Suzuki DR350 DR350S 1990-1999 Service Repair Manual
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This service repair manual covers the DR350 and DR350S models produced from 1990 through 1999. These dual-sport motorcycles are recognized for their versatility, effectively bridging the gap between off-road capability and on-road usability. Engineered by, the DR350 is powered by a 348cc air-cooled, four-stroke engine, typically featuring a Mikuni carburetor and a 5-speed manual transmission. Known for their reliability and robust design, these models are a popular choice for riders seeking an adaptable machine for various terrains and riding conditions. This comprehensive English-language service repair manual provides in-depth information for maintaining and repairing your DR350/DR350S. It covers all essential systems, including the engine, fuel system, cooling system, clutch, lubrication, drivetrain, wheels, tires, brakes, suspension, steering, frame, and electrical system. The manual offers detailed, step-by-step instructions for routine maintenance, component disassembly and reassembly, and troubleshooting. With hundreds of pages of content, it is an invaluable resource for both DIY enthusiasts and professional mechanics aiming to keep their motorcycles in optimal condition. 🏷️ Basic Information Identification Make: Suzuki Model: DR350 Model Variant: DR350S Model Years Covered: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Product Type: Service Repair Manual Digital Format: PDF Download 👋 Introduction Market Position Target Audience: DIY mechanics and experienced professionals seeking detailed repair and maintenance information for their Suzuki DR350/DR350S. Competitive Analysis Advantage: Offers a cost-effective and convenient digital alternative to expensive and cumbersome paper manuals. Key Features Completeness: Complete official full factory service repair manual with hundreds of pages of detailed information. Detail Level: Provides step-by-step instructions based on complete disassembly, supported by hundreds of photos and illustrations. Convenience: Instant download, accessible on multiple devices, and printable for workshop use. 📋 Manual Details Coverage Areas General Information: Covered Fuel System: Covered Cooling System: Covered Engine Top End: Covered Clutch: Covered Engine Lubrication System: Covered Engine Removal Installation: Covered Crankshaft Transmission: Covered Wheels Tires: Covered Final Drive: Covered Brakes: Covered Suspension: Covered Steering: Covered Frame: Covered Electrical System: Covered Appendix: Covered Page Count Estimated Pages: Hundreds of pages Manual Type Type: Official Full Factory Service Repair Manual Language Language: English Format File Format: PDF Accessibility: Downloadable, Viewable on PC, Laptop, Smartphone, Tablet, Web Browser 📖 Manual Coverage Systems Covered Engine Systems: Includes top end, lubrication, cooling, fuel system, and engine removal/installation procedures. Drivetrain Systems: Covers clutch, crankshaft, transmission, wheels, tires, and final drive components. Chassis Systems: Encompasses brakes, suspension, steering, and frame components. Electrical Systems: Detailed coverage of the vehicle's electrical system. Procedures Included Maintenance: Routine maintenance, fluid changes, filter replacements, and general upkeep procedures. Repair: Step-by-step repair instructions for all major mechanical and electrical components, including complete disassembly and reassembly. Troubleshooting: Implied through detailed diagnostic information and specific repair procedures for common issues. Technical Depth Depth: Comprehensive coverage suitable for both DIY enthusiasts and experienced mechanics, with detailed instructions and illustrations. 📊 Manual Specifications File Format Compatibility: Compatible with all versions of Windows and Mac operating systems. Software Requirements: Requires Adobe PDF Reader and Winzip (both free). Print Quality Printability: Fully printable, allowing users to print entire manual or specific pages. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, 4-stroke, SOHC, 1-cylinder Displacement: 348cc (Note: Exact displacement might vary slightly across specific model years or sub-models within the DR350 range, the manual covers this). Performance Horsepower: Approx. 30-34 HP (Varies by year and tuning, manual will provide specific figures). Torque: Approx. 22-24 lb-ft (Varies by year and tuning, manual will provide specific figures). Fuel System Carburetor Type: Mikuni VM33SS (typical for this model, manual will confirm specific jetting and settings). Fuel Type: Unleaded gasoline (manual will specify octane rating). 🔧 Transmission Standard Transmission Type: 5-speed manual Optional Optional Transmissions: N/A Features Clutch Type: Wet multi-plate 📐 Dimensions Exterior Length: Refer to manual for specific dimensions as they can vary slightly by year. Width: Refer to manual for specific dimensions. Height: Refer to manual for specific dimensions. Weights Dry Weight: Approx. 277-282 lbs (126-128 kg) (Varies by model year and equipment, manual will provide exact figures). 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle specific safety features are detailed in manual, not typically rated by agencies like NHTSA). Active Features Braking System: Front: Disc brake; Rear: Disc brake (Drum brake on some earlier models, manual covers both if applicable). Passive Features Lighting: Headlight, taillight, brake light, turn signals (manual covers electrical system related to these). 💡 Technology Features Infotainment Infotainment Features: N/A (This era of dual-sport motorcycle did not feature electronic infotainment systems). Driver Assistance Assistance Systems: N/A (No electronic driver assistance features) Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 2,000 miles or 6 months, but the manual will provide specific Suzuki recommendations. Spark Plug Maintenance: Refer to manual for recommended replacement or inspection intervals. Chain Lubrication:...
This service repair manual covers the DR350 and DR350S models produced from 1990 through 1999. These dual-sport motorcycles are recognized for their versatility, effectively bridging the gap between off-road capability and on-road usability. Engineered by, the DR350 is powered by a 348cc air-cooled, four-stroke engine, typically featuring a Mikuni carburetor and a 5-speed manual transmission. Known for their reliability and robust design, these models are a popular choice for riders seeking an adaptable machine for various terrains and riding conditions.
