Segment:
Dual-sport motorcycle, popular for trail riding and light street use.
Target Audience:
Enthusiasts and owners seeking to perform maintenance and repairs themselves.
Competitors:
Honda XR series, Kawasaki KLR series, Yamaha XT series of the same era.
Vehicle Type:
Versatile dual-purpose motorcycle suitable for off-road and on-road use.
Manual Benefit:
Empowers owners with the knowledge to maintain and repair their DR350S/SES, saving time and money.
Format Advantage:
PDF format offers easy searching, accessibility on multiple devices, and the ability to print specific pages.
Engine Overhaul:
Comprehensive coverage of engine disassembly, inspection, repair, and reassembly.
Transmission And Drivetrain:
Detailed procedures for transmission, clutch, and final drive maintenance and repair.
Fuel And Ignition Systems:
Includes carburetor tuning, fuel pump diagnostics, and ignition system troubleshooting.
Electrical System:
Wiring diagrams, component testing, and troubleshooting for all electrical circuits.
Suspension And Steering:
Front fork overhaul, rear shock absorber servicing, and steering system maintenance.
Brakes:
Front and rear brake system maintenance, caliper rebuilds, and bleeding procedures.
Frame And Bodywork:
Procedures for frame inspection, fairing removal/installation, and seat maintenance.
Wheels And Tires:
Tire replacement, wheel bearing maintenance, and spoke tensioning.
Troubleshooting:
Diagnostic guides for common problems and systematic fault finding.
Estimated Pages:
Likely 300-500 pages, typical for a comprehensive service manual.
Type:
Factory Authorized Service Manual / Repair Manual
Engine Systems:
Top end (cylinder head, valves, piston), bottom end (crankshaft, connecting rod, bearings), lubrication, cooling (air-cooled).
Transmission Drivetrain:
Clutch operation and adjustment, gearbox internals, shift mechanism, drive chain maintenance.
Fuel System:
Carburetor (Mikuni BST series likely), fuel tank, petcock, fuel lines.
Ignition System:
CDI ignition, spark plug specifications, ignition timing, stator and rotor testing.
Electrical Systems:
Lighting circuits, horn, battery, charging system (alternator), starter motor (if applicable), instrumentation.
Suspension:
Front telescopic forks (including oil type, level, seal replacement), rear monoshock absorber (adjustments, servicing).
Brakes:
Hydraulic disc brakes (front and rear), brake fluid type and specifications, caliper service, master cylinder.
Steering:
Handlebar assembly, steering stem bearings, fork clamping.
Chassis:
Frame construction, subframe, swingarm maintenance, linkage bearings (if applicable).
Preventative Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks.
Disassembly Assembly:
Step-by-step instructions for removing, inspecting, and reinstalling major components.
Troubleshooting Guides:
Systematic diagnostic flowcharts for common performance issues.
Technical Specifications:
Torque values, clearances, fluid capacities, electrical resistance values.
Adjustments:
Carburetor idle and mixture, clutch lever play, brake lever free play, suspension sag.
Rebuilds:
Carburetor overhaul, fork seal replacement, brake caliper rebuilding.
Electrical Diagnostics:
Testing of charging system, ignition coil, stator, and wiring harness continuity.
Depth:
Comprehensive, covering everything from basic maintenance to full engine and chassis rebuilds.
Diagnostic Capabilities:
Advanced troubleshooting with detailed symptom-cause-solution tables and diagnostic procedures.
Special Tools:
Identification and usage of specialized tools required for certain repairs.
Type:
Single-cylinder, four-stroke, SOHC, air-cooled
Displacement:
349 cc (21.3 cu in)
Bore X Stroke:
82.0 mm x 64.0 mm (3.23 in x 2.52 in)
Horsepower:
Approx. 26-30 hp (depending on specific tuning and market) at ~7,000 rpm
Torque:
Approx. 20-22 lb-ft (depending on specific tuning and market) at ~5,500 rpm
Carburetor:
Mikuni BST33, 33 mm (flat slide carburetor)
Fuel Type:
Unleaded gasoline (minimum octane rating specified in manual, typically 87 or higher)
Oil Capacity:
Approx. 1.8 L (1.9 US qt) with filter change.
Oil Type:
SAE 10W-40 motorcycle specific, API SG or higher.
Length:
Approx. 2,200 mm (86.6 in)
Width:
Approx. 800 mm (31.5 in)
Height:
Approx. 1,210 mm (47.6 in)
Wheelbase:
Approx. 1,435 mm (56.5 in)
Dry Weight:
Approx. 122 kg (269 lbs) for DR350S, slightly more for SES due to electric start.
Wet Weight:
Approx. 132 kg (291 lbs) for DR350S with fluids.
Fuel Capacity:
13 L (3.4 US gal) including a 2.5 L (0.7 US gal) reserve.
Safety Ratings:
Motorcycles are not typically subjected to standardized crash ratings like cars; safety relies on rider skill and vehicle design.
Braking System:
Front and rear hydraulic disc brakes.
Lighting:
Headlight, taillight, brake light, turn signals.
Frame Construction:
Steel semi-double cradle frame designed for rigidity and impact resistance.
Ergonomics:
Designed for upright riding position, aiding rider control.
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months.
Oil Filter Change:
Every 6,000 km (3,600 miles) or 12 months (or with every oil change for best practice).
Air Filter Cleaning:
Every 1,000 km (600 miles) or more frequently in dusty conditions.
Spark Plug Inspection:
Every 3,000 km (1,800 miles).
Valve Clearance Check:
Every 6,000 km (3,600 miles).
Drive Chain Lubrication:
Every 500 km (300 miles) and after washing.
Engine Oil Grade:
SAE 10W-40, API SG, JASO MA/MB
Fork Oil:
Suzuki SN (or equivalent 10W fork oil), 500 ml per fork leg (specific quantity detailed in manual).
Brake Fluid:
DOT 3 or DOT 4.
Common Problems:
Carburetor jetting can be sensitive to altitude/temperature; potential for minor oil leaks from valve cover or clutch cover gaskets; kickstart mechanism wear on high-mileage units.
Maintenance Tips:
Regular cleaning of the air filter and proper chain maintenance are crucial for longevity.
Heritage:
Suzuki has a long history of producing reliable and capable off-road and dual-sport motorcycles.
Predecessors:
Evolved from earlier Suzuki dual-sport models like the DR350.
Successors:
Contributed to the development of later DR-Z models.
Variants:
DR350S (kick-start only) and DR350SES (electric start option).
Production Years:
DR350 line produced from early 1990s through late 1990s, with the 1995 model being a key year.
Manufacturing Location:
Japan
