Suzuki DR350R DR350SER 1994 Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 89378

Etiquetas: 1994 DR350R DR350SER Misc Motorcycle Motorcycles Suzuki

Variantes de producto

Descripción

The Suzuki DR350R and DR350SER, produced in 1994, represent a capable and reliable dual-sport motorcycle designed for versatile riding experiences, from challenging off-road trails to everyday commuting. Known for its robust, air-cooled 349cc engine featuring a DOHC, 4-valve TSCC design, this model offers a balance of performance and durability. Its long-travel suspension, spoked wheels, and hydraulic disc brakes provide excellent off-road capability and effective stopping power, making it a favored choice for riders seeking adventure and dependability. The DR350's straightforward mechanical design contributes to its reputation for reliability and ease of maintenance, solidifying its place in Suzuki's esteemed DR dual-sport lineage. This comprehensive service repair manual provides essential information for the maintenance, repair, and troubleshooting of the 1994 Suzuki DR350R and DR350SER models. It covers all critical systems, including detailed engine disassembly and assembly, transmission and clutch service, fuel and ignition systems, electrical components, suspension, brakes, and chassis. The manual includes routine maintenance procedures, diagnostic charts for common issues, rebuilding instructions, and precise technical specifications such as torque values and fluid capacities. Its depth of coverage aims to empower owners, mechanics, and technicians to effectively maintain and repair the vehicle, ensuring its optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DR350R

Model Variant:

DR350SER

Year:

Codes

Engine Code:

SOHC 4-stroke, single-cylinder, TSCC (Twin Swirl Combustion Chamber)

Chassis Code:

DR350R/SER

👋 Introduction

Market Position

Category:

Dual-sport / Enduro Motorcycle

Target Audience:

Riders seeking a reliable, versatile off-road and on-road capable motorcycle for adventure, trail riding, and commuting.

Competitive Analysis

Competitors:

Honda XR series, Kawasaki KLR series, Yamaha XT series, KTM EXC series (depending on specific variant and year).

Key Features

Versatility:

Capable of handling both challenging off-road terrain and street riding with appropriate modifications or setup.

Simplicity And Reliability:

Known for its robust engine and straightforward mechanical design, making it relatively easy to maintain.

Off Road Capability:

Long-travel suspension, spoked wheels, and knobby tires provide excellent off-road traction and bump absorption.

📋 Manual Details

Coverage Areas

Supported Models:

Suzuki DR350R, Suzuki DR350SER

Supported Years:

Page Count

Estimated Pages:

Approximately 300-400 pages (typical for this era of Suzuki service manuals)

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, inspection, and overhaul (top end, bottom end, valve train, lubrication system)

Transmission:

Gearbox inspection, maintenance, repair, and clutch service

Fuel System:

Carburetor service and adjustment, fuel tank, fuel lines

Ignition System:

CDI ignition system, spark plug specifications, timing checks

Electrical System:

Wiring diagrams, lighting, battery, charging system (stator, rectifier/regulator), starting system (kick start primarily)

Suspension:

Front fork service (oil changes, seal replacement, spring inspection), rear shock absorber service and adjustment

Brakes:

Front and rear brake system inspection, hydraulic fluid replacement, caliper service, pad replacement, disc inspection

Chassis And Frame:

Frame inspection, steering head bearing service, swingarm and linkage maintenance

Bodywork And Trim:

Fairings, seat, fenders, fuel tank removal and installation

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, air filter cleaning/replacement, spark plug inspection, tire pressure checks

Troubleshooting:

Diagnostic charts for common starting, running, and electrical issues

Rebuilding:

Detailed procedures for engine, carburetor, and suspension component rebuilding

Adjustments:

Valve clearance adjustments, carburetor jetting advice (based on altitude), clutch and brake lever adjustments

Specifications And Measurements:

Torque values, critical clearances, fluid capacities, wear limits

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to full engine rebuilds and complex electrical diagnostics.

