DR350P/SP (’93-MODEL) FOREWORD This chapter describes service data and servicing procedures which differ from those of the DR350N/SN (’92-MODEL). Please refer to the sections 1 through 11 for details which are not given in this section. NOTE: Any differences between DR350N/SN and DR350P/SP in specifications and service data are clearly indicated with the asterisk marks (*). | WIRE ROUTING....... E Pi scousiesiasitianiy sities FORE, i - CONTENTS —— — — [ SPECIFICATIONS........ 7 etnben ieee, ABE A | DR350P........ peu in sited 12-1 DR350SP......... tsa £3 a . 12-2 SERVICE DATA.....00.. i ae aienng 12-3 | DRB5OP os. 0 sescnenee 122 3 | DRB50SP........ sig : - . 12-11 OIL CHECK BALL... giniay eevee 1219 EMISSION CONTROL CARBURETOR COMPONENTS............... 12-20 | maGnero. akitesastseere aeieneujmaes CDI UNIT. sseriastoi 12-22 | REAR SHOCK ABSORBER (DR350P).......... 12-23 WIRING DIAGRAM. IR oa scasnesss 12-24 DR350P.. eee m0 12-24 | DR350SP. 12.25 |SPECIFICATIONS DR350P DIMENSIONS AND DRY MASS Overat engi Overall wigth Groune Seat height Bry mace ENGINE Type Valve ciearance, iN x Number of cylinder Bove ‘Stroke Piston slsplacement Compression ratio Carburetor ir cleane Starter sysiom: Uibreation system ‘TRANSMISSION Chuteh ‘ranemission Gearshift porters Primary reduction vaio Gear ratios, Low ‘nd brs ay oth Top Final reduction raid rive “chain chassis Front suspension Fear suspension Front suspansion stroke Fear whoel travel c Steering angle ‘Turning. radius Front brake’ ear brake Front te. sige oar tre size ELECTRICAL fgnition type ‘gran, omg park plug Generator Heodight Tailight capacimies Fue! tank including reserve. Reserve Engine ol, oi change swith iter ‘change Sverhaul Front fork ei (each tog) 2 165 mm (82.5 in) BBS mm (34.8 in) 4 250 mm (89.2 in} 1440 mm (58.7 in} ‘310 mm (12.2 i) ‘320 mm (36.2 in) 113 kg" (249 Ibs) Four stroke, ait-cooled with SACS, OHC {050.10 mm (0.020.008 inj 0.100.418 mm (0.040.006 in} 1 79.0 mm (3.110 in) 71.2 mm (2°803 in} 348 cm’ (21-3 eu. in) asc MIKUNI TM338S, singlo Palyursthane foam element Primary kick Ory cump Wor mutt plate type Grspeed constant mesh Town, Sup 218 (02/22) 2.416 (29/12) 1733 (26/15) 1.333 (24/18) 1111 (20/18) 1952 (2021) 0.824 Sa 6 (19/23) 57 (87/14) TAKASAGO FK52050 or DA100 DIDS2OVC, 110 inks Telescopic, coil spring, oll damped, spring preload fully adjustable, comprosetin aumping force eure {ink'type, coll spring, gas/oll damped, epring proload fully adjustable, ‘compression damping force edjustable 280\mm (11.0 mn) 280 am (11.0 in} 62° 30° Tig rn (4.65 in) 45° (night & lett) 22mer24) Disc brake, Nydrautically operated Dise brake, hydrautically operated BON100-21 SIM. tube 110/100-12 64M tobe SUZUKI “Per” +30" BST.O.C. above 4300 «/min 'NGK DPAGEA 9 or ND X27EPR UD Flywheel magneto 12V' sow nV Sw 8.81 (2.8/2.1 Usimp. gah 1.8. (0.6/0.4 USiimp. ga 1700 mi (1.8/1.5 UShimp. at) 1800 mi (2°0/1.7 Usimp. at) 2400 mi (2.2/1: USiimp. at) ‘BBB mi (18.8/20.6 US/imp. o2) Asterisk mark (*) indicates the Now “P** model specification,DR3SOP/SP ('93-MODEL) 122 eS oono—o—om*—— DR350SP DIMENSIONS AND DRY MASS Overatt length Overatt width Sverall “heiaht Weetbase 7 Ground clearance Seat "height Dry mass ENGINE Te Valve ciearsnce, 1h ex umber of evindsr Bore Stroke Piston displacement Compression rae Carburetor irl Starter system Uibncation sysiem ‘TRANSMISSION Guten ‘Tranemission Gerrit patter Primary reduction va Georratos, Low ‘nd ara an oh Top Final reduction ratio Brive “chain CHASSIS. Front