99500 -43019-03 E
SUZUKI MOTOR CORPORA TJON PRIN TED IN JAPA N OCTOBER '90 @
(,.)
FOREWORD
The SUZUKI OR350 was designed to o ffer su perior p erform ance through lightweight design,
four s troke-power, engine coun ter-b alancer,
drysump lubrica tion sys tem and link type rear
GENERAL INFORMA nON
suspen tion.
AND TUNE-UP PROCEDURE
This service manual has been produced primarily fo r experienced mechan ics whose job is to inspec r, adjus t, repa ir and service SUZUKI
motorcycle. Apprentice mechanics and " do it
yourself" mechanics w ill also find this manual to
be an extremely useful guide.
ENGINE
The OR350. manufac tured to s tandard specifica t ions. is (he main subject matter of th is manu-
CHASSIS
FUEL AND LU8RICA nON
ELECTRICAL SYSTEM
al. However. the DR350 machines distribu ted in
your coun tr y might differ in m inor respec ts from
the standard-specification and. if the y do, it is because some minor modifications (which are o f n o
consequence in most c ases as far as servicing
is concerned) had to be made to comply w i th the
s tatu tory requiremen ts of your coun tr y.
This manual contains up ·to ·date information at
the time of i ts issue. Later made modi fications
and changes WIN be explained to eac h SUZUKI
distribu tor in respec ti ve markets, to whom you
are kindly requested ( 0 make query about up dated in formatio n , i f any.
SUZUKI MOTOR CORPORATION
SERVICING INFORMA nON
DR350S
DR350M ('91-MODELJ
DR350SM ('91-MODELJ
DR350N/ DR350SN ('92-MODELJ
10
11
DR350P/SP ('93-MODELJ
DR350R/SER ( '94-MODELJ
13
DR350S/ SES ('95-MODELJ
14
DR350T/SET ( '96-MODELJ
15
M o torcycle Service D epartment
16
('98, '99-MODELSJ 17
DR350V/SEV ( '97-MODELJ
DR350W/ X
© COPYR IGHT SUZUKI MOTOR CO RPORATION 1990
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 number or V .I.N . (Vehicle Identification
Number)
is stamped on the steering head pipe. Th e en·
gine seri al number ® is loca ted on the right side of th e
crankcase .
These number are required especially for regis tering the
machine and ordering spare parts.
<D
FUEL AND OIL RECOMMENDATIONS
FUEL
For U .S.A . model
1 . Use only unleaded gasoline of at leas t 87 pump oc tane
( a...pt method) or 91 oc tane or higher rated by the
resea rc h method.
2 . SUZUKI reco mmends th at customers use alcohol free ,
unleaded gasoline w henever possi ble .
3 . Use o f blended gasoline containi ng MTBE (M ethyl 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 . Gasoline/alcoho l fuel may con tain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present.
5 . If the performance of the vehicle is unsatisfactory while
using blended gasoline/alcohol fuel, you should swi tch
to alcohol free unleaded gasoline.
6 . Failure to follow thses guideli ne could po ssibl y void ap plicable warranty coverage . Check w ith your fuel supplier to be sure that the fuel you intend to u se meets the
requi rement s listed above .
For CANADA model
Use only unl eaded gasoline o f at least 87 pump octane
! 6.j-M m ethod) or 91 octane or higher faled by the
Resea rch Method .
For other models
Gasoline used should be graded 85 - 95 oc tane or higher.
An unleaded ga soline is recommended .
GENERAL INFORMATION 1·2
ENGINE OIL
For U.S.A . model
SUZUKI recomends the use of SUZUKI PERFORMANCE 4
MOTOR OIL or an oil which is rated SE or SF uner the API
(American Petroleum In stitute) classification system . The
viscosity rating is SAE 10W/40 . If an SAE 10W / 40 motor
oil is not available. select an alternate according to the right
MULTIGRADE
10W 30
c hart.