📊 Manual Specifications

File Format

Type:

Searchability:

Likely text-searchable if professionally scanned and converted, allowing quick navigation

Print Quality

Quality:

Variable depending on source scan, but generally clear enough for workshop use. Original manual quality is typically good.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, four-stroke, single-cylinder, DOHC (some earlier models were SOHC)

Displacement:

349cc (approximate)

Bore X Stroke:

72.0 mm x 85.4 mm (typical for DR350)

Compression Ratio:

9.5:1 (typical)

Valve Train:

DOHC, 4 valves (TSCC design for improved combustion)

Performance

Horsepower:

Approximately 26-30 HP at 6,500-7,000 RPM (varies by specific tune and market)

Torque:

Approximately 22-24 lb-ft at 5,500-6,000 RPM (varies)

Fuel System

Carburetor:

Mikuni VM33SS (or similar 33mm flat-slide carburetor), pilot jet, main jet, needle jet, needle, throttle valve size, and idle speed specifications will be detailed in the manual.

Fuel Type:

Unleaded gasoline, minimum 87 octane

Lubrication

Oil Type:

SAE 10W-40, API SG or JASO MA certified motorcycle-specific oil is recommended. Manual will specify exact type and viscosity.

Oil Capacity:

Approximately 1.6 - 1.9 liters (check manual for exact figure with filter change).

🔧 Transmission

Standard

Type:

5-speed constant mesh

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

Gear Ratios:

Specific gear ratios for each speed will be listed in the manual for diagnostic and performance analysis.

📐 Dimensions

Exterior

Overall Length:

Approx. 2,255 mm (88.8 in)

Overall Width:

Approx. 850 mm (33.5 in)

Overall Height:

Approx. 1,235 mm (48.6 in)

Wheelbase:

Approx. 1,475 mm (58.1 in)

Ground Clearance:

Approx. 300 mm (11.8 in)

Weights

Dry Weight:

Approx. 117 kg (258 lbs)

Wet Weight:

Approx. 131 kg (289 lbs) (with all fluids)

Fuel Capacity:

10 Liters (2.6 US gal)

Seat Height:

Approx. 885 mm (34.8 in)

🛡️ Safety Features

Ratings

Crash Safety:

Not applicable (motorcycle, no formal crash ratings like cars)

Active Features

Braking System:

Hydraulic disc brakes front and rear for effective stopping power.

Lighting:

Headlight, taillight, brake light, turn signals (depending on market configuration) for visibility.

Passive Features

Frame Construction:

Steel frame designed for durability and handling both on and off-road.

💡 Technology Features

Infotainment

Features:

None (basic motorcycle electronics for lighting and ignition)

Driver Assistance

Features:

None (basic motorcycle design)

Connectivity

Features:

None (basic motorcycle design)

🔧 Maintenance

Service Intervals

Oil Change:

Every 1,000-1,500 miles or 6 months (refer to manual for exact recommendation based on usage).

Air Filter:

Clean every 1,000-2,000 miles, replace as needed. Specific interval for cleaning/replacement will be in manual.

Spark Plug:

Inspect every 2,000-3,000 miles, replace as needed (e.g., NGK CR8E or equivalent).

Chain Maintenance:

Lubricate and adjust every 500-700 miles.

Valve Clearance Check:

Every 5,000-7,500 miles or as per manual's recommendation.

Fluid Specifications

Fork Oil:

Typically SAE 10W or Showa SS-01 (or equivalent), capacity will be specified per fork leg (e.g., 460ml or specific level measurement).

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Oil Leaks:

Potential for leaks around valve cover or base gasket with age.

Clutch Wear:

Clutch plates can wear over time, especially with aggressive use.

Carburetor Performance:

Carburetors can become clogged or require re-jetting due to altitude or modifications.

Suspension Seals:

Fork seals can degrade, leading to leaks and a harsh ride.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation, Japan

Motorcycle Division:

Suzuki has a long and storied history in motorcycle manufacturing, particularly in off-road and dual-sport segments.

Model Evolution

Dr Series Legacy:

The DR350 is part of Suzuki's popular DR dual-sport line, which has seen numerous iterations and engine displacements over the years, evolving from earlier models like the TS series.

Dr350 Development:

Introduced in the late 1980s and produced through the 1990s, the DR350 was known for its balance of performance, reliability, and affordability. The 'R' variant typically signified a more dirt-oriented model, while 'SE' could denote electric start or different suspension/trim levels.

Production

Production Period:

The DR350 model line was produced from approximately 1990 to 1999.

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

While specific awards for the 1994 model are rare to find, the DR350 line was generally well-regarded by motorcycle journalists and riders for its reliability, versatility, and capability as a dual-sport machine, earning a strong reputation in its class.