suspension Rat suspension Front suspension stoke Rear whee wove Caster i Steering angle irra rads 22 Front brake’ Boor brake Front tre size Foor tre sire ELECTRICAL type fgnition uring. Sperk pig Bareery Generator ‘Turn signal fight ‘i Talbrako ght ‘ conse plate light Speedometer ight ; Techometer, light ‘Neutral indicator ight hina g High eam inaicator lish ‘Tuen signal inateator ight. capactries Fuel tank, inching reserve 335 mm (91.9 in)... For Finland, Germany and Sweden 240 mm (88.2 in). Fer italy 2238 mm (88.0 in}. Others 485 mm (34.8 19) 41 248 mm (48.0 In) 4 440 mm (56.7 ia) 290 mm (11-4 in) 800 mm (35:0 in) 4178 kg” {260 tos) Four stroke, air-cooled with SACS, OHC 0.05 "0-10 mm 0.002 --0,008 in} 8.58=0:18 rm (0.004 0.008 in 79.0 mm (3.110 in) 71.2 mm (2.803 in) 449 em (21.3 eu tm) ast MIKUNI 8ST33, sin Polyurethane foam element rary Kick Dry sump Wer multi-plate type spend constant mosh down, Sup ere (62/2) 216 (29112) 1.733 (26118) 11333 (241) 11 on 01382 (20/21) 0.826 (19/23) 2071 (434) TAKAgRO Rks2060 or DAI00 D1Dsz0ve:s ‘Telescopic, coil spring, oll damped, spring preload fully adjustable Compression damping force adjustable {ink type. coll epring, gasiol' damped, spring preload fully adjustable, Compression damping force adjustable 280mm (11.0 in) 280 mm (11-0 in) 62° 30 115 ram (4.53 in) 45° (right left) 23mi75 0 Bise brake, hydraulically operated ise brake, hydraullcally operated 80)100-21 SIP 110/90.18 81P SUZUKI “PEI” +30" BT.0.C. above 4300 vimin NGK OPRGEA-9 or NIPPONDENSO X27EPRU9 NV 10.8 KC (2Ah)/TOHR Three-phase A.C. generator 158. 13V eovssw 1BV 34. For UK 13v aw thors 1BV 21 Vy Gi21W 9.0 L (2.4/2.0 USiimp gal. . . Others 8.0L (2.4/1.8 USiimp gall’. For California (U.S.A.) byte ey tr nt12:3 DR3SOP/SP ('93-MODEL) SERVICE DATA DR350P VALVE + GUIDE Unit: mm (ind Tem - ‘STANDARD uM Valve diam. i 30.6 (1.20) 27.0 ea (1.06) a Valve lift 8.0 ” (0.31) = 8.0 - ie (0.31) Valve clearance (when cold) in 0.05—0.10 (0.602—0.004) x 0.10—0.15 man (0.004—0.006) Vaive guide to vaive stem iN (0.010—0.037 0.35 clearance 5 {0.6004—0.0015) (0.014) _| x (0.030—0.057 0.35 : _(0,0012—0.0022) (0.014) Valve guide 1D. 5.000—5.012, IN. & EX. | __(0.1969—0.1973) Valve stem 0.0. iN 4.975 —4.990 : (0.1959—0.1965) Ex 4.955—4.970 — - - Ie (0.1951—0.1957) Valve stem runout 0.05 ee (0.002) Valve head thickness 0.5 IN. & EX, 7 (6.02) Valve stem end length 1.8 IN. & EX. toon Valve seat width 09-14 - - aes (0.035 —0.043) ones Valve head radial runout 0.03 ee a (0.001) Valve spring free length 35.0 (IN. & EX.) NG (1.38) 37.8 OUTER (as) Valve spring tension (N. & EX) 53-68 kg INNER (11,7—14.3 ibs) — at length 28.0 mm (1.10 in) 13.1—15.1 kg ouTER (28.9—33.3 Ibs) ar at length 31.5 mm (1.24 in) 1DA350P/SP ('93-MODEL) 12.4 ~~ CAMSHAFT +CYLINDER HEAD Unit: mm (in) Tem T STANDARD LIMIT ‘Cam height low 33.430—33.470 33.13 | (13161-13177 | 43043) lees 33.460 33.500 33.16 | (1.3173-1.3189) (7.3055) Camshaft journal oil clearance 0.032—0.066 0.150 Floptside (0.0013—0.0026) (0.0059) : 0.028—0.059 0.150 Lathe (0.0011 —0.0023) (0.0059) Camshaft journal holder 1.0. 22.012 22.025 a (0.8666—0.8671) : 17.512—17.525 Lett side (0.6894—0.6800) - Camshaft journal 0.D. 21.959—21.980 pecs (0.8645 —0.8654) 3 : 17.466—17.484 bata, (0.6876 —0.6883) 5 Camshaft runout 0.10 a (0.004) Cam chain 20-pitch length 128.9 — tS 18.07) Rocker arm 1D. 12.000— 12.018 eas (0.4724—0.4731) : Rocker arm shaft 0.0. 