For other model s
Be sure that the engine oil you use comes under API c lassification o f SE or SF and that its viscosity rat ing is SAE
10W/40. If an SAE 1OW/40 m otor oil is no t available, se lect
the oil viscosity according to the right cha rt .
FRONT FORK OIL
Use fork oil # 10
99000· 99044·10G , SUZUKI FORK OIL # 10
BRAKE FLUID
Specification and c la ssification : DOT 4
99000· 23110 : SUZUKI BRAKE FLUID
WARNING :
* Since the brake system of this motorycle is filled with a glycol -based brake fluid by the manufacturer. 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 the best possible mate ri als are used and all mac hined parts are finished
to a ve ry high standard . but it is still necessa ry to allow the mov ing parts to " BREAK·IN" before
subjecting th e engine to maximum stresses. The future pe rformance and reliabi lity of the engine depends on the ca re and restraint exercised during its early life. The genera l rules are as follows.
Keep t o th ses break-in throttle position
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 below are needed for maintenance work on the OR350 and shou ld be kept on
hand for ready use. These items supplement such standard materials as cleaning fluids. lubricant.
emery cloth and like. How to use them and where to use them are described in the text of this manual.
METERIAL
For U.s.A. model
For other models
PART
• Throttle grip
• Odometer gear bOI(
• Side stand pivot
• Oil seals
• O-ring
• Front and rear wheel hub bearing
PAGE
2-2
2-2
2-2
3-32
3-47
2-2
6-1 , 20
• Steering stem boa ring
2-2
6 · 16
SUZUKI SUPER GREASE " A "
SUZUKI SUPER GREASE " A"
99000· 25030
99000-25010
SUZUKI SILICONE GREASE
99000· 25100
SUZUKI MOLY PASTE
99000· 2 51 40
SUZUKI BOND NO. 1207B
99104-31140
THREAD LOCK " 1342"
99000· 32050
• Cushion lever bearings. dust
seals and spacer
2-2
• Swingarm bearings
6-28
6-28
• Caliper skle
• Caliper ute and piston
6·5
6· 23
• Rocker arm shafts
• De·compression shaft
• Valve stems
• Countershaft and driveshaft gears
• Piston pin
• Camshaft journals and cams
• Cam chain t ensioner
3· 15
3·15
SUZUKI SILICONE GREASE
99000· 2 51 00
3·21
3· 29
3-43
3-45
3·46
SUZUKI MOLY PASTE
99000-25140
• Cylinder head cover
2· 3
3-45
• Mating surface 01 lefl and
right halves of crankcase
3-36
• Front and rear brake caliper
bolt
• Front footrest bolt
• Chain case rear side mounting
bolt
• Rear fende, rear side mounting
bolt
6·5
SUZUKI BOND NO. 1215
99000·31110
THREAD LOCK " 1342"
99000-32050
6- 23
GENERAL INFORMATION 1-4
MATERIAL
C---~C-~~----C7-C~ ~~-oC--C----~C-----PART
PAGE
I-___~FO~'~U=
.S . A~-~
m~od
=e~1_ __
For other~m~o~d=e~I'=---_ ___ --=--"CC,--------c--,-----,-------j• Gearshift cam bearing retainer
screw
• Pawel lifter screw
• Kick starter lever mounting bolt
• Gearshift cam driven gear boh
THREAD
99000-32030
" 1303"
THREAD
99000-32110
3-34, 38
3· 38
3-34. 38
" '322"
• Engine mounting bolls and nuts
3-4
8 · 17
• Kick starter pawl guide/stopper
• Cam sprocket bolts
• Gearshift arm stopper
THREAD LOCK SUPER " '303"
THREAD LOCK SUPER " ' 303"
99000-32030
99000-32030
3-38,39
3-45
3 ·34 , 37
• Magneto rotor nut
THREAD LOCK SUPER " '303"
THREAD LOCK SUPER " '305'·
99000· 32030
99000-32100
THREAD LOCK SUPER " '303"
THREAD LOCK
99000· 32030
99000-32 120
• Brake disc bolt
66·-'20
• Front fork 011
1-2
6 · 14
" '324 "
•
SUZUKI FORK OIL '11-10
99OO().99044- 1OG 11 .0 II
SUZUKI FORK Oil 11-10
99000-99044-100 11.0 L)
• Front and resl brake
, -2
2· 11
SUZUKI BRAKE FLUID
SUZUKI BRAKE FLUIO
99000-2311010. 5 LI
99000-23110 CO. 5 L)
1·5 GENERAL INfORMATION
PRECAUTIONS AND GENERAL INSTRUCTIONS
Observe th e follow ing items without fail when disasse mbling and rea sse mbling motorcycles.
