Class:
Dual-sport / Enduro motorcycle
Target Audience:
Riders seeking a reliable and versatile off-road and on-road capable motorcycle for adventure, trail riding, and commuting.
Competitors:
Honda XR series, Kawasaki KLR series, Yamaha XT series during its production era.
Versatility:
Adaptable for both trail riding and street legal use, making it a popular choice for dual-sport enthusiasts.
Durability:
Known for its robust construction and reliable single-cylinder engine, capable of enduring demanding conditions.
Simplicity:
Relatively straightforward mechanical design, making maintenance and repairs more accessible.
Primary Coverage:
Mechanical repair, maintenance, and troubleshooting
Secondary Coverage:
Electrical systems, chassis, and bodywork
Type:
Factory Service Manual (FSM) / Repair Manual
Engine:
Detailed disassembly, assembly, inspection, and repair of engine components, including top-end, bottom-end, valvetrain, cooling system, and lubrication.
Transmission:
Clutch operation, gearbox disassembly and reassembly, shift mechanism, and related components.
Fuel System:
Carburetor adjustment, overhaul, and troubleshooting; fuel tank, lines, and pump (if applicable).
Electrical System:
Ignition system, starting system, charging system, lighting, wiring diagrams, component testing, and troubleshooting.
Brakes:
Front and rear brake system maintenance, overhaul, bleeding procedures, and component replacement.
Suspension:
Front fork (telescopic) disassembly, seal replacement, oil levels, and rear shock absorber inspection and service.
Chassis And Frame:
Frame inspection, steering head bearings, swingarm and linkage maintenance, and wheel bearing service.
Bodywork And Trim:
Panel removal and installation, seat, fenders, and fuel tank.
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement, valve clearance checks.
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting guides.
Overhaul And Rebuild:
Detailed step-by-step instructions for complete engine, transmission, and carburetor rebuilds.
Adjustment:
Carburetor synchronization and adjustment, throttle cable adjustment, brake lever adjustment.
Inspection:
Comprehensive pre-ride inspection, component wear assessment, and diagnostic checks.
Depth:
Extensive detail suitable for both intermediate DIY mechanics and professional technicians. Covers basic maintenance to complete engine rebuilds and advanced electrical diagnostics.
Format:
PDF (Portable Document Format)
Searchability:
Typically text-searchable, allowing for quick location of specific information.
Printable:
Designed for printing individual pages or the entire manual.
Quality:
Digital PDF format ensures clear, crisp diagrams and text, superior to aged paper copies.
Type:
N/A (Digital Download)
Type:
Four-stroke, air-cooled, SOHC, single-cylinder
Bore X Stroke:
82.0 mm x 64.0 mm
Valve Train:
SOHC, 4 valves
Horsepower Estimated:
Approx. 30-35 HP (varies by tuning and specific model configuration)
Torque Estimated:
Approx. 28-30 Nm (varies by tuning and specific model configuration)
Carburetor:
Mikuni VM33SS (single, constant velocity)
Fuel Type:
Unleaded gasoline
Type:
CDI (Capacitor Discharge Ignition)
Crash Test Data:
Not applicable to motorcycles in the same manner as automobiles.
Braking System:
Disc brakes front and rear. Front: Hydraulic disc. Rear: Hydraulic disc.
Suspension Stability:
Telescopic front forks and mono-shock rear suspension contribute to stability and control.
Lighting:
Headlight, taillight, brake lights, turn signals (depending on regional specification).
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
Every 6,000 km (3,600 miles) or 12 months.
Air Filter Cleaning:
Every 1,000 km (600 miles) or as needed in dusty conditions.
Valve Clearance Check:
Every 6,000 km (3,600 miles)
Spark Plug Replacement:
Every 12,000 km (7,200 miles)
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after washing/riding in rain.
Engine Oil Type:
SAE 10W-40 API SG or SH
Engine Oil Capacity:
1.8 L (1.9 US qt) without filter change, 2.0 L (2.1 US qt) with filter change.
Fork Oil Type:
Telescopic fork oil (e.g., Showa SS-8 or equivalent)
Fork Oil Capacity:
Refer to manual, typically around 370-390cc per leg.
Brake Fluid Type:
DOT 3 or DOT 4
Common Wear Items:
Clutch plates, valve stem seals, fork seals, wheel bearings, swingarm bushings, countershaft seal (prone to leaks).
Carburetor Performance:
Mikuni VM33SS can be sensitive to altitude and temperature; requires proper tuning and cleaning.
Countershaft Seal Leak:
A common leak point is the seal behind the front sprocket.
Wiring Harness Wear:
On older models, general wear and tear on the wiring harness can lead to intermittent electrical issues.
Manufacturer:
Suzuki Motor Corporation, a Japanese manufacturer known for a wide range of vehicles and marine engines.
Generations:
The DR350 was introduced in the early 1990s and evolved through various iterations, including the DR350S (street-legal), DR350SE (electric start), and the DR350T (trail-oriented). This 1996 model represents a later iteration.
Production Period:
Approximately 1990-1999
Manufacturing Location:
Japan
