Suzuki DR350N DR350SN 1992 Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 89376

Mots clés: 1992 DR350N DR350SN Misc Motorcycle Motorcycles Suzuki

Variantes de produits

Description

The Suzuki DR350N / DR350SN, a dual-sport motorcycle from 1992, embodies versatility and durability, designed for riders who seek adventure on both paved roads and unpaved trails. Featuring a robust 299 cc air-cooled, four-stroke engine, this model offers a balanced performance suitable for light off-roading and everyday commuting. Its engineering prioritizes reliability, a hallmark of Suzuki's legacy in the dual-sport segment, making it a practical and dependable choice for a variety of riding conditions. This comprehensive service repair manual in English provides essential information for maintaining and repairing your 1992 Suzuki DR350N / DR350SN. It covers detailed procedures for engine mechanicals, fuel and ignition systems, transmission, drivetrain, suspension, brakes, wheels, tires, and the electrical and frame systems. Included are step-by-step repair instructions, scheduled maintenance intervals, troubleshooting guides, torque specifications, and wiring diagrams, empowering owners and technicians to keep the motorcycle in optimal condition.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DR350N / DR350SN

Year:

Vehicle Type:

Dual-sport Motorcycle

👋 Introduction

Market Position

Market Segment:

Entry-level to mid-range dual-sport motorcycles, popular for trail riding, light off-roading, and commuting.

Competitive Analysis

Competitors:

Honda XR series, Kawasaki KLR series, Yamaha XT series.

Key Features

Versatility:

Designed for both on-road and off-road use, offering a balance of performance and practicality.

Durability:

Known for its robust construction and reliability, making it a suitable choice for demanding use.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, disassembly, assembly, inspection, valve adjustments, piston and cylinder inspection, crankshaft and connecting rod checks, camshaft timing.

Engine Fuel System:

Carburetor disassembly, cleaning, adjustment, jetting, fuel pump operation (if applicable), fuel tank and lines.

Engine Ignition System:

CDI ignition system, spark plug specifications, ignition coil testing, troubleshooting ignition failures.

Transmission:

Gearbox disassembly and assembly, clutch operation, gear selection, shift mechanism.

Drivetrain:

Final drive chain and sprockets, lubrication, adjustment, replacement.

Suspension Front:

Telescopic front fork disassembly, service, oil change, seal replacement, spring inspection, damping adjustments.

Suspension Rear:

Monoshock rear suspension system, shock absorber service, linkage lubrication and inspection, swingarm maintenance.

Brakes Front:

Hydraulic disc brake system, caliper inspection and service, brake pad replacement, master cylinder overhaul, brake fluid specifications and bleeding procedures.

Brakes Rear:

Drum brake system inspection, adjustment, shoe replacement, linkage lubrication.

Wheels And Tires:

Spoke wheel maintenance, rim inspection, bearing service, tire pressure recommendations, tire replacement guidelines.

Electrical System:

Lighting system (headlight, taillight, turn signals), wiring diagrams, fuse identification and replacement, battery maintenance and testing, starter motor operation, charging system (stator, regulator/rectifier).

Frame And Bodywork:

Frame inspection, handlebars, seat, fuel tank removal and installation, fender mounting, general body panel service.

Procedures Included

Scheduled Maintenance:

Detailed service intervals for oil changes, filter replacements, valve clearance checks, chain adjustment, brake inspections, and other routine maintenance tasks.

Troubleshooting:

Diagnostic procedures for common problems, fault finding charts, symptom-based troubleshooting guides for engine performance, electrical issues, and starting problems.

Repair Procedures:

Step-by-step instructions for component removal, installation, adjustment, and rebuilding for all major vehicle systems.

Torque Specifications:

Essential torque values for critical fasteners throughout the motorcycle, ensuring proper assembly and preventing damage.

Wiring Diagrams:

Comprehensive electrical system wiring diagrams for accurate diagnosis and repair of electrical faults.

Technical Depth

Diagnostic Capabilities:

Covers advanced diagnostic techniques for engine performance issues, electrical system faults, and component wear.

Rebuild Instructions:

Detailed procedures for complete engine, transmission, and suspension component rebuilds.