11.973—11.984 IN. &EX. | (0.4714—0.4718) Cylinder head distortion — 0.05 (0.002) Cylinder head cover distortion _ 0.05 = (0.002) De-compression lever play 0-2 (0-0.08) CYLINDER + PISTON + PISTON RING Unit: mm (in) Tem =a ‘STANDARD tIMIT. Piston to cylinder clearance 0.055—0.065 0.120 (0.0022 — 0.0026) (0.0047) Cylinder bore 79.000—79.015 79.075 (3.1102~3.1108) (3.1132) Piston diam, 78.940—78.955 (3.1079—3.1085) (i088) ‘Measure at 15 mm (6 in) from the skirt end. Cylinder distortion si Katt 0.05 (0.002) Piston ring free end gap rare approx. (By dy and | R AppIOX. (6144) igen Piston ring end gap = 0.15—0.30, 0.70 (0.006-0.012) (0.028) = 0 36-050 O7012-5 DR3SOPISP ('93-MODEL) TEM ‘STANDARD MIT. Piston ring to groove clearance| 0.180 ues (0.007) 0.150 ~ fal _— (0.006) Piston ring groove width ise 1.01—1.03 f (0.040—0.041) 1,011.03 ang ___(0.640—0.041) aa 2.01 2.03 bs (0.079—-0.080) a Piston ring thickness i 0.97—-0.99 i (0.038—0.039) 0.97—-0.99 208 (0.038—0.039) Piston pin bore 20.002— 20.008 20.030 =i (0.7875—0.7877) (0.7886) Piston pin 0.0. 19.996 — 20.000 19.980 (0.7872—0.7874) (0.7866) CONROD + CRANKSHAFT + BALANCER Unit: mm (in) Trem ‘STANDARD LIMIT Corod small end 1.0. 20.006 20.014 20.040 (0.7876 —0.7880) (0.7890) Conrod deflection 3.0 (0.12) Conrod big end side clearance 0.10—0.55 1.0 1 (0.004—0.022) (0.04) Conrod big end width 21.95 22.00 . (0.864—0.866) Crank web to web width 60.0 + 0.1 (2.362 + 0.004) Crankshaft runout 0.05 ale (0.002) Balancer spring free length 7 10.3 (0.41) OIL PUMP: TEM ‘STANDARD Oil pump reduction ratio_ 1.590 (35/22) Oil pressure (at 60°C, 140°F) ‘Above 40 kPa (0.4 kg/em?, 5.7 psi) Below 140 kPa ( 1.4 kg/cm, 19.9 psi) at 3 000 r/min.DR3S0PISP ('93-MODEL) 1: |S _ Riis P83 00D) 12.6 CLUTCH Unit: mm ind TEM ‘STANDARD Mit Clutch Tever play 10-15 sae (0.4—0.6) : - Drive plate thickness 2,722.88 2.42 - (0.107—0.113) (0.095) Drive plate claw width 15.8—16.0 16.2 (0.62—0.63) (0.60) fen plate distortion 0.10 = (0.004) _| Clutch spring free length 29.8 (i168) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio TEM STANDARD. omit Primary reduction ratio 2.818 (62/22) — Final reduction ratio 3.357 (47/14) Gear ratios Low 2.416 (29/12) — 2nd 1.783 (26/15) — 3rd 1.333 (24/18) “ath 7.111 (20/18) = sth 0.952 (20/21) —_| Top 0.826 (19/23) = Shift fork to groove clearance 0.1-0.3 O5 (0.004—0.012) (0.020) Shift fork groove width No.1,No.2 5.06.1 re & No.3 (0.197—0.200) Shift fork thickness No. 1,No.2 48-49 a &No.3 | _(0.189—0.193) Drive chain Type | _D.1.D. 520VC5 or RK520SO Links 110 = 20-pitch length — ne Drive chain slack 7 25-40 (10-16)12-7_DR35OPISP ('93-MODEL) CARBURETOR TEM SPECIFICATION Carburetor type = TM33 SS Bore size 33 mm 1.D. No ____14D0 Idle t/min. 1400 * 100 rmin Float height 14.2 = 1.0 mm (0.56 + 0.04 in} Main jet (MJD : #127.5 Main air jet (MAJ) 0.7 mm Jet needle WN) SFP96-3rd Needle jet (NJ) 7 PS Cutaway (C.A) 1.5 Pilot jet (PJ) #375 By-pass 18.P.) 0.8 mm. Pilot outlet (.0.) 0.6 mm Valve seat VS) 7.8mm Starter jot (G.S.) #50 Pilot screw (PS) 1 Va turn back —_| Pilot air jet PAS) 7.1mm Throttle cable play (pulling cable) 0.5—1.0 mm (0.02—0.04 in) ELECTRICAL Unit: mm (in) TEM __ SPECIFICATION NOTE Ignition timing ¥30°B.T.D.C. above 4 300 r/min Spark plug ND.: X27EPR-U9 Type N.G.K.: DPR9EA-9 i 0.8—0.9 CE (0.63—0:04) ‘Spark performance ‘Over 8 (0.3) at 1 atm. Ignition coll resistance Terminal — Primary 0.11.08 eats Plug cap— Secondary 12~22 ko uid Magneto coil resistance Lighting 01-150 Y-8 Power source *350—650 0 W—8r Pick-up No.1 ¥350—700 0 G—BI oe Pick-up No.2 350-700 9 Y=Gr Magneto no-load