Suzuki DR350 User manual

SUZUKI MOTOR

RPORA

PRINTED IN JAPAN OCTOBER '90 @

99500

43019

(,.)

FOREWORD

The

SUZUKI

OR350

was

designed

ffer

su-

perior

erfor

man

thr

ough

lightweight

gn,

four

roke

power

engine

coun

-b

alancer,

drysump

lubrica

ion

sys

and

link

rear

suspen

tion.

This

service

manual

has

been

produced

primari

experienced

cha

ics

whose

job

is to in-

spec

adjus

t, repair

and

service

SUZUKI

motor

cycle

Apprent

ice

mechanics

and

you

self"

mechanics

ill

also

manual

extremely

useful

guide

The

OR350

manu

fac

ured

to s

tandard

fi-

ions.

(he

main

jec

matter

manu

al. H

owever.

the

DR350

machines

distribu

d in

your

coun

might

iffer

in mi

nor

spec

standard

-s

pecification

and.

the

, it

cause

some

minor

modifications

(whi

are

of no

consequence

most

ase

far

servici

concerned)

had

made

comply

the

atu

ory

requiremen

your

coun

This

manual

contai

·to·

date

information

the

ime

iss

Later

made

mod

fications

and

changes

WIN

explained

ZUKI

dis

ribu

respec

market

s, to

whom

you

are

kindly

requested

make

query

about

dated

format

n, if

any

SUZUKI

MOTOR

CORPORATION

tor

cycle

Service

partm

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

-MODELJ

DR350P

('93-MODELJ

DR350R

/SER ('

-MODELJ

DR350S

/SES

('95

-MODELJ

DR350T

SET

-MODELJ

DR350V

SEV

-MODELJ

DR350W

/X ('

,'99-MODELSJ

ORA

TION

1990

VIEW

DR350L

LEFT SIDE

RIGHT SIDE

TENT

VIN

AND

SERIAL

NUMBER

LOCATIONS

. •

. .

...

. 7-7

FUEL

AND

OIL

RECOMMENDATIONS

.. . . . . . . . . •

. . .

....

• 7-7

BREAK

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

V.I.N.

(Vehicle

Identif

ica

tion

Number)

is st

amped

e steeri

head pipe.

e en·

gine

serial

number

® is l

oca

ted on

the

rig

side

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

at least

pump

tane

(

a...pt

method)

91 octane

high

rated

research

method.

2 . SUZUKI r

eco

mmend

at cus

tomer

e al

hol

free,

unleaded gasoline wh

eneve

r possible.

3 . Use of blended gasoline

containi

MTBE

ethy

l Ter·

tiary

Butyl

Ether) is

permitted

4 . Use

blended gasoline/alcohol fuel is

permined

provided

at it

contains

not

than

hanol. Gaso-

line/

alcoho

l fuel

may

con

tain

methanol

ap-

propriate

cosolvents

and corrosion in

hib

ito

rs are present.

5 .

the

performance

the

vehicle

unsatisfactory

while

using

blended gasoline/al

cohol

fuel,

you

should

swi

alcohol free unleaded gasoline.

6 . Failure to

thses guideline

possibly

void

ap-

plicable

warranty

cove

rage.

Check

ith

sup

plier

be sure

you

intend

to u

meets

requir

emen

ts l

isted

above

For

CANADA

model

Use

only

unl

eaded gasoline of at least

pump

octane

6.j-M

od) or 91

octane

high

fal

Research

Method

For

other

models

Gasoline used should be graded

tane

higher.

unleaded gasoline is r

ecommended

ENGINE OIL

For U.

S.A

model

SUZUKI

recomends

the use

SUZUKI PERFORMANCE 4

MOTOR

OIL or an oil

which

rat

uner

the

API

(American

Petroleum Ins

titute)

classification

system

. The

viscos

y r

ating

is SAE

10W

SAE

motor

oil is

not

available. sel

ect

alternat

according

the

right

hart.

