Sub Model:
DR350S, DR350SE
Model Years Covered:
1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Chassis Code General:
Internal Suzuki designations likely vary by year and specific sub-model
Segment:
Dual-sport motorcycle, appealing to riders seeking versatility for on-road and off-road use.
Competitors:
Honda XR series, Yamaha TT-R/XT series, Kawasaki KLR series.
Versatility:
Capable on trails and suitable for commuting or light touring, making it a popular choice for a wide range of riders.
Durability:
Known for its robust, air-cooled engine and sturdy chassis, contributing to longevity with proper maintenance.
Comprehensive Coverage:
Complete service, repair, troubleshooting, and maintenance for DR350, DR350S, and DR350SE models.
Estimated Pages:
Over 300 pages (typical for this era of comprehensive service manuals)
Type:
Service and Repair Manual
Format:
Digital Download (PDF)
Engine:
Complete engine overhaul, top-end rebuild, bottom-end assembly, valve adjustment, carburetor tuning/rebuilding.
Fuel System:
Fuel tank, petcock, fuel lines, carburetor (Mikuni VM33SS common), fuel filter, fuel pump (if applicable).
Transmission:
Clutch operation, gear shifting mechanisms, transmission disassembly and reassembly, lubrication.
Drivetrain:
Final drive chain and sprockets, rear swingarm, linkage, wheel bearings.
Suspension:
Front forks (telescopic, cartridge type), rear shock absorber (Monocross suspension), fork seal replacement, oil changes, spring rates.
Brakes:
Front and rear disc brake systems, brake caliper service, master cylinder overhaul, brake pad replacement, fluid bleeding, brake lines.
Electrical System:
Ignition system (CDI), stator, ignition coil, wiring diagrams, lighting (headlight, tail light, indicators), battery, charging system, starter motor (for SE models).
Frame And Body:
Frame inspection, body panel removal and installation, seat, fenders, handlebars, controls.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks.
Troubleshooting:
Diagnostic procedures for common running issues, electrical faults, starting problems.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension rebuilds, brake system repairs.
Adjustments:
Carburetor jetting, idle speed, clutch cable, throttle cable, valve clearances.
Depth:
Comprehensive, covering everything from basic owner maintenance to full engine and chassis rebuilds. Includes detailed torque specifications and clearances.
Type:
4-stroke, SOHC, 2-valve, single-cylinder
Displacement:
349 cc (approx.)
Bore X Stroke:
74.0 mm x 80.0 mm (typical)
Compression Ratio:
9.5:1 (typical)
Horsepower:
Approximately 25-30 HP (depending on year and tuning)
Torque:
Approximately 20-25 lb-ft (depending on year and tuning)
Carburetor:
Mikuni VM33SS (common, variable jetting depending on specific model and year)
Fuel Type:
Unleaded gasoline
Overall Length:
Approximately 2200 mm (varies slightly by model)
Overall Width:
Approximately 830 mm (varies slightly by model)
Overall Height:
Approximately 1200 mm (varies slightly by model)
Wheelbase:
Approximately 1460 mm (varies slightly by model)
Dry Weight:
Approximately 114-125 kg (varies by sub-model, DR350SE with electric start is heavier)
Wet Weight:
Approximately 125-138 kg (estimated, with fluids)
Fuel Tank Capacity:
Approximately 10 liters
Oil Change:
Every 2,000 km or 6 months, whichever comes first (typical, check manual for exact specification).
Air Filter Service:
Clean every 1,000 km, replace as needed (check manual).
Valve Adjustment:
Every 4,000 km or annually (typical, check manual for exact specification).
Spark Plug Replacement:
Inspect every 2,000 km, replace as needed (check manual).
Engine Oil:
API SE, SF, SG, SH, SJ; SAE 10W-40 or 20W-50 (check manual for specific viscosity recommendation based on temperature).
Brake Fluid:
DOT 3 or DOT 4 (check manual for exact type).
Fork Oil:
Specific weight and volume detailed in manual (typically 10W fork oil).
Oil Leaks:
Can occur around the valve cover or stator cover with age; seals may need replacement.
Carburetor Issues:
Mikuni VM33SS can be prone to clogging if fuel is not clean or if the bike sits for extended periods without fuel stabilizer. Jetting may need fine-tuning for altitude or modifications.
Countershaft Seal:
Can wear out, leading to oil leaks near the front sprocket.
Cam Chain Tensioner:
Some models may have a manual cam chain tensioner that requires periodic adjustment; automatic versions can sometimes fail.
