caliper carrier had to be ground to give enough clearence. would you like to see pictures of mine. as for gearing i went with 1 less tooth on the rear as that what came with my wheels. getting good accel and plenty on top


Hi thanks for the offer Thumbs Up If i have any issues i'll let you know but it all seems fairly straight forward so far, and having access to machines at work is a bonus Very Happy
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