voltage Bee cael More than 40 V (AC) at 5 000 r/min. y-8 Regulated voltage 12—14 V at 5 000 rimin. Asterisk mark (*) indicates the New ‘“P'’ model specifications.DR3SOPISP ('93-MODEL) 12-8 WATTAGE Unit: W 17m ‘SPECIFICATION Headlight = 55 Taillight 5 BRAKE +WHEEL Unit: mm (in) TEM omit Brake lever play - (0-0. Rear brake pedal height 5 a (0.2) Brake disc thickness 35 +02 Front (0.138 * 0.008) 4.0 + 0.2 3.5 Rear (0.157 + 0.008) (0.138) Brake dise runout 0.30 7 (0.012 } Master cylinder bore ant io F,083, 12.700—12.743 E - pea (0.5000—0.5017) = Master cylinder piston diam. Flank (887 20,984 = 12.657 —12.684 fey (0.4983—0.4994) Brake caliper cylinder bore ae 27.000—27.050 (1.6630—1.0650) 27.000—27.050 bo (1,0630—1.0650) Brake caliper piston diam. a 26.900—26.950 (1.0591 —1.0610) 26.900—26.950 bem (1.0591—1.6610) ‘Wheel rim runout 2.0 Axial — (0.08) Radial —— om Wheel axle runout = 0.25 Front — (0.010) 0.25 peer (0.010) Tire size Front 80/100-21 51M —— Rear 110/100-18 64M == Tire tread depth 4.0 Front | (0.16) ieee 4.0 cos (0.16)('93-MODEL) SUSPENSION Unit: mm (in) ITEM e ‘STANDARD uM NOTE] Front fork stroke 280 — 11.0) Front fork spring free length 7 608 | (23.9) Front fork oil level 145 (5.7) Rear shock absorber gas pressure 1 000 kPa a (10 kg/cm?2, 142 psi) Rear shock absorber spring *268.2 pre-set length (10.6) | Rear wheel travel 280 a Lr (11.0) ‘Swingarm pivot shaft runout _ 0.3 (0.01) TIRE PRESSURE COLD INFLATION. ; TIRE PRESSURE ra kgfom? psi FRONT 100 1.0) 14 REAR 100 1.0 14 Asterisk mark (*) indicates the New ''P’’ model specification.DR35OP/SP ('93-MODEL) 12-10 FUEL + OIL TEM ‘SPECIFICATION NOTE Fucl type Use only unleaded gasoline of at least 87 pump octane ("-$ method) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary | For U.S.A. Buty! Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. Use only unleaded gasoline of at least 87 pump octane ("$4 method) or 91 octane | For Canada or higher rated by the Research Method. Gasoline used should be graded 85-95 octane or higher. An unleaded gasoline is | For the others recommended. Fuel tank including reserve 9.5L (2.5/2.1 US/imp gal) reserve 7.8L (0.5/0.4 US/imp gal) Engine oll type ‘SAE 10W/40, API SE or SF Engine oil capacity 1 700 mi Change (1.8/1.5 US/imp at i + 900 mi Filter change| (2.0/1.7 US/Imp at) 2 100 mi (2.2/1.8 US/imp at) Front fork oil type Fork oil #10 Front fork oil capacity (each leg) 586 mi (19.8/20.6 US/imp oz) Brake fluid type bor 4 Overhaul12.11. DR3SOPISP ('93-MODEL) DR350SP VALVE + GUIDE Unit: mm (ind TEM 7 ‘STANDARD TiMit Valve diam ma 398, - 27.0 Shy (1.06) _| | Valve lift IN. en — 8.0 ee (0.31) _| Vaive clearance (when cold) nT (oe 88a) (0.10—0.15 Ee (0.004—0.006) Valve guide to valve stem W (cee 837, cae, clearance i —01 . 0.030—0.057 0.35 er (0.0012—0.0022) (0.014) Valve stem 0.0 4.975 4.990 hit (0.1959—0.1965) x 4.955 —4.970 s (0.1951—0.1957) _| | Valve stem runout IN. & EX. ae ie Valve head thickness AREER by Valve stem end length IN. & EX. - a s, Valve seat width ine oon dbaa) 7 | Vaive head radial runout neatoe ees Vaive spring free length 7 35.0 (IN. & EX.) INNER - (1.38) 7.8 ‘OUTER — Gia | Valve spring tension (IN. & EX.) nee a SSG kg: at length 28.0 mm (1.10 in) 13.1—15.1 kg ‘OUTER (28:9-33.3 Ibs) - at length 31.5 mm (1.24 in)DRISOPISP ('S3-MODEL) 12-12 CAMSHAFT + CYLINDER HEAD Unit: mm (in) [r TEM ‘STANDARD MIT Cam height in 33.430—33.470 33.13 (1.3161—1.3177) (1.3043) x 33.460— 33.500 33.16 (1,3173—1.3189) (1.3055) Camshaft journal oil