Suzuki DR350P DR350SP 1993 Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 89377

Etiquetas: 1993 DR350P DR350SP Misc Motorcycle Motorcycles Suzuki

Variantes de producto

Descripción

The Suzuki DR350P and DR350SP, produced in 1993, represent a capable and versatile dual-sport motorcycle. These models are recognized for their robust air-cooled engines, reliable performance, and suitability for a wide range of riding conditions, from commuting to off-road excursions. The DR350 series, including the DR350P (Dual Sport) and DR350SP (Street Legal), offered a compelling balance of power and handling, making them a popular choice for riders seeking an adaptable machine. Their engineering emphasizes durability and ease of maintenance, contributing to their enduring appeal. This comprehensive service repair manual provides detailed information to assist owners and technicians in maintaining and repairing the 1993 Suzuki DR350P and DR350SP. Coverage includes in-depth procedures for engine mechanicals, fuel and ignition systems, transmission, drivetrain, suspension, braking systems, and the electrical system. The manual also details scheduled maintenance, troubleshooting common issues, and specific repair processes for components like the carburetor and suspension. With its extensive scope, this guide is an essential resource for ensuring the optimal performance and longevity of your Suzuki DR350 motorcycle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DR350P / DR350SP

Model Variant:

DR350P (Dual Sport), DR350SP (Street Legal)

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Market Position:

The Suzuki DR350 series was a popular choice in the late 80s and early 90s for riders seeking a versatile dual-sport motorcycle capable of handling both on-road commuting and off-road adventures. It occupied a niche between lighter trail bikes and larger adventure touring machines.

Competitive Analysis

Competitive Analysis:

Competed with models like the Honda XR series, Kawasaki KLR series, and Yamaha XT series, offering a balance of performance, reliability, and affordability.

Key Features

Key Features:

Robust air-cooled engine, capable suspension for varied terrain, reliable performance, and relatively simple mechanicals, making it a favored platform for customization and long-term ownership.

📋 Manual Details

Coverage Areas

Countries Of Sale:

Global (North America, Europe, Asia, etc.)

Page Count

Page Count:

Approximately 300-400 pages (estimated for typical service manuals of this era and scope)

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, piston, crankshaft, valves, timing, lubrication system, cooling system (air-cooled design).

Fuel System:

Carburetor (Mikuni VM series), fuel tank, fuel lines, fuel pump (if applicable).

Ignition System:

CDI ignition, spark plug, ignition coils, stator.

Transmission:

5-speed gearbox, clutch system, gear shifting mechanism, transmission lubrication.

Drivetrain:

Chain drive, sprockets, rear swingarm, bearings.

Suspension Front:

Telescopic front forks, internal components, seals, oil types, damping adjustments.

Suspension Rear:

Monoshock rear suspension (SU-STRS system), shock absorber, linkage, rear spring preload adjustment.

Braking System Front:

Hydraulic disc brake, caliper, master cylinder, brake fluid, pad replacement, rotor specifications.

Braking System Rear:

Hydraulic disc brake, caliper, master cylinder, brake fluid, pad replacement, rotor specifications.

Electrical System:

Wiring diagrams, battery, charging system (alternator/stator), lighting (headlight, taillight, turn signals), instrumentation, starter motor (if electric start equipped).

Frame And Bodywork:

Frame inspection, body panel removal and installation, seat, fuel tank, fenders, handlebars.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug checks, valve clearance adjustments, brake inspections.

Troubleshooting:

Diagnosis of common problems, electrical issues, starting problems, running issues, suspension issues, brake issues.

Engine Repair:

Complete engine disassembly, inspection, reassembly, and tuning procedures.

Carburetor Service:

Carburetor cleaning, jetting, adjustments, and overhaul.

Suspension Rebuild:

Front fork seal replacement, rear shock absorber service, linkage maintenance.

Brake System Service:

Brake pad replacement, caliper servicing, bleeding procedures, master cylinder overhaul.

Electrical Diagnostics:

Wiring harness tracing, component testing, multimeter usage, troubleshooting electrical faults.

Wheel And Tire Service:

Tire replacement, wheel balancing, spoke tensioning.

Technical Depth

Depth:

Comprehensive, covering all aspects from routine maintenance to major overhauls and diagnostics. Suitable for both DIY enthusiasts and professional mechanics.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution scans, clear text and images, suitable for printing.

