DR350 Rebuild

[Jimbobvt]

Ok im new to motorcycle maintainence, but have been working on cars since i could see under the hood. Im trying to clean the intake manifold on a suzuki dr350 (199 as it is rusted/muddy. This bike was poorly taken care of and runs like garbage, but i think i can fix it. one of my main problems is currently i cant figgure out how to remove the timing chain. Does this require a special tool? If so where can i get it and what is it called, and is there any other things i can use instead. currently this thing is driving me nuts.

[Jimbobvt]

grr auto smilies thats a 1998 dr350

[Phease]

Don't know much about your bike, but.........

Doing an camchain replacement on a honda cb250 which runs directly down the centre of the engine block i used a chain breaker to break the chain at the top then i attached the new chain to one of the detached ends of the old chain with one of the bolts and then just ran them both round until only the new chain was in place and the old chain was completely out of the engine, then just remove the old chain from the link and join up both endws oif the new chain.

As i said i don't know how it sits in your engine but you may be able to do it this way.

[dirtyfingers]

Um..... why are you trying to remove the timing chain? Anyways, the RIGHT way to do it is to split the lower case halves, remove the crankshaft, and then take off the chain. I've never thought a timing chain with a master link was a good idea. A chain is only as good as its weakest link. Are you just trying to get the chain off the cams so you can get the head off?

[Jimbobvt]

Yes dirtyfingers, the Only reason i want this chain off is to get the head off. As far as removing the lower halves, is there anything besides the obvious bolts that need to be removed? Ive Pulled all the bolts on the lower halves (after removing everything else alternator, gears, etc.)

[bandit12]

Does the timing gear (top) not bolt onto the cam
by two 10mm bolts? I recently took the top end
off of a 125 motor by taking out the two bolts and
lowering the gear enough to get the chain off the
gear. Don't forget to tie off the chain so you don't
lose it, but it isn't to bad to retrieve if you do lose
it.

[TsPerformance]

On my sp 125 the cam gear was attached to the cam by means of screws if your is like that, which it does in this 350 " http://houseofmotorcycles.bikebandit..._id~706269.asp " So just remove the cam gear sprocket and take bottom end off take magneto or whatever is down there..

Thats what i did with my 125 so if its completely off the wall donnt listen to me

[TsPerformance]

for a mocrofiche go to bikebandit.com and go to oem parts

[Kropatchek]

Try this link
http://www.dr350.kenet.co.uk/camgear.php

Greetz
Kropatchek

[Jimbobvt]

The cam gear does bolt on as you said, but the prob is the metal bracket attached to the two bolts on the other side of the cam gear. the metal ends are bent up and pounded down on the bolts, making them impossible to turn.