For

other

models

sure

that

e engine oil

you

use

comes

under

I clas-

ifi

cat

ion of

and

that

its

viscosity

rat

ing

SAE

. If an SAE 1OW/

tor

oil is not available,

ect

the

oil vi

scosity

cco

rding

to th

right

cha

FRONT FORK OIL

Use

fork

oil

99000

99044·10G

, SUZUKI FORK

OIL

BRAKE FLUID

Specification

and class

ifi

tion

DOT

99000

23110

: SUZUKI BRAKE FLUID

WARNING

GENERAL

INFORMATION

1·2

MULTIGRADE

10W

* Since

the

brake

syste

this

motorycle

filled

with

glycol

-based brake

fluid

the

manufac

turer.

not

use

mix

different

types

fluid

such

silicone

-based

and

petroleum

-based

fluid

for

refilling

the

system.

otherwise

serious

damage

will

result

* Do

not

use any

brake

fluid

taken

from

oil

used

unsealed

containers

Never

re-use

brake

fluid

left

over

from

the

servicing

and

stored

for

long

period.

BREAK-IN PROCEDURES

During

manufacture

only

best

possible

mate

rials are

ed and all

hined

parts

are finished

a very

high

standard

but

is still

nece

ssary to

allow

the

mov

ing

parts

to " BREAK·IN"

befor

subjec

ting

e engine

maximum

tre

sses.

future

ormance

and reli

abi

lity

the

engine

pends on

e care and

restraint

exercised

during

early

lif

The

general rules are

fol

lows.

Keep to

ses break-in

thrott

le p

osition

Initial

hours

: Less

than

throttle

hours

less

than

3/4

throttle

1·3

GENERAllNFDRMATIDN

SPECIAL

MATERIALS

The

materials

listed bel

are needed

for

maintenance

work

OR350

and shou

kept

hand

for

ready use. These

items

supp

ement

standard

mat

erials as cleaning

fluid

lubricant.

emery

clot

h and like. H

use

them

and

where

use

them

are described in

the

ext

this

manual.

METERIAL

For

U.s.A

model

SUZUKI SUPER GREASE " A"

99000

25030

SUZUKI SILICONE GREASE

99000

25100

SUZUKI MOLY PASTE

99000

·251

SUZUKI BOND NO.

1207B

99104-31140

THREAD LOCK "

1342

99000

32050

For

other

mod

els

SUZUKI

SUPER

GREASE "

99000-25010

SUZUKI SILICONE GREASE

99000

·2

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

6-1,

2-2

6·

2-2

6-28

6·5

6·

• Rocker arm

shafts

3·

• De

·co

mpression shaft

3·15

• Valve stems 3·21

• Countershaft and driveshaft gears 3·

• Piston pin 3-

• Camshaft journals and cams 3-

• Cam chain tensioner 3·

• Cylinder head

cove

r 2·3

• Mating surface

efl

and 3-

right halves of crankcase

• Front and rear brake caliper 6·5

bolt

• Front footrest bolt

• Chain case rear side

mounting

bolt

•

Rear

fende, rear side

mounting

bolt

GENERAL

INFORMATION

1-4

ERIAL

C---

C-~~----C7-C~

-o

C--C----~C------

PART

I-

___

_ 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

SUZUKI BRAKE FLUID

99000-2311010

THREAD LOCK

99000-32

•

'324

SUZUKI

FORK

Oil

11-10

99000-99044-100

11.0

SUZUKI BRAKE FLUIO

99000-23110

•

Gearshift

cam

bearing

reta

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

arm

stopper

•

Magneto

rotor

nut

• Brake

disc

bolt

• Front

fork

011

•

Front

and r

esl

brake

3·

3-4

8· 17

3-45

3·

6-'

6·

1-2

6·

, -2

2·11

1·5

GENERAL

INfORMATION

PRECAUTIONS

AND

GENERAL INSTRUCTIONS

Observe

foll

ing

items

without

fail

when

disasse

mbling

and reasse

mbling

motorcycles.

not

run e

ine

with

littl

e or

ven

til

ion.

o Be sure

replace pa

cki

gaskets.

circlips.

O-rin

and

tter

ins

new

ones

CAUTION:

Never reuse a

circlip

After

a eirelip has been

removed

from

shaft

. it

should

discarded

and a

new

circlip

must

installed

When

installing

new

circlip

cafe

must

taken

not

expand

the

end

gap

larger

than

required

slip

the

eirelip

over

the

shaft.

After

installing a circlip,

always

insure

that

it is

completely

eated

its

groove

and

securely

fitted

Tighten

bolts

and

nuts

e ones

larger

diameter

ose of s

mal

ler

diame

ter. and fr

inside

outside

diagonally, to

e speci

tightening

torque.

D Use special

tools

where

specif

ied.

a Use speci

ed genuine

parts

com

ed oils.

