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It lives! 1996 DR350SE

Discussion in 'Mechanical & Technical' started by james1300, Apr 4, 2012.

  1. james1300

    james1300 Track School Dazed

    1996 Suzuki DR350SE Lives!
    After following some advise from members on this forum and in the (2) threads about carb cleaning, it lives! LOOKY>>
    Looky Some More>>>
    It was scarey how EZ it started too.
    I used the Clymer and Suzuki service manuals. Tore the carb down as far as it would go. Then using 'Yamaha' carb. cleaner and Berrymans B-12 Chem tool cleaned the daylites outta the carb.
    I replaces ALL the o'rings, the diaphram and bowl gasket.
    I have a 'petcock' o'ring on order. I will remove the petcock from the tank and check for debris as soon as the o'ring arrives.
    I may also end up using a R/C car axle flat washer to slip under the 'fixed' needle on the slide. To fatten up the mid range a bit.
    But, until I know I have a unobstructed flow of fuel (petcock inspection) I'm leaving everything as is.

    (I think I have a problem because it runs fine on 'prime' but, when I switch to 'Run' it acts like it's starving for fuel. ( I poured a gallon of fresh fuel into the tank)So, its down to one of two things that I can think of. Dirty petcock or, bad petcock diaphram.)
    Any other suggestions to check?


    Hey Guy's! I just got an email from 'Harbor Freight'. Here is a 25% OFF coupon. Good for SUNDAY ONLY! Coupon link>>
    Last edited: Apr 5, 2012
  2. so...

    tell us about your carb cleaning methods.

    what finally got the jets really super-d-duper clean?

  3. james1300

    james1300 Track School Dazed

    I went overboard. I used Yamaha Carb clean on the body of the carb, and Berrymans B-12 chem tool on the brass jets.
    I used a Harbor Freight Ultra Sonic Cleaner with Yamaha carb cleaner in it to clean the carb body. After several Ultra Sonic cycles with the Yamaha cleaner, I shot highly compressed air through every hole I could find. Then sat it aside. Mean while I soaked the brass jets in Berrymans for 12 hours. Then after draining the Yamaha cleaner out of the Ultra sonic cleaning machine. I sat the brass jets in a 'shot glass', added Berrymans into the glass and sat it in the Ultra Sonic machine. Ran it aprox. 30 minutes. They came out discolored but clean.
    Reassembled the carb paying attention to float level height and 'It Lives'!
    Rode it down to D.O.L. and bought tabs for it!

    25% OFF Harbor Freight Coupon! Good for SUNDAY ONLY>>>
    Last edited: Apr 5, 2012
  4. Good ending to a new found fun bike.....Glad to hear it...
  5. hot. thanks James!
  6. james1300

    james1300 Track School Dazed

    I also replaced the throttle cables, throttle pipe and, handle bars. I used a 'Cable Luber' and Lubed all the cables, clutch too. While I had it apart I also replaced the vacume line from the carb to the petcock, and fuel line. All the hose's on the carb got refreshed.
  7. Nice indeed! Thanks for the tip on the Ultra Sonic, think I'll be picking one up.
  8. james1300

    james1300 Track School Dazed

    EDIT! Just got a 25% OFF Harbor Freight Coupon! Good for SUNDAY ONLY!

    Check and use Harbor Freights 20% off coupon. Remember, don't use anything too harsh in the tank! The Yamaha Cleaner, actually etched the plastic transparent U/S tank cover.
    Last edited: Apr 5, 2012
  9. :eek:ccasion:vtr2:
  10. james1300

    james1300 Track School Dazed

    Now, I'm looking for a Suzuki tail light and stock Turn signals!
    90-98 DR350SE
  11. james1300

    james1300 Track School Dazed

  12. That it does! Thank you Sir:mfclap:
  13. I used to work at Wenatchee Cycle Center and bought two diff Dr250s and 2 350s. Had every mod available including the last one with a big bore kit. If I remember right it was a 454cc kit. Tried different exhaust, carb kits, Fox Shocks and progressive spring kits. Large tanks, etc. Anyway. Had alot of fun on these bikes :mfclap:and wish I still had one. Congratulations on a great bike.
  14. james1300

    james1300 Track School Dazed

  15. james1300

    james1300 Track School Dazed

    OK, it was the petcock diaphram. Suzuki no longer supports this petcock. (no repair kit available).
    Suzuki will try and sell you a new Suzuki petcock $129.00! Yikes!
    K&L Supply has a diaphram kit. $35.00 plus freight.
    OR, I used a new Yamaha 'Raptor' petcock. No diaphram in this one! On/off and reserve.
    Factory fresh. It bolts right up! Even comes with (2) new bolts and the correct o'ring.
    $30.00 to my door! I did the happy dance!

    Last edited: Aug 23, 2012
  16. Now all you need is a supermoto wheel set!
  17. james1300

    james1300 Track School Dazed

    Know of any? And a over size Brake kit? I'd smoke the stock front rotor and pads in no time.
    Last edited: Aug 23, 2012
  18. I have a complete front end and wheels from my DRZ I'm parting out...
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