Binding Type

Binding Type:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

Searchability

Searchability:

Searchable PDF text for quick access to information.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, air-cooled, SOHC, 4-valve

Displacement:

348 cc

Bore X Stroke:

82.0 mm x 60.2 mm

Compression Ratio:

9.5:1

Valve Clearance Intake Cold:

0.04 - 0.08 mm (0.0016 - 0.0031 in)

Valve Clearance Exhaust Cold:

0.07 - 0.11 mm (0.0028 - 0.0043 in)

Lubrication System:

Wet sump

Performance

Horsepower Est:

Approximately 28-30 hp @ 7,000 rpm (varies by tuning and emissions)

Torque Est:

Approximately 23-25 lb-ft @ 6,000 rpm

Fuel System

Carburetor Model:

Mikuni VM33SS

Carburetor Jets:

Main Jet: #130, Pilot Jet: #17.5, Needle Jet: J-5, Jet Needle: 4th clip from top (typical, may vary).

Fuel Tank Capacity:

10.0 L (2.6 US gal) / 12.0 L (3.2 US gal) for SP with larger tank.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet multi-plate

Features

Gear Ratios:

1st: 2.538 (33/13), 2nd: 1.857 (26/14), 3rd: 1.400 (21/15), 4th: 1.105 (21/19), 5th: 0.913 (21/23).

Final Drive:

Chain drive, 520 pitch (e.g., 15T front, 46T rear is a common stock ratio).

Transmission Oil Capacity:

Approximately 1.3 L (1.4 US qt) with filter change, 1.1 L (1.2 US qt) without.

Transmission Oil Spec:

API SG, SAE 10W-40 or 20W-50 motorcycle specific engine oil.

📐 Dimensions

Exterior

Length:

Approx. 2255 mm (88.8 in)

Width:

Approx. 830 mm (32.7 in)

Height:

Approx. 1185 mm (46.7 in)

Seat Height:

Approx. 885 mm (34.8 in)

Wheelbase:

Approx. 1480 mm (58.3 in)

Weights

Dry Weight:

Approx. 122 kg (269 lbs) for DR350P

Wet Weight:

Approx. 134 kg (295 lbs) for DR350P (with fluids)

Front Tire Size:

80/100-21 M/C 51P

Rear Tire Size:

110/90-18 M/C 61P

Wheel Bolt Pattern:

Not Applicable (Spoked wheels with hub and axle).

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycles are typically not rated by agencies like NHTSA or Euro NCAP).

Active Features

Active Features:

Disc brakes front and rear for effective stopping power, balanced suspension for stability.

Passive Features

Passive Features:

Sturdy frame construction, appropriate lighting for visibility.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic instrumentation: speedometer, odometer, trip meter, neutral indicator light, high-beam indicator).

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km (1,800 mi) or 6 months.

Air Filter Cleaning Interval:

Every 1,500 km (900 mi) or 3 months (more frequently in dusty conditions).

Valve Clearance Check Interval:

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

Chain Adjustment Interval:

Check and adjust chain slack every 1,000 km (600 mi) or as needed.

Fluid Specifications

Engine Oil Spec:

API SG, JASO MA, SAE 10W-40 or 20W-50 motorcycle oil.

Brake Fluid Spec:

DOT 3 or DOT 4

Fork Oil Type:

Suzuki Fork Oil SS-04 (or equivalent 10W viscosity fork oil)

Fork Oil Quantity:

Approx. 363 ml (12.3 US oz) per fork leg (check manual for exact amount)

Known Issues

Known Issues:

Carburetor clogging due to fuel instability, potential wear in the swingarm and steering head bearings, occasional ignition coil failure, weak clutch springs on high-mileage units.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Suzuki has a long and storied history in motorcycle manufacturing, particularly known for its versatile dual-sport and off-road machines like the popular DR series.

Model Evolution

Model Evolution:

The DR350 was introduced in 1990 as a successor to the DR350S. It evolved through various iterations, including the DR350SE (electric start) and the DR350S (kick start). The 'P' and 'SP' designations often refer to specific market or slight variant differences. The 1993 model represents a mature iteration of this successful platform.

Production

Production Years:

1990-1999

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Recognitions:

While not a recipient of specific 'awards' in the traditional sense, the DR350 series was widely praised in enthusiast publications and forums for its reliability, versatility, and value, earning it a strong reputation among riders.

Ratings

Owner Satisfaction Ratings:

Consistently high owner satisfaction ratings for its category during its production years, often cited for its durability and ease of maintenance.