clearance | pion: sige (09038 085,, Cae, z 0.028—0.059 0.150 bine {0.0011 —0.0023) (0.0059) Camehatt journal holder UD. TRiaht sige (22.012 22.025, z 17.612—17.525 ie ah (0.6894—0.6900) ‘Camshaft journal 0.0. rig (21,259 21,980, 17.466—17.484 pete aide (0.6876 0.6883) aaat Camshaft runout aly Cam chain 20-pitch length 1289 Rocker arm 1. Neo (7088 37,038, Rocker arm shaft 0.D. WE EX wra7s 3888, = Cylinder head distortion —s = oe : Cylinder head cover distortion = ——|- oe : De-compression lever play 0-2 = (0-0.08) CYLINDER + PISTON + PISTON RING Unit: mm (in) TEM STANDARD MIT Piston to cylinder clearance 0.055 0.065 0.120 (0.0022—0.0026) (0.0047) Cylinder bore 79.000 79.015 79.075 (3.1102—3.1108) (3.113: Piston diam. 76.840— 78.985 (3.1079—3.1085) (bee a Measure at 15 mm (0.6 in) from the skirt end. uf Cylinder distortion 0.08 (0.002) _ Piston ring free end ga 70.2 8.2 . oe eee APPFOX. (0.40) (0.32) 11.4 8.9 " eae ApPIOX. (0.44) (0.35) Piston ring end ga 0.70 bara iid (0.028) _ | 0.70MODEL) 12:13 DRISOPISP (' [______ tem ‘STANDARD Limit Piston ring to groove clearance); .1 aa 0.180 . (0.007) __| 0.150 co #08 (0.006) Piston ring groove width a 7.01—1.03 Be o (0.040—0.041) a 1.01—1.03 am (0.040—0.041) = 2.01 2.03 ‘ _(0.079—0.080) Piston ring thickness ae — iB (0.038—0.039) 0.97—0.99 an (0.038—0.039) zileme: Piston pin bore 20.002—20.008 20.030 (0.7875—0.7877) (0.7886) Piston pin 0.0 19.996 20.000 19.980 (0.7872—0.7874) (0.7866) CONROD + CRANKSHAFT + BALANCER Unit: mm (in) 1TEM ‘STANDARD LiMit Corod small end 1.D. 20.006—20.014 20.040 (0.7876—0.7880) (0.7890) Conrod deflection 3.0 (0.12) Conrod big end side clearance 0.10—0.55 1.0 (0.004—0.022) (0.04) Conrod big end width 21.95—22.00 (0.864—0.866) Crank web to web width 60.0 + 0.1 a (2.362 + 0.004) Crankshaft runout ou 0.05 _ (0.002) Balancer spring free length = 10.3 (0.41) OL PUMP ITEM ‘STANDARD TMi Oil pump reduction ratio 1.590 (35/22) Oil pressure (at 60°C, 140°F) ‘Above 40 kPa (0.4 kg/cm?, 5.7 psi) Below 140 kPa ( 1.4 kg/cm, 19.9 psi) at 3 000 r/min.DRISOPISP (‘93-MODEL) 1 CLUTCH Unit: mm (ind Trem ‘STANDARD Limi ‘Clutch lever play 10-15 a (0.4—0.6) ni Drive plate 2,722.88 2.42 {0.107—0.113) (0.095) Drive plate claw width 15.8 16.0 15.2 (0.62=0.63) (0.60) Driven plate distortion es 0.10 a E (0.004) | Clutch spring free length oe 29.5 G16) TRANSMISSION + DRIVE CHAIN Unit: mm {in} Except ratio TTEM ~__ STANDARD LIMIT Primary reduction ratio 2.818 (62/22) = Final reduction ratio 3.071 (43/14) — Gear ratios Low 2.416 (29/12) = 2nd 1.733 (26/15) 3rd 1.333 (24/18) — [ath 1.111 (20/18) - Sth (0.952 (20/21) ee Top 0.826 (19/23) a Shift fork to groove clearance 0.1-0.3, 0.5 : (0.004—0.012) (0.020) | Shift fork groove width No.1,No.2 5.0-5.1 = & No.3 {0.197—0.200) x Shift fork thickness No.1,No.2 4.8—4.9 & No.3, (0.189—0.193) Drive chain ~ [_Type | _D.1.D. 520VC5 or RK520SO_ = Links 108 = ee 20-pitch length = ech Drive chain slack 25-40, x (1.0-1.6) CARBURETOR ‘SPECIFICATION ve E03 £33 C £28 Carburetor type BST33SS. = Hye) eeatt Bore size 33 mm = = 1D. No "14E9 uf 8 HTAEC [Fae Idle r/min. [1500 = 100 r/min = ae Float height 14.6 + 1.0mm + 7 (0.57 + 0.04 in) Main jet (MJ) *# 127.5 wee *# 127.5 Main air jet (MAJ) 0.6 mm = = Jet needle U.N) 5CD16 = *SCD56-4th Asterisk mark (*) indicates the New “P’” model specifications. a dade. ea ead, Se TE ae ae ee ee12.15 DR3SOP/SP ('93-MODEL) ‘SPECIFICATION pe : 33 E26 Needle jet WJ) o. = +05 Throttle valve hv.) #115 = = Pilot jet | #a7.s = #375 By-pass 0.8 