🏷️ Basic Information

Make:

Suzuki

Model:

DR350

Generation:

1st Generation

Engine Type:

4-stroke, single-cylinder, OHC, 4-valve

👋 Introduction

Category:

Dual-sport motorcycle

Target Audience:

Riders seeking a versatile, reliable, and capable off-road and on-road machine; DIY mechanics and professional technicians

Competitors:

Honda XR series, Kawasaki KLR series, Yamaha XT series

Versatility:

Capable of both on-road commuting and off-road exploration

Reliability:

Known for its robust and durable engine and chassis

Simplicity:

Relatively straightforward mechanical design, making maintenance accessible

Off-Road Capability:

Sufficient ground clearance, suspension travel, and rugged construction for trail riding

📋 Manual Details

Model Years Covered:

1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999

Total Pages:

398

Type:

Workshop Service Manual / Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine:

Complete overhaul, disassembly, assembly, tuning, troubleshooting

Fuel System:

Carburetor service, fuel tank, fuel lines, fuel pump (if applicable)

Ignition System:

CDI, spark plug, ignition timing

Lubrication System:

Oil pump, oil filter, oil passages, lubrication specifications

Cooling System:

Air-cooled system, cylinder head and barrel cooling fins

Transmission:

Gearbox disassembly, assembly, inspection, lubrication, shift mechanism

Clutch:

Clutch operation, disassembly, assembly, adjustment, friction plates

Suspension:

Front fork (telescopic), rear shock absorber (monoshock), linkage, adjustments

Brakes:

Front and rear brake systems (disc or drum depending on variant), hydraulic system, pad/shoe replacement, bleeding

Wheels And Tires:

Wheel bearing inspection, tire pressure, spoke tension (if applicable)

Electrical System:

Wiring diagrams, lighting system, battery, charging system, starting system, fuses, switches

Frame And Body:

Frame inspection, body panel removal and installation, seat, fuel tank, fenders

Controls:

Throttle control, clutch lever, brake lever, foot controls, cable adjustments

Exhaust System:

Exhaust pipe and muffler maintenance

Maintenance:

Routine checks, periodic maintenance, lubrication points, fluid changes

Troubleshooting:

Systematic diagnosis of common problems, fault finding charts

Repair:

Detailed step-by-step repair instructions for all major components

Disassembly:

Component breakdown procedures with pictorial guidance

Assembly:

Reassembly procedures with emphasis on correct component fitting

Adjustments:

Carburetor adjustment, clutch adjustment, throttle cable adjustment, suspension settings

Testing And Inspection:

Component testing procedures, wear limits, diagnostic checks

Depth:

Comprehensive, from basic maintenance to full engine rebuilds and electrical diagnostics

Pictorial Representation:

Detailed illustrations, exploded diagrams, and photographs guiding each procedure

Special Tools:

Identification and usage instructions for specific Suzuki service tools

Torque Specifications:

Precise torque values for all critical fasteners and threaded connections

Wear Limits:

Specifications for acceptable wear on engine components, bearings, etc.

📊 Manual Specifications

Compatibility:

Windows, Mac, Linux OS

Printability:

Yes, all pages are printable

Binding:

Digital (PDF) - Instant Download

Digital Quality:

High-resolution PDF suitable for viewing and printing

Reader Requirement:

Adobe Reader (or compatible PDF viewer)

⚙️ Engine Specifications

Displacement:

346cc (variants may exist, e.g., 349cc for some models)

Bore X Stroke:

74.0 mm x 80.0 mm (typical)

Compression Ratio:

9.2:1 to 9.7:1 (depending on variant)

Valve Train:

SOHC, 4 valves

Horsepower:

Approx. 25-30 HP (at crankshaft, depending on year/tuning)

Torque:

Approx. 20-24 Nm (at crankshaft, depending on year/tuning)

Carburetor:

Mikuni VM33SS (typical), constant velocity carburetor

Fuel Type:

Unleaded gasoline, 91 octane (RON + MON)/2 or higher recommended

Ignition Type:

CDI (Capacitor Discharge Ignition)

