The 1996 DR350T is a versatile dual-sport motorcycle renowned for its durability and off-road prowess, while also being street-legal for versatile riding. This model embodies a reputation for robust engineering and reliable performance, making it a favored choice for riders seeking adventure on trails and roads alike. Its relatively simple mechanical design contributes to its accessibility for maintenance and repairs, further enhancing its appeal as a dependable companion for various riding conditions. This comprehensive service manual provides detailed guidance for the mechanical repair, maintenance, and troubleshooting of the 1996 DR350T. It covers essential systems including the engine, transmission, fuel system, electrical components, brakes, suspension, and chassis. With extensive information suitable for both amateur enthusiasts and professional technicians, this manual offers step-by-step instructions for routine servicing, complex overhauls, and diagnostic procedures, ensuring the optimal upkeep and longevity of your motorcycle. 🏷️ Basic Information Identification Make: Suzuki Model: DR350T Model Variant: DR350SET Year: 1996 👋 Introduction Market Position Class: Dual-sport / Enduro motorcycle Target Audience: Riders seeking a reliable and versatile off-road and on-road capable motorcycle for adventure, trail riding, and commuting. Competitive Analysis Competitors: Honda XR series, Kawasaki KLR series, Yamaha XT series during its production era. Key Features Versatility: Adaptable for both trail riding and street legal use, making it a popular choice for dual-sport enthusiasts. Durability: Known for its robust construction and reliable single-cylinder engine, capable of enduring demanding conditions. Simplicity: Relatively straightforward mechanical design, making maintenance and repairs more accessible. 📋 Manual Details Coverage Areas Primary Coverage: Mechanical repair, maintenance, and troubleshooting Secondary Coverage: Electrical systems, chassis, and bodywork Page Count Estimated Pages: 300-400 Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, inspection, and repair of engine components, including top-end, bottom-end, valvetrain, cooling system, and lubrication. Transmission: Clutch operation, gearbox disassembly and reassembly, shift mechanism, and related components. Fuel System: Carburetor adjustment, overhaul, and troubleshooting; fuel tank, lines, and pump (if applicable). Electrical System: Ignition system, starting system, charging system, lighting, wiring diagrams, component testing, and troubleshooting. Brakes: Front and rear brake system maintenance, overhaul, bleeding procedures, and component replacement. Suspension: Front fork (telescopic) disassembly, seal replacement, oil levels, and rear shock absorber inspection and service. Chassis And Frame: Frame inspection, steering head bearings, swingarm and linkage maintenance, and wheel bearing service. Bodywork And Trim: Panel removal and installation, seat, fenders, and fuel tank. Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement, valve clearance checks. Troubleshooting: Diagnostic procedures for common issues, symptom-based troubleshooting guides. Overhaul And Rebuild: Detailed step-by-step instructions for complete engine, transmission, and carburetor rebuilds. Adjustment: Carburetor synchronization and adjustment, throttle cable adjustment, brake lever adjustment. Inspection: Comprehensive pre-ride inspection, component wear assessment, and diagnostic checks. Technical Depth Depth: Extensive detail suitable for both intermediate DIY mechanics and professional technicians. Covers basic maintenance to complete engine rebuilds and advanced electrical diagnostics. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Typically text-searchable, allowing for quick location of specific information. Printable: Designed for printing individual pages or the entire manual. Print Quality Quality: Digital PDF format ensures clear, crisp diagrams and text, superior to aged paper copies. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, air-cooled, SOHC, single-cylinder Displacement: 346cc Bore X Stroke: 82.0 mm x 64.0 mm Compression Ratio: 9.5:1 Valve Train: SOHC, 4 valves Performance Horsepower Estimated: Approx. 30-35 HP (varies by tuning and specific model configuration) Torque Estimated: Approx. 28-30 Nm (varies by tuning and specific model configuration) Fuel System Carburetor: Mikuni VM33SS (single, constant velocity) Fuel Type: Unleaded gasoline Ignition Type: CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Type: Constant mesh, 5-speed manual Features Clutch: Wet multi-plate Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 2215 mm (87.2 in) Width: Approx. 830 mm (32.7 in) Height: Approx. 1200 mm (47.2 in) Wheelbase: Approx. 1460 mm (57.5 in) Weights Dry Weight: Approx. 127 kg (280 lbs) Wet Weight: Approx. 140 kg (309 lbs) (with fluids) Fuel Capacity Tank Capacity: 10.0 L (2.6 US gal) 🛡️ Safety Features Ratings Crash Test Data: Not applicable to motorcycles in the same manner as automobiles. Active Features Braking System: Disc brakes front and rear. Front: Hydraulic disc. Rear: Hydraulic disc. Suspension Stability: Telescopic front forks and mono-shock rear suspension contribute to stability and control. Passive Features Lighting: Headlight, taillight, brake lights, turn signals (depending on regional specification). 💡 Technology Features Infotainment System: Not applicable (basic motorcycle design of the era). Driver Assistance Features: None. Connectivity Features: None. 🔧 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. Air Filter...