This comprehensive English-language service repair manual provides in-depth information for maintaining and repairing your DR350/DR350S. It covers all essential systems, including the engine, fuel system, cooling system, clutch, lubrication, drivetrain, wheels, tires, brakes, suspension, steering, frame, and electrical system. The manual offers detailed, step-by-step instructions for routine maintenance, component disassembly and reassembly, and troubleshooting. With hundreds of pages of content, it is an invaluable resource for both DIY enthusiasts and professional mechanics aiming to keep their motorcycles in optimal condition.
DIY mechanics and experienced professionals seeking detailed repair and maintenance information for their Suzuki DR350/DR350S.
Competitive Analysis
Advantage:
Offers a cost-effective and convenient digital alternative to expensive and cumbersome paper manuals.
Key Features
Completeness:
Complete official full factory service repair manual with hundreds of pages of detailed information.
Detail Level:
Provides step-by-step instructions based on complete disassembly, supported by hundreds of photos and illustrations.
Convenience:
Instant download, accessible on multiple devices, and printable for workshop use.
📋 Manual Details
Coverage Areas
General Information:
Covered
Fuel System:
Covered
Cooling System:
Covered
Engine Top End:
Covered
Clutch:
Covered
Engine Lubrication System:
Covered
Engine Removal Installation:
Covered
Crankshaft Transmission:
Covered
Wheels Tires:
Covered
Final Drive:
Covered
Brakes:
Covered
Suspension:
Covered
Steering:
Covered
Frame:
Covered
Electrical System:
Covered
Appendix:
Covered
Page Count
Estimated Pages:
Hundreds of pages
Manual Type
Type:
Official Full Factory Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
Accessibility:
Downloadable, Viewable on PC, Laptop, Smartphone, Tablet, Web Browser
📖 Manual Coverage
Systems Covered
Engine Systems:
Includes top end, lubrication, cooling, fuel system, and engine removal/installation procedures.
Drivetrain Systems:
Covers clutch, crankshaft, transmission, wheels, tires, and final drive components.
Chassis Systems:
Encompasses brakes, suspension, steering, and frame components.
Electrical Systems:
Detailed coverage of the vehicle's electrical system.
Procedures Included
Maintenance:
Routine maintenance, fluid changes, filter replacements, and general upkeep procedures.
Repair:
Step-by-step repair instructions for all major mechanical and electrical components, including complete disassembly and reassembly.
Troubleshooting:
Implied through detailed diagnostic information and specific repair procedures for common issues.
Technical Depth
Depth:
Comprehensive coverage suitable for both DIY enthusiasts and experienced mechanics, with detailed instructions and illustrations.
📊 Manual Specifications
File Format
Compatibility:
Compatible with all versions of Windows and Mac operating systems.
Software Requirements:
Requires Adobe PDF Reader and Winzip (both free).
Print Quality
Printability:
Fully printable, allowing users to print entire manual or specific pages.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, SOHC, 1-cylinder
Displacement:
348cc (Note: Exact displacement might vary slightly across specific model years or sub-models within the DR350 range, the manual covers this).
Performance
Horsepower:
Approx. 30-34 HP (Varies by year and tuning, manual will provide specific figures).
Torque:
Approx. 22-24 lb-ft (Varies by year and tuning, manual will provide specific figures).
Fuel System
Carburetor Type:
Mikuni VM33SS (typical for this model, manual will confirm specific jetting and settings).
Fuel Type:
Unleaded gasoline (manual will specify octane rating).
🔧 Transmission
Standard
Transmission Type:
5-speed manual
Optional
Optional Transmissions:
N/A
Features
Clutch Type:
Wet multi-plate
📐 Dimensions
Exterior
Length:
Refer to manual for specific dimensions as they can vary slightly by year.
Width:
Refer to manual for specific dimensions.
Height:
Refer to manual for specific dimensions.
Weights
Dry Weight:
Approx. 277-282 lbs (126-128 kg) (Varies by model year and equipment, manual will provide exact figures).
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle specific safety features are detailed in manual, not typically rated by agencies like NHTSA).
Active Features
Braking System:
Front: Disc brake; Rear: Disc brake (Drum brake on some earlier models, manual covers both if applicable).
Passive Features
Lighting:
Headlight, taillight, brake light, turn signals (manual covers electrical system related to these).
💡 Technology Features
Infotainment
Infotainment Features:
N/A (This era of dual-sport motorcycle did not feature electronic infotainment systems).
Driver Assistance
Assistance Systems:
N/A (No electronic driver assistance features)
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 2,000 miles or 6 months, but the manual will provide specific Suzuki recommendations.
Spark Plug Maintenance:
Refer to manual for recommended replacement or inspection intervals.
Chain Lubrication:
Regularly recommended, frequency depends on riding conditions (detailed in manual).
Fluid Specifications
Engine Oil Type:
Suzuki recommends specific SAE viscosity grades (e.g., 10W-40 or 20W-50) and JASO MA compliant motorcycle oil. Manual will specify exact type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (manual will confirm exact specification).
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, fork seals, and electrical connectors can be common wear items.
Potential Problems:
Some models may experience occasional carburetor jetting issues, electrical connection corrosion, or stator/regulator problems over time (manual will aid in diagnosis).
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation
Model Evolution
Dr Series Context:
The DR350 was a popular dual-sport motorcycle known for its versatility, bridging the gap between off-road capability and on-road usability. It evolved from earlier DR models and was later succeeded by the DR-Z series.
Production
Production Years:
1990-1999
🏆 Awards & Recognition
Recognitions
Industry Recognition:
While specific awards for the DR350 are not widely documented, it was generally well-regarded in its segment for reliability and versatility.
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