Oil Type:

SAE 10W-40 motorcycle oil, API SG or higher

Oil Capacity:

Approx. 1.7 - 1.8 liters (with filter change)

🔧 Transmission

Type:

5-speed constant mesh

Final Drive:

Chain drive

Transmission Variants:

No automatic or alternative transmissions offered

Clutch Type:

Wet, multi-plate

Transmission Oil Type:

SAE 80 or 90 API GL-4 gear oil

Transmission Oil Capacity:

Approx. 0.9 - 1.0 liters

📐 Dimensions

Length:

Approx. 2225 mm (930 Series), 2180 mm (SE/S)

Width:

Approx. 820 mm (930 Series), 815 mm (SE/S)

Height:

Approx. 1240 mm (930 Series), 1220 mm (SE/S)

Wheelbase:

Approx. 1450 mm

Ground Clearance:

Approx. 285 mm (930 Series), 300 mm (SE/S)

Dry Weight:

Approx. 122 kg (930 Series), 117 kg (SE/S)

Curb Weight:

Approx. 134 kg (with fluids, depending on variant)

Fuel Tank Capacity:

Approx. 10 liters (including 2.5L reserve)

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycle safety is assessed through independent road tests and manufacturer compliance)

Brakes:

Disc brakes (front and rear on most models), enhancing stopping power

Lighting:

Headlight, taillight, brake light, turn signals for visibility

Frame Construction:

Robust steel frame designed for durability and stability

Suspension:

Absorbs road imperfections, providing a stable ride

💡 Technology Features

Infotainment System:

N/A (This is a 1990s era motorcycle, no digital infotainment systems)

ABS:

N/A (ABS was not available on the DR350)

Electric Start:

Available on DR350SE models from 1994 onwards; standard on most other models is kickstarting.

🔧 Maintenance

Oil Change Interval:

Every 3,000 km or 6 months, whichever comes first

Oil Filter Replacement:

With every oil change

Air Filter Cleaning:

Every 1,000 km or more frequently in dusty conditions

Spark Plug Replacement:

Every 6,000 km or as needed based on inspection

Chain Lubrication Inspection:

Every 500 km or as needed

Valve Clearance Check:

Every 6,000 km or as specified in the manual

Engine Oil:

SAE 10W-40 motorcycle oil, API SG or higher

Brake Fluid:

DOT 3 or DOT 4 (refer to specific year's manual for exact type)

Fork Oil:

SAE 10W (typically, but manual will specify exact type and viscosity)

Carburetor Jetting:

Can be sensitive to altitude and modifications; requires proper jetting for optimal performance.

Suspension Seals:

Fork seals can wear over time, leading to leaks; rear shock can lose damping effectiveness.

Cam Chain Tensioner:

Can become noisy if not maintained; manual will detail inspection and replacement procedures.

Electrical Connections:

Corrosion or loose connections can cause intermittent electrical issues, especially in older bikes.

Kickstand Switch:

On some models, the kickstand safety switch can fail, preventing starting.

📚 Vehicle History

Brand Focus:

Suzuki has a long history of producing reliable and performance-oriented motorcycles, particularly in the dual-sport and off-road segments.

Predecessors:

Followed Suzuki's tradition of popular dual-sport models like the TS series.

Key Developments:

The DR350 introduced a reliable 4-stroke engine to a segment often dominated by 2-strokes or less powerful 4-strokes, offering a balance of performance and usability. Later models (post-1994) featured significant upgrades like electric start (DR350SE) and improved suspension. This manual covers the evolution of the DR350 throughout its production run, likely including details on these variations.

Production Period:

The DR350 was produced from 1990 to 1999. This manual specifically covers the 1991-1999 models.

🏆 Awards & Recognition

Motorcycle Journal Awards:

The DR350 was generally well-received by the motorcycle press for its balance of performance, reliability, and value, often lauded as a capable all-rounder.

User Satisfaction:

High user satisfaction due to its longevity and ease of maintenance.

Emission Standards:

Meets emission standards for its respective production years; manual will contain relevant specifications.