Suzuki DR350 User manual

SUZUKI MOTOR CO RPORA TJ ON PRINTED IN JAPAN OCTOBER '90 @
99500 - 43019 - 03 E
(,.)

FOREWORD
The SUZUKI OR350 was designed to o ffer su-
perior p erfor man ce thr ough lightweight de si gn,
four st roke - power , engine coun t er -b alancer,
drysump lubrica t ion sys t em and link ty pe rear
suspen tion.
This service manual has been produced primari -
ly fo r experienced me cha n ics whose job is to in-
spec r, adjus t, repair and service SUZUKI
motor cycle . Apprent ice mechanics and " do it
you r self" mechanics w ill also fi nd th is manual to
be an extremely useful guide .
The OR350 . manu fac t ured to s tandard s pe ci fi-
ca t ions. is (he main su b jec t matter of th is manu -
al. H owever. the DR350 machines distribu te d in
your coun tr y might d iffer in mi nor re spec ts fr om
t he standard -s pecification and. if the y do , it is be -
cause some minor modifications (whi ch are of no
consequence in most c ase s as far as servici ng
is concerned) had to be made to comply wi th the
st atu t ory requiremen ts of your coun tr y.
This manual contai ns up ·to· date information at
the t ime of i ts iss ue . Later made mod i fications
and changes WIN be explained to ea ch SU ZUKI
dis t ribu t or in respec ti ve market s, to whom you
are kindly requested (0 make query about up -
dated in format io n, if any .
SUZUKI MOTOR CORPORATION
Mo tor cycle Service De partm en t
GENERAL INFORMA nON
AND TUNE-UP PROCEDURE
ENGINE
FUEL
AND LU8RICA nON
ELECTRICAL SYSTEM
CHASSIS
SERVICING INFORMA nON
DR350S
DR350M ('91-MODELJ
DR350SM ('91-MODELJ
DR350N / DR350SN (' 92 -MODELJ
DR350P / SP ('93-MODELJ
DR350R /SER (' 94 -MODELJ
DR350S /SES ('95 -MODELJ
DR350T / SET (' 96 -MODELJ
DR350V / SEV (' 97 -MODELJ
DR350W /X ('
98 ,'99-MODELSJ
© COPYRIGHT SUZUKI MOTOR CO RP ORA TION 1990
10
11
13
14
15
16
17

VIEW OF DR350L
LEFT SIDE
RIGHT SIDE

ON TENT
VIN AND SERIAL NUMBER LOCATIONS . • .. . . ... .. .. .. . .. . 7-7
FUEL AND OIL RECOMMENDATIONS .. . . . . . . . . • .. . . . .... • 7-7
BREAK - IN PROCEDURES .• . ...•....•• ........ . . .... •... 7·2
SPECIAL MATERIALS .. .....•. . ...•...• . . ...•. . . .. .. .. 7-3
PRECAUTIONS AND GENERAL INSTRUCTIONS .. . . . . .. . . • . • 7-5
SPECIFICATIONS .. ........ . .. . . . ... ... . . .. .. ..• ... . . 1-6

1·1 GENERAL INFORMATION
VIN AND SERIAL NUMBER LOCATIONS
The frame serial numb er or V.I.N. (Vehicle Identif ica tion
Number) <D is st amped on th e steeri ng head pipe. Th e en·
gine serial number ® is l oca ted on the rig ht side of th e
crankcase .
These number are r equired especially for regist ering the
machine and order ing spare parts .
FUEL AND OIL RECOMMENDATIONS
FUEL
For U.S.A. model
1 . Use only unleaded gasoline of at least 87 pump oc tane
( a...pt method) or 91 octane or high er rated by th e
research
method.
2 . SUZUKI r eco mmend s th at cus tomer s us e al co hol free,
unleaded gasoline wh eneve r possible.
3 . Use of blended gasoline containi ng MTBE (M ethy l Ter·
tiary Butyl Ether) is permitted .
4 . Use of blended gasoline/alcohol fuel is permined provided
th at it contains not more than 10 % et hanol. Gaso-
line/
alcoho l fuel may con tain up to 5% methanol if ap-
propriate cosolvents and corrosion in hib ito rs are present.
5 .
If the performance of the vehicle is unsatisfactory while
using blended gasoline/al cohol fuel, you should swi t ch
to alcohol free unleaded gasoline.
6 . Failure to
follow thses guideline co u ld possibly void ap-
plicable
warranty cove rage. Check w ith yo ur fu el sup -
plier
to be sure th at th e fu el you intend to u se meets th e
requir
emen ts l isted above .
For
CANADA model
Use only unl eaded gasoline of at least 87 pump octane
! 6.j-M me th od) or 91 octane or high er fal ed by th e
Research
Method .
For
other models
Gasoline used should be graded 85 - 95 oc tane or higher.
An unleaded gasoline is r ecommended .

