Suzuki DR350M DR350SM 1991 Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 89375

Etiquetas: 1991 DR350M DR350SM Misc Motorcycle Motorcycles Suzuki

Variantes de producto

Descripción

The DR350M and DR350SM, produced in 1991, represent a versatile dual-sport motorcycle designed for both on-road and off-road excursions. Building on a reputation for reliable engineering, these models offer tractable power delivery and a robust design, making them a popular choice for riders seeking adaptable performance. The DR350 line is recognized for its value and capability, evolving from earlier successful models and contributing to a strong heritage in motorcycle manufacturing. This comprehensive service and repair manual provides detailed guidance for the maintenance, troubleshooting, and repair of your 1991 DR350M/SM. It covers all essential systems, including the engine, transmission, chassis, brakes, and electrical components, with step-by-step instructions for disassembly, reassembly, and adjustments. The manual is an invaluable resource for owners and technicians, offering diagnostic charts, special tool identification, and routine maintenance schedules to ensure optimal performance and longevity of the motorcycle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DR350M / DR350SM

Year:

Product Name:

Suzuki DR350M DR350SM 1991 Service Repair Manual PDF Download

👋 Introduction

Market Position

Segment:

Dual-Sport / Enduro Motorcycle

Competitive Analysis

Competitors 1991:

Honda XR series, Kawasaki KLR series, Yamaha XT series

Key Features

Vehicle Philosophy:

Versatile performance for both on-road and off-road use, known for reliability and tractable power delivery.

Manual Value Proposition

Benefit To Owner:

Empowers owners to perform detailed maintenance, diagnostics, and repairs, saving time and money while ensuring optimal vehicle performance and longevity.

Digital Advantage:

Instant access, easy navigation, searchable content, and no physical wear and tear compared to paper manuals.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Maintenance, Troubleshooting

Page Count

Estimated Pages:

Extensive (typically 300+ pages for this era of service manual)

Manual Type

Type:

Service & Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine overhaul, top-end rebuild, bottom-end procedures, valve adjustment, carburetor tuning, ignition system, cooling system (air-cooled nature considered), lubrication

Transmission:

Clutch service, gearbox inspection and repair, shift mechanism, lubrication

Chassis:

Frame inspection, swingarm and linkage service, suspension (forks, rear shock), steering head bearings

Brakes:

Hydraulic brake system (front and rear disc brakes), caliper service, master cylinder overhaul, brake pad replacement, bleeding procedures

Electrical:

Wiring diagrams, lighting system, charging system (stator, regulator/rectifier), ignition system components, battery service, starter system

Fuel System:

Fuel tank, fuel lines, carburetor service (cleaning, jetting, float adjustment), fuel petcock

Wheels And Tires:

Wheel bearing service, spoke adjustment (if applicable), tire pressure recommendations, tire replacement

Bodywork And Trim:

Panel removal and installation, seat service, graphics and decals

Procedures Included

Maintenance:

Routine maintenance, oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning

Troubleshooting:

Diagnostic charts for common problems, symptom-based troubleshooting guides

Repair:

Step-by-step disassembly and reassembly instructions for all major components and systems

Special Tools:

Identification of required special tools for specific procedures

Technical Depth

Depth:

Comprehensive (suitable for DIY enthusiasts and professional mechanics, covering routine maintenance to complete engine rebuilds and electrical system diagnostics)

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable (depending on scan quality)

Print Quality

Quality:

Digital (high-resolution for clarity)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC, Air-cooled

Displacement:

346cc

Bore X Stroke:

76.0 mm x 76.0 mm

Compression Ratio:

9.5:1

Carburetor:

Mikuni VM33SS (single)

Ignition System:

CDI (Capacitor Discharge Ignition)

Performance

Horsepower Approx:

Approx. 30-32 HP (varies by market and tune)

Torque Approx:

Approx. 20-22 lb-ft (varies by market and tune)

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Approx. 2.6 US gallons (10 Liters)

Lubrication

Oil Type:

SAE 10W-40 API SE or SF motorcycle oil

Oil Capacity:

Approx. 1.9 US quarts (1.8 Liters) with filter change

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet multi-plate

Features

Final Drive:

Chain drive

Transmission Oil Type:

API GL-1 SAE 80W Gear Oil (shared engine/transmission oil system typically, but manual will specify)

📐 Dimensions

Exterior

Length:

Approx. 86.8 in (2205 mm)

Width:

Approx. 35.0 in (890 mm)

Height:

Approx. 48.4 in (1230 mm)

Wheelbase:

Approx. 56.7 in (1440 mm)

Weights

Dry Weight:

Approx. 262 lbs (119 kg)

Wet Weight:

Approx. 282 lbs (128 kg) (with fluids)

Wheels And Tires

Front Tire Size:

80/100-21 48P (Spoke wheel)

Rear Tire Size:

110/90-18 61P (Spoke wheel)

Suspension

Front Suspension Type:

Telescopic, Coil Spring, Oil Dampened

Rear Suspension Type:

Swingarm Type, Monoshock (Remote Reservoir on SM)

🛡️ Safety Features

Ratings

Safety Standards:

Compliant with prevailing motorcycle safety regulations of the era.

Active Features

Braking System:

Hydraulic front and rear disc brakes for responsive stopping power.

Passive Features

Frame Construction:

Sturdy steel frame designed for durability and handling stability.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation: speedometer, odometer, neutral indicator, high beam indicator).

Driver Assistance

Driver Assistance Systems:

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km (1,800 miles) or 6 months, whichever comes first.

Air Filter Cleaning Interval:

Every 3,000 km (1,800 miles) or more frequently in dusty conditions.

Valve Clearance Check Interval:

Every 6,000 km (3,600 miles) or 12 months.

Spark Plug Replacement Interval:

Every 12,000 km (7,200 miles) or as needed based on inspection.

Fluid Specifications

Engine Oil Viscosity:

SAE 10W-40

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Known Issues

Common Wear Items:

Cam chain tensioner, clutch plates, wheel bearings, fork seals, carburetor jets (clogging).

Specific Failures:

Some models experienced early cam chain tensioner failure; manual will guide on inspection and replacement.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycles:

Suzuki has a long and storied history in motorcycle manufacturing, particularly known for innovation in engine technology and performance.

Model Evolution

Dr Series Lineage:

The DR350 is part of Suzuki's highly successful DR line of dual-sport motorcycles, evolving from earlier models and influencing later generations.

Production

Dr350 Production Years:

1990-1999 (with variations like DR350S, DR350SE, DR350SM)

Manufacturing Location:

Japan (typically)

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

The DR350 line was generally well-regarded for its robust design, versatility, and value, making it a popular choice for adventure riders and commuters alike.