Bike Type:
Dual-sport motorcycle, known for its versatility on and off-road.
Target Audience:
Riders seeking a capable and relatively simple machine for commuting, trail riding, and adventure touring.
Key Competitors:
Honda XR series, Kawasaki KLR series, Yamaha XT series of the same era.
Engine Configuration:
Single-cylinder, four-stroke engine, often with a focus on reliability and accessible torque.
Suspension Setup:
Long-travel suspension designed for off-road capability, often featuring adjustable front forks and a rear monoshock.
Durability Simplicity:
Known for robust construction and relatively straightforward mechanicals, making them easier to maintain.
Engine Systems:
Engine disassembly, assembly, troubleshooting, tuning, carburetion, lubrication, cooling (air-cooled), ignition system, exhaust system.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox disassembly and assembly, final drive (chain and sprockets) inspection and replacement.
Chassis Suspension:
Front fork (telescopic, possibly with adjustable damping on some variants) disassembly, servicing, and replacement; rear shock absorber (monoshock) servicing and adjustment; swingarm and linkage maintenance.
Braking System:
Front and rear disc brake systems, caliper maintenance and rebuild, hydraulic system bleeding, brake pad replacement, master cylinder inspection.
Electrical System:
Wiring diagrams, lighting system (headlight, taillight, turn signals), battery maintenance, charging system (stator, regulator/rectifier), starter system, ignition system components (CDI unit, spark plug).
Fuel System:
Fuel tank inspection and cleaning, fuel petcock operation, fuel lines, carburetor model identification, disassembly, cleaning, reassembly, jetting specifications, float bowl adjustment.
Bodywork Frame:
Seat removal, fuel tank mounting, side cover removal, fender inspection and replacement, frame inspection for damage or cracks.
Maintenance Procedures:
Oil changes, oil filter replacement, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, tire pressure checks, brake fluid level checks, valve clearance adjustment.
Repair Procedures:
Complete engine rebuild, carburetor overhaul, fork seal replacement, shock absorber servicing, brake caliper rebuild, electrical component troubleshooting and replacement.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon problems, fault finding charts based on symptoms.
Depth Of Information:
Highly detailed, suitable for professional mechanics and experienced DIY enthusiasts. Covers complete disassembly, rebuilding, and tuning of all major components.
Diagnostic Capabilities:
Includes specific diagnostic steps, measurement specifications (e.g., compression, clearances), and troubleshooting flowcharts.
File Format Details:
PDF (Portable Document Format), generally well-scanned with searchable text if OCR has been applied. Allows for easy navigation and printing.
Print Quality Recommendation:
Optimized for digital viewing and printing. Graphics and diagrams are typically clear and legible.
Binding Type Original Manual:
Typically a saddle-stitched or perfect-bound booklet for original printed versions.
Paper Type Original Manual:
Durable paper stock suitable for workshop environments.
Engine Type:
Four-stroke, air-cooled, SOHC
Displacement:
346 cc (21.1 cubic inches)
Bore X Stroke:
78.0 mm x 72.0 mm (approximate, may vary slightly by sub-model or region)
Compression Ratio:
9.4:1 (typical, may vary)
Valve Train:
SOHC, 2 valves per cylinder
Horsepower Approximate:
26-30 hp @ 7,000-8,000 rpm (varies by year and tuning)
Torque Approximate:
20-23 lb-ft @ 5,000-6,000 rpm (varies by year)
Carburetor Type:
Mikuni VM33 (or similar constant velocity carburetor) for most models.
Fuel Capacity:
3.4 US gallons (12.9 liters) (approximate, check specific model)
Fuel Type:
Unleaded gasoline, 87 octane or higher recommended.
Ignition System:
CDI (Capacitor Discharge Ignition)
Oil Type:
SAE 10W-40 API SG or higher motorcycle specific oil.
Oil Capacity:
1.7 US quarts (1.6 liters) with filter change.
Oil Filter Type:
Internal oil filter element, typically requires specific Suzuki part number.
Transmission Type:
5-speed constant mesh sequential gearbox.