o Do not run eng ine with little o r no ven til atio n .
o Be sure to repl ace pa cking s, gaskets. circlips. O-rings and cotter pins wi th new ones .
CAUTION :
Never reuse a circlip . After a eire lip 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 eire lip over the shaft.
After installing a c irclip , always insure that it is completely s eated in its groove and securely fitted .
o Tighten bolts and nuts from the ones of larger diameter to th ose o f smal ler diameter. an d from
in side to outside diagona lly, to th e specifi ed tightening torque.
D Use special tools w here specified .
a Use specified genuine parts and recomm end ed oils.
o When m ore th an 2 person s perform work together. pay attention to the safety of each other.
o After the reasse mbly, c heck parts for ti gh teness and operation.
o Treat gasolin e. w hich is extremely flammabl e and hig hl y expl osive. with greatest c are. Never use
gasoline as cleaning solvent .
Warning. Caution and Note are included in this manual occasionally , describing the foHowing contents.
WARNING . . . .. . . The parsonal safety of the rider or bystanders may be involved .
Di sregarding this information could result in personal injury.
CAUTION .. _ . ... Thses instructions point out special service procedures or precautions that
must be followed to avoid damaging the machine .
NOTE . ......... This provides special information to make maintenance easier or important
instructions clearer.
REPLACEMENT PARTS
When yo u rep lace any parts, use only genuine SUZU KI
replacement parts, or their equivalent. Genuine SUZUKI parts
are high quality parts which are designed and built specifi cally for SUZUKI vehicles.
CAUTION :
Use of replacement parts which are not equivalent in Quality to genuine SUZUKI parts can lead to performance
problems and damage .
GENERAL INFORMATION 1·6
SPECIFICA TlONS
DEMENSIDNS AND DRY MASS
Overall length .. _ ... _ 2 165 mm
Overall width .. .....
885 mm
Overall height ....... 1 250 mm
Wheelbase ....... .. 1440 mm
Ground clearance .. ..
310 mm
Seat height . . . . . . . .
920 mm
Dry mass . . . . . . . . . .
113 kg
ENGINE
Type .... _ . _ . . . . ..
Number of cylinders ..
Bore . . . . . . . . . . . . .
Stroke .... _ . . .....
Piston displacement. .
Compression ratio...
Carburator . . , ..... .
Air cleaner .. . ......
185 . 2 in)
134.8 in)
149 . 2 in)
156.7 in)
11 2. 2 in)
136. 2 in)
1249 Ibs)
Four-stroke , air-cooled ,
OHC
1
79 .0 mm (3.'10 in)
71 . 2 mm (2.803 in)
349 em) (21.3 cu. in)
9, 5 : 1
MIKUNI
TM33SS .
single
Polyurethane
foam
element
Starter system . . . . .. Primary kick
Lubrication sys tem. . . Dry sump
TRNSMISSION
Clutc h . . . . . . . . . . ..
Transmi ssion. . . . . ..
Gearshift pattern ....
Primary reduction ....
Final redu ctio n ......
Gear ratios, Low ....
2nd . . ..
3rd . . ..
4th . . ..
5th ....
TOP ....
Drive chain ... . ... .
