🏷️ Basic Information

Make:

Suzuki

Model:

DR350

Model Variant:

DR350S

Model Years Covered:

1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999

👋 Introduction

Description:

The Suzuki DR350 and DR350S models were popular dual-sport motorcycles known for their versatility and reliability, appealing to both off-road enthusiasts and commuters seeking an economical and capable machine.

Competitors:

Competed with models like the Honda XR series, Kawasaki KLR series, and Yamaha XT series in the dual-sport segment.

Versatility:

Designed for on-road and off-road use, bridging the gap between dirt bikes and street bikes.

Durability:

Renowned for robust construction and longevity, especially the engine.

Simplicity:

Relatively straightforward mechanical design, making maintenance accessible.

📋 Manual Details

Manual Type:

Workshop Service Repair Manual

Language:

English

File Format:

PDF

Page Count:

398

Delivery Method:

Instant Download

Printable:

True

Software Requirement:

Adobe Reader

Operating System Compatibility:

Windows, Mac, Linux

📖 Manual Coverage

Engine:

Complete engine disassembly, assembly, troubleshooting, repair, adjustments, specifications, internal components

Fuel System:

Carburetor service, fuel tank, fuel lines, fuel pump (if applicable)

Ignition System:

CDI, spark plugs, wiring, timing

Transmission Clutch:

Clutch operation, adjustment, disassembly, assembly, gear shift mechanism

Drivetrain:

Chain drive, sprockets, wheel hub assembly

Suspension:

Front forks (telescopic), rear shock absorber, linkage (if applicable), adjustments, seal replacement

Brakes:

Front and rear brake systems (likely disc), caliper service, master cylinder, brake lines, bleeding procedures

Electrical System:

Wiring diagrams, lighting, battery, charging system, starter motor, switches, fuses

Cooling System:

Air-cooled (typically for this model), engine heat management

Exhaust System:

Muffler, pipes, mounting

Frame Chassis:

Frame inspection, components, mounting points

Wheels Tires:

Spoke wheel maintenance, tire pressure, bearing service

Controls:

Handlebars, levers, cables, footpegs

Bodywork:

Fairings (if applicable), fenders, seat, tank removal/installation

Maintenance:

Periodic maintenance, lubrication, inspections, fluid changes, adjustments

Troubleshooting:

Problem diagnosis for various systems, fault finding guides

Repair:

Detailed step-by-step instructions for all mechanical and electrical repairs

Disassembly Assembly:

Component removal and installation procedures

Adjustments:

Carburetor, clutch, brakes, suspension, ignition timing adjustments

Cleaning Lubrication:

Specific procedures for cleaning and lubricating various components

Depth:

Comprehensive, bumper-to-bumper coverage suitable for DIY and professional mechanics

Pictorial Content:

Detailed illustrations, exploded diagrams, drawings, and photos

Special Tools:

Reference to required special service tool numbers and their usage

Specifications:

Tightening torques, wear limits, adjustment values, performance specifications

Diagnostic Information:

Included where necessary for troubleshooting

Safety Precautions:

Special notes, important points, precautions, DANGER, CAUTION, NOTE remarks

📊 Manual Specifications

File Format:

PDF

Print Quality:

High resolution, suitable for printing all pages

Searchability:

Likely searchable text content within the PDF

Completeness:

100% complete and intact, no missing/corrupt pages/sections

⚙️ Engine Specifications

Type:

Four-stroke, SOHC, single-cylinder

Displacement:

348cc (approximately)

Cooling System:

Air-cooled

Bore X Stroke:

Typically around 82.0 mm x 66.0 mm (need to confirm specific factory spec)

Horsepower:

Approx. 28-32 HP (varies by year and tuning)

Torque:

Approx. 25-28 Nm (varies by year and tuning)

Carburetor:

Mikuni BST Series (e.g., BST33/BST39 - specific size dependent on year/model)

Fuel Type:

Unleaded gasoline

Fuel Capacity:

Typically around 10-12 liters

🔧 Transmission

Type:

5-speed constant mesh

Type:

N/A (standard 5-speed)

Clutch:

Wet, multi-plate

Final Drive:

Chain drive

📐 Dimensions

Length:

Approx. 2200-2250 mm (varies by year/specifics)

Width:

Approx. 850-900 mm (varies)

Height:

Approx. 1200-1250 mm (varies)

Dry Weight:

Approx. 120-130 kg (varies by year/equipment)

Wet Weight:

Approx. 135-145 kg (varies)

🛡️ Safety Features

Description:

Motorcycle safety relies on rider skill and maintenance; no formal crash ratings apply. Manual emphasizes safe operating procedures.

Brakes:

Disc brakes front and rear for effective stopping power.

Lighting:

Headlight, taillight, brake lights, turn signals for visibility.

💡 Technology Features

Description:

As a dual-sport motorcycle from the 1990s, the DR350 does not feature modern infotainment systems like touchscreens or audio players. Focus is on essential functions.

Description:

No advanced driver assistance systems. Relies on rider skill and basic mechanical systems.

Description:

No connectivity features. Basic analog instrumentation.

🔧 Maintenance

Oil Change:

Typically every 3,000-5,000 km or annually, depending on usage (refer to manual for exact spec).

Air Filter:

Clean/replace as needed based on riding conditions, typically every 5,000-10,000 km.

Spark Plug:

Inspect/replace every 10,000-15,000 km.

Chain Maintenance:

Regular cleaning, lubrication, and tension adjustment (every 500-1000 km recommended).

Engine Oil:

Suzuki recommends specific motorcycle-grade oil, typically SAE 10W-40 or 20W-50 API SG or higher. Check manual for precise grade.

Brake Fluid:

DOT 3 or DOT 4 brake fluid (check manual for specific recommendation).

Fork Oil:

Specific weight fork oil, typically SAE 5W or 10W (refer to manual for capacity and type).

Carburetor Issues:

Mikuni BST carburetors can sometimes suffer from sticky slides or pilot circuit blockages, requiring cleaning and adjustment.

Oil Leaks:

Valve cover gasket and output shaft seal are common areas for minor oil leaks over time.

Suspension Wear:

Fork seals and rear shock bushings can wear out, requiring replacement for optimal performance.

Electrical Connections:

Corrosion or loose connections can affect lighting or ignition systems, especially in older bikes.

📚 Vehicle History

Description:

Suzuki has a long history of producing reliable and performance-oriented motorcycles, from smaller commuters to powerful sportbikes and off-road machines.

Dr Series:

The DR line represents Suzuki's commitment to the dual-sport segment, with the DR350 being a mid-displacement offering that evolved with technological updates throughout its production run.

Production Years:

1990-1999 (globally)

Key Changes During Production:

Introduction of electric start on some models (DR350SE), suspension refinements, carburetor updates, minor cosmetic changes.

🏆 Awards & Recognition

Description:

While specific awards are not widely documented, the DR350 gained a reputation among riders and magazines for its balance of performance, reliability, and value in the dual-sport category.