Optional Gearbox:
N/A (standard 5-speed for this generation).
Clutch Type:
Wet multi-plate clutch, cable actuated.
Final Drive:
O-ring sealed chain drive.
Gear Ratios:
Specific ratios detailed in the manual for each gear. (e.g., 1st: 2.5, 2nd: 1.77, 3rd: 1.33, 4th: 1.09, 5th: 0.92 - typical range, check manual for exact numbers)
Transmission Oil Type:
Manual specifies gearbox oil type; typically similar to engine oil or specific gear oil if separate.
Overall Length:
Approx. 2,200 mm (86.6 in)
Overall Width:
Approx. 850 mm (33.5 in)
Overall Height:
Approx. 1,250 mm (49.2 in)
Wheelbase:
Approx. 1,430 mm (56.3 in)
Ground Clearance:
Approx. 285 mm (11.2 in)
Dry Weight:
Approx. 113 kg (249 lbs)
Curb Weight:
Approx. 120 kg (265 lbs) (with fluids)
Front Suspension Travel:
Approx. 10.4 inches (265 mm)
Rear Suspension Travel:
Approx. 10.4 inches (265 mm)
Seat Height:
Approx. 34.8 inches (885 mm)
Safety Certification Standards:
Meets relevant EPA and DOT regulations for street-legal motorcycles in its production era. Specific crash test ratings not typically provided for this class of motorcycle.
Braking System:
Dual disc brakes (front and rear) with hydraulic actuation. Offers good stopping power for its class.
Lighting:
Headlight, taillight, brake light, and turn signals for visibility.
Frame Construction:
Steel frame provides structural integrity.
Tire Specification:
Dual-sport tires (e.g., 80/90-21 front, 110/80-18 rear, subject to specific models and user preferences).
Infotainment System:
N/A (Basic motorcycle instrumentation, typically speedometer, odometer, high beam indicator, neutral indicator).
Driver Assistance Features:
N/A (No electronic rider aids like ABS or traction control on these models).
Connectivity Options:
N/A (No Bluetooth, USB, or integrated navigation).
Oil Change Interval:
Every 3,000 km (1,860 miles) or 6 months, whichever comes first. (Refer to manual for precise interval).
Air Filter Cleaning:
Every 2,000 km (1,240 miles) or annually. More frequently in dusty conditions. (Refer to manual).
Spark Plug Replacement:
Every 6,000 km (3,730 miles) or annually. Check gap at 3,000 km. (Refer to manual).
Valve Clearance Check:
Every 6,000 km (3,730 miles) or annually. (Refer to manual for specific values).
Engine Oil Spec:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
Brake Fluid Spec:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Spec:
Not applicable (air-cooled engine).
Carburetor Issues:
Can be prone to clogging if fuel is left stagnant or is contaminated. Accelerator pump diaphragm can wear over time. Pilot jet can be sensitive to dirt.
Suspension Wear:
Fork seals can leak over time, requiring replacement. Rear shock absorber can lose damping capability with high mileage.
Electrical Components:
Voltage regulator/rectifier can be a failure point on older models, leading to charging issues. CDI units are generally robust but can fail.
Decarbonization:
As with any air-cooled engine, carbon buildup in the combustion chamber is normal and may require periodic decarbonization or decoking.
Suzuki Motorcycle Legacy:
Suzuki has a long history in motorcycle manufacturing, known for performance and reliability across various segments including dirt bikes, sportbikes, and cruisers.
Dr Series Development:
The DR series has roots in Suzuki's highly successful RM motocross bikes and DR-Z dual-sport models, often featuring air-cooled engines for simplicity and lighter weight.
Dr350 Specifics:
Introduced as a versatile dual-sport option, the DR350 aimed to bridge the gap between off-road capability and street legal usability. It was produced for many years with various iterations, including kick-start only, electric start, and differing suspension/carburetion setups.
Manufacturing Location:
Primarily Japan.
Production Period:
The DR350 line was produced from the early 1990s through the late 1990s/early 2000s depending on market and specific model variants. The 90-94 manual covers a key early period of its development.