mm, 0.8 mm, = a 0.8 mm Pilot outlet 0) | __*1.0 mm = [08 mm Valve seat 1.5mm = = Starter jet cs #435 te t= Pilot screw PS a PRE-SET oa EOESEL (134 turns back) Pilot air jot (PAS) 13mm - 4.2 mm Throttle cable play 0.51.0 mm ‘i 7 (pulling cable) (0.02~0.04 in) eS ‘SPECIFICATION £.02,04, ITEM 17,21,28, | €15,22 £24 £39 34,54 - Carburetor type —_rast338s ~ = = Bore size 33 mm = = = 1D. No 14£0 *I4EA TTaEE 7T4ED, idle r/min. 76002 2 - 1 40060 100 e/min timin Float height 14.6 1.0 mm (0.57 « - - : £0.04 in) Main jet (MJ) | #135 | "#1278 ca r= Main air jet MAJ) | 0.6 mm = = = Jet needle (U.N. | SCD86-3rd_| *SCDS6-ath t= re Needle jet (W.J) 03 *0-5 te +06 Throttle valve hv.) | #116 = = = Pilot jet (P.) | #42.5 +7375 ic = By-pass (6.P.) = = a Pilot outlet (P.0.) = = *0.9 mm Valve seat WS.) = = Starter jet (GS) | #45 435 | te Pilot screw (P.S.) | PRE-SET PRE-SET (1% turns - “2% tums back) back) Pilot air jot PASI] 1.3mm | *1.2mm a 7.35 mm Throttle cable play O5—1.0 mm (pulling cable) (0.02— - - + 0.04 in) Asterisk mark (*) indicates the New ‘'P’’ model specifications. E-02: U.K. E-O4: France E-15: Finland E-17: Sweden E-21: Belgium E-22: Germany E-24: Australia E-25: Netherlands E-34: Italy E-39:Austria E-94: BarbadosDR3ISOPISP (' \ODEL) 12-16 EE ELECTRICAL Unit: mm (in) TEM SPECIFICATION NOTE ignition timing ¥30°B.T.D.C. above 4 300 r/min 9 = Spark plug ND.: X27EPR-US Type N.G.K.: DPROEA-9 0.8—0.9 | Sep: (0.30.04) | Spark performance a Over 6 (0.3) at 1 atm. ition coil resist minal — Tanition coil resistance Play eens Terminal Secondary 12-22 ko Bia ea Magneto coll resistance Charging 01-150 YnY. Power source| ¥350—650 0 W-6r Pick-up No.1 =350— 700 2 G-BI Pick-up No.2 #360— 700 & Y—Gr NMagnataino-load yoltegs More than"60 V (AC) at 5 000 r/min. yY-Y | (when engine is cold) Regulated voltage 13.0— 15.5 V at 5 000 r/min. Magneto Max. output Approx. 125 W at 5 000 r/min Battery . YTAL-BS E24 Tomy destneton FTAL-BS For the others | [_ Capacity 12V 10.8 KC (3Ah)/10HR annie oe 1.320 at 20°C (68°F) Fuse size 15 A WATTAGE Unit: W ‘SPECIFICATION cm €03,28,33 E02 The others Headlight Hi 60 < = Lo 55 = = Position light a4 4 Tail/Brake light a 5/21 « = | Turn signal light 21 = = | Tachometer light 3 = = Speedometer light 1.7 = = Turn signal indicator fight 1.7 = = High beam indicator light 17, = = Neutral indicator light 1.7 = = License light 5 = = Asterisk mark (*) indicates the New “‘P’ model specifications.12.17 DR350P/SP ('93-MODEL) BRAKE + WHEEL Unit: mm (in) iTem ‘STANDARD LIMIT Brake lever play 0-0.3 (0—0.01) Rear brake pedal height 5 (0.2) Brake disc thickness aa 3.5 + 0.2 3.0 an (0.138 + 0.008) (0.118) 4.0 + 0.2 3.5 ee (0.157 + 0.008) (0.138) Brake disc runout 7 0.30 (0.012) Master cylinder bore et 12,700— 12.743 i {0.5000—0.5017) 12.700—12.743 | - ae (0.5000—0.5017) | _ Master cylinder piston diam. |, 12.657 12.684 font | _ (0.4983—-0.4994) 12.657—12.684 ions (0.4983—0.4994) aras Brake caliper cylinder bore poet 27.000—27.050 be (1,0630— 1.0650) 30.230-30.280 eee (1.4902 —1.1921) Brake caliper piston diam. Base 26.900—26.950 (1.0591 — 1.0610) 30.160—30.180 es (1.4874 —1.1882) Wheel rim runout 5 20 Ale a (0.08) 2.0 Reel (0.08) Wheel axle runout 0.25 Front - (0.010) eens 0.25 (0.010) Tire size Front 80/100-21 51P — Rear 110/90-18 61P ——e Tire tread depth 3.0 Go (0.12) 3.0 oe) (0.12)eS ——_—_—— SSS EO ‘SUSPENSION Unit: mm (in) iTeM ‘STANDARD LIMIT NOTE Front fork stroke 280 - 1.0) Front fork spring free length 602 (23.7) Front fork oil level 152 aie, 6.0) Rear shock absorber gas pressure| 1 000 kPa [O10 kg/em?, 142 psi) Rear shock absorber spring 268.2 pre-set length (10.6) | Rear wheel travel 280 (11.0) ‘Swingarm pivot shaft runout ena 03 (0.01) TIRE PRESSURE COLD INFLATION | __ SOLO RIDING DUAL RIDING TIRE PRESSURE | kPa |kg/cm?