When

an 2 persons

perf

orm

work

oget

her.

pay

ttenti

safety

each other.

After

the

reasse

mbl

eck

parts

tighteness and

operat

ion.

Treat

gasoline. wh

ich

is ex

emely

mmabl

e and highly

plos

with

greatest care. Never use

gasoline as cleaning

solven

Warning. Caution and Note are included in this manual occasionally, descri

bing

e foHowing

conten

ts.

WARNING

. . .

. .

The

parsonal

safety

the

rider

bystanders

may

involved

Disregarding

this

information

could

result

per

sonal

injury.

CAUTION

...

Thses

instructions

point

out

special

service

procedures

precaution

that

must

followed

avoid

damaging

the

machine

NOTE .

.........

This

provides

special

information to

make

maintenance

easier

impor

ant

instructions

clearer.

REPLACEMENT PARTS

Whe

u replace a

parts,

use

only

genuine

SUZUKI

replacement parts,

their equivalent. Genuine SUZUKI parts

are

high

quality pa

which

are designed and

built

pecifi

cally for SUZUKI vehicles.

CAUTION:

replace

ment

parts

which

are

not

equivalent

Quali-

genuine SUZUKI

parts

can lead

performance

problems

and

damage

SPECIFICA

TlONS

DEMENSIDNS

AND

DRY

MASS

Overall

length

...

_ 2

165

185.2

in)

Overall

width

.....

885

134.8

in)

Overall

height

.......

250

149.2 in)

Whee

ase

.......

1440

156.7

in)

Ground

clearance

310

2.2

in)

Seat

height

........

920

136.2

in)

Dry

mass

..........

113

1249

Ibs)

ENGINE

Type

....

_. _. . . .

Four-stroke, air-cooled,

GENERAL

INFORMATION

1·6

ELECTRICAL

' t SUZUKI "

PEl

9"'

ype

.......

gnition

timing

. . . .

5 ° B.T.D

.C.

below

300

rIm

and

° B.T.D.C.

above

300

min

Spark

plug

........

NGK

DPR9EA

-9 or

NIPPON DENSO

X27EPR-U9

OHC

CHASSIS

Number

cylinders

Bore . . . . . . . . . . . . .

(3.'10

in)

Stroke

....

_. .

.....

71 .2

(2.803

in)

Piston

displacement.

349

em)

(21.3

cu.

in)

Compression

rati

o...

5 : 1

Carburator

. . ,

.....

MIKUNI

TM33SS

single

Air

cleaner

......

Polyurethane

foam

ement

Starter

system

. . . .

Primary

kick

Lubri

cation

sys

tem.

. .

Dry

sump

TRNSMISSION

lut

ch . . . . . . . . . .

Wet

multi

plate

typ

Transmi

sion.

. . . .

6-speed

constant

mesh

Gearshift

pattern

....

down

, 5-

Primary

reduction

....

818

(62

22)

Final redu

ctio

......

357

(

Gear

rati

os,

Low

....

2.416

(29

12)

2nd

. .

733

126/15)

3rd . .

1.333

4 /

18)

4th

. .

111

120

18)

5th

....

0.952120

21)

TOP

....

0.826

119

23)

Dri

chain

...

TAKASAGO

RK520S0

IDO

DID

520VC5.

110

link

Front

sus

pens

ion

....

Tele

scop

ic, coil

spring

oil

damped

spring

preload

fully

way

ad-

justable

compression

damping

force

justab

Rear

suspension

. . . . .

Link

type

suspension

sys

tem

gas

loi

damped

, spring preload

fully

way

adjustable

compression

and re-

bound

damp

ing

force

adjustable

Stee

angle

.....

(right

and

eft)

Caster

.....

30'

Trail

.....

. _

.....

118

(4.6

in)

Turning

radius

......

2.2 m

(7.2

ttl

brake

.......

s c

Rear

brake

.........

Disc

Front

tire

size .

......

100-21

51M

Rear

tire

size . . . . .

110

100

64M

CAPACITIES

Fuel

tank

inc

luding

reserve

...

9.5 L

.5/2.1 USl

imp

gal)

reserve

..........

1.8 L

(0.5

0.4

gal)

Engine oil, oil

change

1700

.8 /1

USlimp

qt)

Front

fork

oil

.......

586

(19

.8 /

20.6

oz)

These

spec

ications

are

subject

change

without

notice

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