ENGINE OIL
For U. S.A . model
SUZUKI recomends the use of SUZUKI PERFORMANCE 4
MOTOR OIL or an oil which is rat ed SE or SF uner the API
(American Petroleum Ins titute) classification system . The
viscos it y r ating is SAE 10W / 40 . If an SAE 10 W/ 40 motor
oil is not available. sel ect an alternat e according to the right
c hart.
For other models
Be
sure that th e engine oil you use comes under AP I clas-
s ifi cat ion of SE or SF and that its viscosity rat ing is SAE
1 0W / 40 . If an SAE 1OW/ 40 mo tor oil is not available, se l ect
the oil vi scosity a cco rding to th e right cha rt .
FRONT FORK OIL
Use fork oil # 10
99000 · 99044·10G , SUZUKI FORK OIL # 10
BRAKE FLUID
Specification and class ifi ca tion : DOT 4
99000 · 23110 : SUZUKI BRAKE FLUID
WARNING :
GENERAL INFORMATION 1·2
MULTIGRADE
10W 30
* Since the brake syste m of this motorycle is filled with a glycol -based brake fluid by the manufac -
turer. do not use or mix different types of fluid such as silicone -based and petroleum -based fluid
for refilling the system. otherwise serious damage will result .
* Do not use any brake fluid taken from oil or used or unsealed containers .
* Never re-use brake fluid left over from the previous servicing and stored for a long period.
BREAK-IN PROCEDURES
During manufacture only th e best possible mate rials are us ed and all ma c hined parts are finished
to a very high standard . but it is still nece ssary to allow the mov ing parts to " BREAK·IN" befor e
subjec ting th e engine to maximum s tre sses. Th e future pe rf ormance and reli abi lity of the engine de -
pends on th e care and restraint exercised during it s early lif e. The general rules are as fol lows.
Keep to th ses break-in thrott le p osition
Initial 10 hours : Less than 1 /2 throttle
Up to 15 hours : less than 3/4 throttle

1·3 GENERAllNFDRMATIDN
SPECIAL MATERIALS
The materials listed bel ow are needed for maintenance work on th e OR350 and shou ld be kept on
hand
for ready use. These items supp l ement su ch standard mat erials as cleaning fluid s. lubricant.
emery clot h and like. H ow to use them and where to use them are described in the t ext of this manual.
METERIAL
For U.s.A . model
SUZUKI SUPER GREASE " A"
99000 · 25030
SUZUKI SILICONE GREASE
99000 · 25100
SUZUKI MOLY PASTE
99000 ·251 40
SUZUKI BOND NO. 1207B
99104-31140
THREAD LOCK " 1342 "
99000 · 32050
For other mod els
SUZUKI SUPER GREASE " A"
99000-25010
SUZUKI SILICONE GREASE
99000 ·2 51 00
SUZUKI MOLY PASTE
99000 - 25140
SUZUKI BOND NO. 1 215
99000 · 31110
THREAD LOCK " 1342 "
99000-32050
PART
• Throttle grip
• Odometer gear bOI(
• Side stand pivot
• Oil seals
• O-ring
•
Front and rear wheel hub bearing
• Steering stem boa ring
• Cushion lever bearings. dust
seals and spacer
• Swi ngarm bear ings
• Caliper skle
• Caliper ute and piston
PAGE
2-2
2-2
2-2
3- 32
3- 47
2-2
6-1, 20
2-2
6· 16
2-2
6-28
6-28
6·5
6· 23
• Rocker arm shafts 3· 15
• De ·co mpression shaft 3·15
• Valve stems 3·21
• Countershaft and driveshaft gears 3·
29
• Piston pin 3- 43
• Camshaft journals and cams 3- 45
• Cam chain tensioner 3· 46
• Cylinder head cove r 2·3
3- 45
• Mating surface 01 l efl and 3- 36
right halves of crankcase
• Front and rear brake caliper 6·5
bolt 6- 23
• Front footrest bolt
• Chain case rear side
mounting
bolt
•
Rear fende, rear side mounting
bolt

