Category:
Dual-sport motorcycle
Target Audience:
Off-road enthusiasts, commuters, light touring riders
Competitors:
Honda XR series, Kawasaki KLR series, Yamaha XT series
Versatility:
Designed for both on-road and off-road use, offering a balance of capability and user-friendliness.
Reliability:
Known for its robust engine and durable components, making it a popular choice for long-term ownership.
Simplicity:
Relatively simple mechanical design compared to more modern, complex motorcycles, making maintenance and repairs more accessible.
Years Covered:
1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001
Regions Covered:
Global (with potential regional variations noted)
Page Count:
Approximately 300-400 pages (estimated for a comprehensive service manual of this era)
Manual Type:
Complete Repair & Service Manual
Engine:
Engine overhaul, top-end (cylinder head, valve train), bottom-end (crankshaft, connecting rod, piston), lubrication system, cooling system (air-cooled, oil cooler if applicable)
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel tank, fuel lines, fuel pump (if applicable)
Transmission:
Clutch (operation, adjustment, replacement), gearbox (disassembly, inspection, reassembly), shift mechanism
Drivetrain:
Final drive (chain maintenance, sprocket replacement), swingarm, rear suspension linkage
Brakes:
Front and rear brake systems (disc brakes), hydraulic components (master cylinder, caliper, brake lines), pad replacement, bleeding procedure
Suspension:
Front telescopic forks (fork seal replacement, oil change, internal inspection), rear monoshock absorber (adjustment, rebuild)
Electrical System:
Ignition system (spark plug, coil, CDI unit), lighting system (headlight, taillight, indicators), starting system (kick starter, electric starter components for SE models), charging system (stator, regulator/rectifier), battery, wiring diagrams
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fuel tank, fenders, handlebars, controls
Maintenance:
Routine checks, oil changes, filter replacements, chain adjustment, brake adjustments, valve clearance checks and adjustment
Troubleshooting:
Diagnostic charts and procedures for common performance issues, electrical faults, and mechanical problems
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly, including detailed torque specifications
Rebuilds:
Comprehensive guides for engine, transmission, and suspension component rebuilds
Depth:
Comprehensive, covering everything from basic user maintenance to complete engine and chassis overhauls. Includes detailed specifications and diagnostic procedures.
Engine Type:
Four-stroke, SOHC, single-cylinder, air-cooled
Bore X Stroke:
80.0 mm x 69.0 mm
Horsepower Approximate:
28-30 HP @ 7000 RPM (varies by year and tuning)
Torque Approximate:
25-27 lb-ft @ 5500 RPM (varies by year and tuning)
Fuel Delivery:
Mikuni VM33SS carburetor
Fuel Type:
Unleaded gasoline
Oil Type:
SAE 10W-40 API SG or higher (refer to manual for specific recommendations)
Oil Capacity:
Approximately 1.7 Liters (1.8 US qt) with filter change
Ignition System:
CDI (Capacitor Discharge Ignition)
Starting Method:
Kick start (all models), Electric start (DR350S, DR350SE)
Length:
Approximately 2200 mm (86.6 in)
Width:
Approximately 820 mm (32.3 in) at handlebars
Height:
Approximately 1175 mm (46.3 in) at seat
Wheelbase:
Approximately 1450 mm (57.1 in)
Ground Clearance:
Approximately 260 mm (10.2 in)
Dry Weight:
Approximately 123 kg (271 lbs) for DR350S, 127 kg (280 lbs) for DR350SE
Wet Weight:
Approximately 135 kg (298 lbs) for DR350S, 139 kg (306 lbs) for DR350SE (estimated with fluids)
Fuel Capacity:
13 Liters (3.4 US gal)
Safety Ratings:
N/A (Motorcycles are not typically rated by agencies like NHTSA or Euro NCAP in the same way as cars.)
Braking System:
Hydraulic disc brakes front and rear
Lighting:
Halogen headlight, taillight, brake light, turn signals
Frame Construction:
Steel semi-double cradle frame
Oil Change Interval:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first (refer to manual for exact schedule)
Air Filter Cleaning Interval:
Every 1,000 km (600 miles) or as needed in dusty conditions
Valve Clearance Check Interval:
Every 6,000 km (3,600 miles)
Spark Plug Replacement Interval:
Every 12,000 km (7,200 miles)
Engine Oil Specification:
SAE 10W-40 API SG or higher
Brake Fluid Specification:
DOT 4
Fork Oil Specification:
Suzuki Fork Oil SS-05 or equivalent (e.g., 10W fork oil), 450ml per fork leg (refer to manual for exact type and quantity)
Common Problems:
Carburetor performance issues (jetting for altitude/modifications), clutch wear, occasional starter clutch wear (SE models), suspension seal leaks.
Preventative Maintenance:
Regular chain lubrication and adjustment, proper carburetor cleaning and adjustment, timely oil and filter changes are crucial for longevity.
Suzuki Motorcycles:
Suzuki has a long history of producing reliable and capable motorcycles, with a strong presence in off-road and dual-sport segments.
Dr350 Lineage:
The DR350 was a significant model in Suzuki's dual-sport lineup, evolving from earlier DR models and bridging the gap to later, more technologically advanced machines.
Key Updates:
Introduction of electric start (DR350S/SE) and significant updates to suspension and engine tuning throughout its production run.
Production Years:
1990-2001
Manufacturing Location:
Japan