|_psi_| kPa_|kg/cm4|_psi FRONT 150 | 1.50 | 22 | 150 | 1.50| 22 REAR 150 | 1.50 | 22 | 175 [1.75 | 25 FUEL + OIL Te ‘SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (2M method) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary | For U.S.A. Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents. and. corrosion inhibitor is permissible Use only unleaded gasoline of at least 87 pump octane (®! method) or 91 octane | For Canada or higher rated by the Research Method. Gasoline used should be graded 85-95 octane or higher. An unleaded gasoline is | For the others recommended Fuel tank including reserve BOL For California (2.1/1.8 US/imp gal) W.S.A.) 9.0L (2.4/2.0 USlimp gal) ete reserve *2.0L (0.5/0.4 US/imp gal) Engine oil type SAE 10W/A0, API SE or SF Engine oil capacity 1 700 mi Cheese (1.8/1.5 US/Imp at) 4 1 900 mi Filter change} (2.0/1.7 US/Imp qt) 2 100 mi Overhead (2.2/7.8 US/imp ath Front fork oil type Fork oil #10 Front fork oil capacity (each leg) 569 mi12.19 DR3SOP/SP ('93-MODEL) Eee eee OIL CHECK BALL REMOVAL * Drain engine oil. ‘* Remove the rear brake master cylinder bolts. ‘+ Remove the clutch cable bracket bolts ‘* Remove the oil pipe bolt on the clutch cover. * Remove the kick starter lever. + Remove the clutch cover. ‘+ Remove the oil check ball (@ and spring @ by removing the bushing @. REASSEMBLY Reassemble the spring @, oil check ball @ and bushing @) to the clutch cover (@) as shown in the illustration. CAUTION: When fitting the bushing @ to the clutch cover, face the rubber part of bushing to the outside.EMISSION CONTROL CARBURETOR COMPONENTS DR350S motorcycles are equipped with precision, manufactured carburetors for emission level con- trol. These carburetors require special mixture control components and other percision adjustments to function properly. There are several carburetor mixture control components in each carburetor assembly. Three (3) of thses components are machined to much closer tolerances than standard machined carburetor jets. These three (3) particular jets—MAIN JET, NEEDLE JET, PILOT JET— must not be replaced by stan- dard jets. To aid in identifying these three (3) jets a different design of letter and number are used. If replacement of these close tolerance jets becomes necessary, be sure to replace them with the same type close tolerance jets marked as in the examples shown below. The jet needie is also of special manufacture. Only one clip position is provided on the jet needle. If replacement becomes necessary the jet needle may only be replaced with an equivalent performing replacement component. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possi- ble for the best possible performance and durability. Conventional Figures Used onsenses toons! 