Adjustment Procedures:

Precise instructions for adjusting carburetor mixture, idle speed, valve clearances, chain tension, and brake systems.

Special Tools:

Identification of specialized tools required for specific maintenance and repair tasks.

📊 Manual Specifications

File Format

File Format:

Searchability:

Searchable text for quick information retrieval.

Print Quality:

High-resolution, printable pages.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC, air-cooled, single-cylinder

Displacement:

299 cc (approx.)

Bore X Stroke:

72.0 mm x 73.2 mm (approx.)

Compression Ratio:

9.5:1 (approx.)

Valve Train:

SOHC, 2 valves per cylinder

Performance

Horsepower:

Approximately 25-30 HP (specific figures may vary slightly by region and tuning)

Torque:

Approximately 20-24 Nm (specific figures may vary)

Fuel System

Fuel Delivery:

Mikuni VM33SS carburetor

Fuel Type:

Unleaded gasoline

Fuel Capacity:

10.0 L (2.6 US gal, approx.)

Cooling System

Cooling Method:

Air-cooled

🔧 Transmission

Standard

Transmission Type:

Constant-mesh, 6-speed sequential

Clutch Type:

Wet, multi-plate

Gear Ratios:

Specific gear ratios are detailed within the manual for each gear.

Features

Final Drive:

O-ring sealed chain, 520 pitch

📐 Dimensions

Exterior

Length:

Approx. 2170 mm (85.4 in)

Width:

Approx. 825 mm (32.5 in)

Height:

Approx. 1195 mm (47.0 in)

Wheelbase:

Approx. 1435 mm (56.5 in)

Weights

Dry Weight:

Approx. 113 kg (249 lbs)

Wet Weight:

Approx. 125 kg (276 lbs) (with all fluids)

Maximum Load:

Refer to manual for specific load ratings.

🛡️ Safety Features

Ratings

Safety Certification:

N/A (Motorcycles typically do not have the same formal safety ratings as cars; focus on mechanical safety features.)

Active Features

Braking System:

Hydraulic front disc brake, rear drum brake providing effective stopping power.

Lighting:

Headlight, taillight, and brake light for visibility.

Passive Features

Frame Construction:

Steel frame providing structural integrity.

Ergonomics:

Designed for rider control and comfort in various riding conditions.

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a 1992 motorcycle; no advanced infotainment features.)

Driver Assistance

Driver Assistance Features:

N/A (This is a 1992 motorcycle; no electronic rider aids.)

Connectivity

Connectivity Options:

N/A (This is a 1992 motorcycle; no connectivity features.)

🔧 Maintenance

Service Intervals

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.

Valve Clearance Check:

Every 6,000 km (3,600 miles).

Air Filter Cleaning:

Every 1,500 km (900 miles) or more frequently in dusty conditions.

Chain Lubrication Adjustment:

Every 500 km (300 miles) and after washing or riding in the rain.

Fluid Specifications

Engine Oil:

SAE 10W-40 API SE, SF or SG classification (Check manual for specific grade recommendations).

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:

SAE 10W (Check manual for exact specification and volume per fork leg).

Brake Fluid:

DOT 3 or DOT 4 (Check manual for specific recommendations).

Known Issues

Carburetor Cleaning:

Mikuni carburetors can be prone to clogging if fuel is not fresh or if the bike sits for extended periods.

Clutch Cable:

Clutch cable adjustment and lubrication are important for smooth operation.

Rear Shock Seals:

Over time, rear shock seals can degrade, leading to oil leakage and reduced damping performance.

Countershaft Seal:

The countershaft seal can sometimes develop leaks, requiring replacement.

📚 Vehicle History

Brand Heritage

Suzuki Legacy:

Suzuki has a long and successful history in motorcycle manufacturing, known for innovation and performance across various categories.

Model Evolution

Dr Series:

The DR series represents Suzuki's commitment to versatile dual-sport motorcycles, with the DR350 being a significant model offering a balance of off-road capability and street usability.

Production

Production Years:

The DR350 was produced from the late 1980s through the late 1990s, with the 1992 model being a key iteration.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While specific awards for the 1992 DR350N/SN are not widely documented, the DR series generally received positive reviews for its performance and value within the dual-sport segment.