GENERAL INFORMATION 1-4
MA T ERIAL
C--- ~ C-~~----C7-C~ ~~ -o C--C----~C------ PART
I- ___ ~ FO ~ ' ~U = .S . A ~- ~ m ~ od = e ~ 1 __ _ For other~m~o ~ d=e ~ I'=--- _ ___ --=--"CC,--------c--,-----,-------j-
PAGE
THREAD
99000 - 32030
"1303" THREAD
99000 - 32110
" '322"
THREAD LOCK SUPER " '303 " THREAD LOCK SUPER " ' 303 "
99000 - 32030 99000-32030
THREAD LOCK SUPER " '303 " THREAD LOCK SUPER " '305 '·
99000 · 32030 99000 - 32100
THREAD LOCK SUPER " '303 "
99000 · 32030
SUZUKI FORK OIL '11-10
99OO().99044-1 OG 11 .0 II
SUZUKI BRAKE FLUID
99000-2311010 .5 LI
THREAD LOCK
99000-32 1 20
•
" '324 "
SUZUKI FORK Oil 11-10
99000-99044-100 11.0 L)
SUZUKI BRAKE FLUIO
99000-23110 CO .5 L)
• Gearshift cam bearing reta i ner
screw
• Pawel lifter screw
• Kick starter lever mounting bolt
• Gearshift cam driven gear boh
• Engine mounting bolls and nuts
• Kick starter pawl guide/ stopper
• Cam sprocket bolts
• Gearshi ft arm stopper
• Magneto rotor nut
• Brake disc bolt
• Front fork 011
• Front and r esl brake
3- 34 , 38
3· 38
3- 34 . 38
3-4
8· 17
3- 38 , 39
3-45
3· 34 , 37
6-'
6· 20
1-2
6· 14
, -2
2·11

1·5 GENERAL INfORMATION
PRECAUTIONS AND GENERAL INSTRUCTIONS
Observe th e foll ow ing items without fail when disasse mbling and reasse mbling motorcycles.
o Do not run e ng ine with littl e or no ven til at ion.
o Be sure to replace pa cki ng s, gaskets. circlips. O-rin gs and co tter p ins wi th new ones .
CAUTION:
Never reuse a circlip . After a eirelip has been removed from a shaft . it should be discarded and a
new circlip must be installed .
When installing a new circlip , cafe must be taken not to expand the end gap larger than required
to slip the eirelip over the shaft.
After installing a circlip, always insure that it is completely s eated in its groove and securely fitted .
o Tighten bolts and nuts fr om th e ones of larger diameter to th ose of s mal ler diame ter. and fr om
inside to outside diagonally, to th e speci fi ed tightening torque.
D Use special tools where specif ied.
a Use speci
fi ed genuine parts a nd re com me nd ed oils.
o
When more th an 2 persons perf orm work t oget her. pay a ttenti on to th e safety of each other.
o
After the reasse mbl y, ch eck parts f or tighteness and operat ion.
o
Treat gasoline. wh ich is ex tr emely fl a mmabl e and highly ex plos iv e. with greatest care. Never use
gasoline as cleaning
solven t.
Warning. Caution and Note are included in this manual occasionally, descri
bing th e foHowing conten ts.
WARNING . . . .. . . The parsonal safety of the rider or bystanders may be involved .
Disregarding
this information could result in per sonal injury.
CAUTION .. _. ... Thses instructions point out special service procedures or precaution s that
must be followed to avoid damaging the machine .
NOTE . ......... This provides special information to make maintenance easier or impor t ant
instructions clearer.
REPLACEMENT PARTS
Whe n yo u replace a ny parts, use only genuine SUZUKI
replacement parts, or their equivalent. Genuine SUZUKI parts
are
high quality pa rt s which are designed and built s pecifi -
cally for SUZUKI vehicles.
CAUTION:
U se of replace ment parts which are not equivalent in Quali-
ty to genuine SUZUKI parts can lead to performance
problems and damage .