1 234567890 Components Emission Type Figures Used Onciose Tolerance | | FO J 4 5G 7 AGO Jet Components The carburetor specification for the emission-controlled DR35OS are as follows. Carburetor Main’ Needle Jet Pilot Pilot .D. No. Jet Jet Needle Jet Screw T4EC PRE-SET (California model) D1 #311: DO NOT qaE8 #1275 O68 SCD16 315 po.Nor, (Other state models) The pilot screw is pre-set by the factory utilizing specialized testing and adjusting procedures. The pilot screw is not adustable as the idle circuit is “‘sealed’” after factory adjustment. Adjusting, inter- ferring with, improper replacement, or resetting of any of the carburetor components may adversely affect carburetor performance and cause the motorcycle to exceed the exhaust emission level limits. If persons, who are unaware of these special carburetor servicing requirements tamper with the car- buretors the Suzuki dealer should restore the carburetors to their original condition or if unable to ef- fect repairs, contact the distributors representative for further technical information and assistance.12.21 DR3SOPISP ('93-MODEL) MAGNETO MAGNETO COIL * Remove the frame covers and seat. * Disconnect the magneto lead wires. Measure the resistance between the lead wires with a pocket tester as shown in the illustration. 09900-25002 : Pocket tester Magneto coil resistance (DR350P) Lighting coil : 0.1—1.5 9 (Y—B) Power source coil : 350—650 9 (W—Br) Pick-up coil No.1 : 350—700 9 (G—BI) Pick-up coil No.2 : 350—700 9 (Y—Gr) i RaSOP. Magneto coil resistance (DR350SP) 1-1.5 9 (Y-Y) 350—650 0 (W—Br) io) Pick-up coil No.1 : 350-700 2 (G—BI) rt Pick-up coil No.2 : 350—700 9 (Y—Gr) WIRE COLOR B: Black Gr: Gray BI: Blue © W: White DR350SP. Br: Brown Y : Yellow oe br G: Green MAGNETO STATOR INSTALLATION Pick-up coil No.1DR3SOPISP ('93-MODEL) 12-22 CDI UNIT ‘* Remove the frame covers and seat. * Disconnect the CDI unit lead wires. Check the continuity and measure the resistance values with a pocket tester. 09900-25002: Pocket tester DR350P_ WIRE COLOR ee Ww ay le soap es Te s ee ro eye Y Yellow 310 aS BAW: Black with White tracer esse sae = BN Block wh Votow voces = . Bie: Bue wan ack wacer BIR: Bue wih Red voce a Gi: Green with Red acer WISI: White with Blue wacor WIR: White with Red tracer Unit: kK Poke of water ter =| ey | we | ow [om] ow 5-40 [10-100] = | 3-30 ]s0-s05] = 0 {os-10[08-10} s-40 |=} 0 [30-600] = $-a0 [10 100| =» | 3-30 [80-600] = 3-40 |» [0 _}30=800] =. 19 10080-1000] [over 109] = 05-10 [Over 100] = OS-10] 3-40-| 3-00 [10-300] O8=10| Over 70] = o_[os-10[08-10] 3-40 | = 20-600] = == [=| te = 5-00 [10-700] 10-260 f0~ 1000 —= | 8-60 [Ove 100] = |Over 100 NOTE: As capacitors, diodes, etc. are used inside this CDI unit, the resistance values will deffer when an ohmmeter other than SUZUKI pocket tester is used. NOTE: Remove the spark plug and place the spark plug on the cylinder head cover kick the engine and check the sparks of the spark plug. If no sparking at spark plug gap, replace the CDI unit or inspect the magneto coils, ignition coils and spark plug. If the magneto coils, ignition coils and spark plug checked are correct, the CDI unit may be faulty, replace the CDI unit with a new one.12-23 DR35OP/SP ('93-MODEL) REAR SHOCK ABSORBER (DR350P) SHOCK ABSORBER SPRING PRE-LOAD ADJUSTMENT Using the universal clamp wrench, adjust the spring tension of the shock absorber by turning the spring pre-load adjuster ring as follows. ‘Standard spring pre-set length: 268.2 mm (10.6 in) 09910-60611: Universal clamp wrench CAUTION After adjusting the pre-load, tighten the spring adjuster lock ring securely SETTING TABLE Spring length STD: 268.2 mm (10.6 in) Softer : 273.2 mm (10.8 in} Stiffer : 260.2 mm (10.2 in) Damping force adjuster (STD) Compression : Fully turned-out position Rebound; 2% turned-out position from the fully turned-in position. NOTE: Fully turned-in position provides stiffest damping force.DR3SOP/SP ('93-MODEL) 12-26 WIRE ROUTING