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-   -   DR350s clutch problem? (http://www.horizonsunlimited.com/hubb/suzuki-tech/dr350s-clutch-problem-27029)

dr350ryder 9 May 2007 04:54

DR350s clutch problem?
I have a 91 dr350s that has been sitting for quite a while due to a faulty regular/rectifier that was causing it to not spark. Now that I have that figured out, once it is started the engine dies every time I put it into gear. I have tried adjusting the clutch cable several times but it is not helping. As far as I know, there was nothing wrong with the clutch before the bike got parked. Anyone have any suggestions?:helpsmilie:

lecap 9 May 2007 08:11

Side stand switch

dr350ryder 9 May 2007 18:23

where would i find that? on my wiring diagram it shows it wiring to the cdi unit but i'm not seeing it on my bike. is it inside the magneto?

samson 9 May 2007 19:15

you can find the switch at the sidestand , just follow the wire til you find the conector . Pul it out and take a litle piece of elec wire then just connect the two pins of the connector . trey it . now you now if it was the switch or not.:mchappy:

dr350ryder 9 May 2007 21:34

i found where the switch was supposed to be. previous owner disconnected it and just looped it by attaching the hot wire to the ground wire. tried connecting 2 of them that i had. but not sure if the switches are good or bad or even the right ones for the bike. could he have damaged the cdi unit by trying to bypass the side switch?:confused1:

samson 10 May 2007 19:20

dr 350
leaf the conector looped and NO this can do notting wrong with the cdi
somtime the clutch stiks a little bit when the bike is stald for a long time
just put it in free gear and puss a bit back and for til its loos

Nigel Marx 10 May 2007 22:04

Stuck Clutch?
When a bike has been sitting for a while the oil on the clutch plates gets squeezed out until there is only the thinnest film left. This acts make the plates act like a suction cup to each other and they don't separate easily. A couple of things to try is to use a cable tie or rope or similar to tie the clutch lever make over-night and then try again.
If this doesn't work start the bike in neutral, paddle forward with your feet until you are moving as fast as you can and just put it in gear. There may be a jolt, but that's OK. Now ride with the clutch in and putting the back brake on and off until it breaks free. It shouldn't take long. I have never had a Japanese bike clutch that wouldn't break free this way and most will free up almost instantly. Old British bikes are another story......


Nigel in NZ

motomech 11 May 2007 20:24

If it is not an electrical problem, then it is most likely the thrust washers. This model uses two hardened washers that strattle the clutch basket and eventualy they get groves worn into them and the clutch plates no longer septerate as they should. They can be flipped over one time. I used to have to get into the clutch of my DR every 10,000 for this problem. There's a German guy(Ludwig?) who does a nice write-up about this on his Dr350SE site, Google it.

B.T.W. The rectifier/regulator ASM is a componate of the charging system and has no direct effect on ignition(spark).

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