SPECIFICA TlONS
DEMENSIDNS AND DRY MASS
Overall length .. _ ... _ 2
165 mm 185.2
in)
Overall width .. ..... 885 mm 134.8
in)
Overall height ....... 1 250 mm 149.2 in)
Whee lb ase ....... .. 1440 mm 156.7
in)
Ground clearance .. .. 310 mm 11 2.2
in)
Seat height ........ 920 mm 136.2
in)
Dry mass .......... 113 kg 1249
Ibs)
ENGINE
Type .... _. _. . . . .. Four-stroke, air-cooled,
GENERAL INFORMATION 1·6
ELECTRICAL
I
't ' t SUZUKI " PEl "
9"' I on ype ....... .
I gnition timing . . . . .. 5 ° B.T.D .C. below
2 300 rIm in and
30 ° B.T.D.C. above
4 300 r/ min
Spark plug ........ . NGK DPR9EA -9 or
NIPPON DENSO
X27EPR-U9
OHC CHASSIS
Number of cylinders .. 1
Bore . . . . . . . . . . . . . 79 .0 mm (3.'10 in)
Stroke .... _. . ..... 71 .2 mm (2.803 in)
Piston displacement. . 349 em) (21.3 cu. in)
Compression rati o... 9, 5 : 1
Carburator . . , ..... . MIKUNI
TM33SS .
single
Air cleaner .. . ...... Polyurethane foam
el ement
Starter system . . . . .. Primary kick
Lubri cation sys tem. . . Dry sump
TRNSMISSION
C lut ch . . . . . . . . . . .. Wet multi - plate typ e
Transmi s sion. . . . . .. 6-speed constant mesh
Gearshift pattern .... 1- down , 5- up
Primary reduction .... 2. 818 (62 / 22)
Final redu ctio n ...... 3. 357 ( 47 11 4)
Gear rati os, Low .... 2.416 (29 / 12)
2nd . . .. 1. 733 126/15)
3rd . . .. 1.333 12 4 / 18)
4th . . .. 1. 111 120 / 18)
5th .... 0.952120 / 21)
TOP .... 0.826 119 / 23)
Dri ve chain ... . ... . TAKASAGO RK520S0
or DA IDO DID .
520VC5. 110 link s
Front sus pens ion .... Tele scop ic, coil spring ,
oil damped , spring
preload fully way ad-
justable , compression
damping force ad -
justab le
Rear
suspension . . . . . Link type suspension
sys tem , gas loi l
damped , spring preload
fully way adjustable ,
compression and re-
bound damp ing force
adjustable
Stee ri ng angle . ..... 45 ° (right and l eft)
Caster ..... . ..... _ 62
D
30'
Trail ..... .. . _ ..... ' 118 mm (4.6 in)
Turning radius ...... 2.2 m (7.2 ttl
Fr on t brake ....... . Di s c
Rear
brake ......... Disc
Front tire size . ...... 80 ' 100-21 51M
Rear tire size . . . . . .. 110 / 100 - 18 64M
CAPACITIES
,
Fuel tank
inc luding reserve ... 9.5 L (2 .5/2.1 USl imp
gal)
reserve .......... 1.8 L (0.5 / 0.4 US /I mp
gal)
Engine oil, oil change . 1700 ml (1 .8 /1 .5
USlimp qt)
Front fork oil ....... 586 ml (19 .8 / 20.6
US /I mp oz)
These spec if ications are subject to change
without notice .