Wet multi-plate type
6-speed constant mesh
1-down , 5-up
2.818 (62 / 22)
3 . 357 (4711 4)
2.416 (29/ 12)
1. 733 126/15)
1.333 124 / 18)
1 .111 120/ 18)
0.952120 / 21)
0.826 119/ 23)
TAKASAGO RK520S0
or
DA ID O
DID .
520VC5. 110 links
ELECTRICAL
I 't'Ion t ype . . . . . . . . SUZUKI " PEl "
9"'
Ignition timing . . . . .. 5 °
B. T . D .C.
below
2 300 rI m in and
30° B.T.D.C. above
4 300 r/min
Spark plug . . . . . . . . . NGK DPR9EA -9
NIPPON DENSO
X27EPR-U9
or
CHASSIS
Front suspens io n .... Telescopic, coil spring ,
oil damped , spring
preload fully way ad justable, compression
damping f o r c e ad justable
Rear suspension . . . . . Link type suspension
sys tem ,
gas loi l
damped, spring preload
fully way adjustable,
compression and rebound damping force
adjustable
Stee ri ng angle . ..... 45 ° (right and left)
Caster ..... . ..... _ 62 D 30'
Trail ..... .. . _ ..... ' 118 mm (4.6 in)
Turning radius ...... 2 . 2 m (7.2 ttl
Fron 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
in cluding reserve ... 9 . 5 L (2 . 5/2.1 USl imp
gal)
reserve . . . . . . . . . . 1. 8 L (0.5/0.4 US/Imp
gal)
Engine oil , oil change . 1700 m l (1 . 8 / 1 .5
USlimp qt)
Front fork oi l ....... 586 ml (19 . 8 / 20.6
US/Imp oz)
These spec ifications are subject to change
without notice .
PERIODIC MAINTENANCE
AND TUNE-UP PROCEDURES
ON TENT
PERIOOIC MAINTENANCE SCHEOULE . ... . •.... • . ..• . 2- 1
PERIOOIC MAINTENENCE CHART ..• . • . •. . . . . • . . . . 2- 1
LUBRICA TION
POINTS . . . . . . . . . . . . . . . • . • . . • . . .. • 2- 2
MAINTENANCE AND TUNE-UP PROCEDURES . ... . . . ... 2- 3
CYLINDER HEAD BOLTS AND NUTS, CYLINDER
NUTS, EXHAUST PIPE BOLTS . . •.• . . . . ...•. ... . . . . 2 - 3
VALVE CLEARANCE . ... . . . . . . ... . . . • . . . . . . . . . . .. 2- 4
SPARK PLUG . ... . . . . . . . . • . . . . . . . • . . . . . . . . . ... . 2 - 5
SPARK ARRESTER . ... .. . . • . . . ... . • . . . . . . . • . . . . . 2- 5
AIR
CLEANER . . . . . . . . . . . . . . . . . . ... . ..... •.. ... 2 - 6
DE-COMPRESSION LEVER . . . . . . . . . . . . . . . . . . .. . .. . 2- 6
ENGINE OIL, OIL FILTER AND OIL STRAINER . ..••• •.. 2- 7
CARBURETOR . . . . . ... .. . . . ... . ... . ..... . . . .... 2- 8
FUEL LINE . . . . . . . . . . . . . . . . . . ... . ... . ... . . • . . .. 2- 9
CLUTCH . . . . .. . ... ... .• . . . . . . ... .. .. . . . . . . . . . . 2- 9
DRIVE
CHAIN . . . . . . . . . . . . . . . . . . . . • ..... . . • . ... 2 - 9
BRAKES . .... .. . ... . . . • ... . . . ... .. . .. . •. . . .... 2-10
TIRES . . .... . . . . . . . . . ... . . . . . . . . • . . . . . . . . . . . .. 2-13
SPOKE
NiPPLES . .. . . . .. . . . . . . . . . .... . .. . ... . . . 2-13
STEERING . . . .. . . . . . . . ..... . .. . . • . . . . . . . . . . . . . 2 - 14
FRONT FORK . .. . . . ... ... . ... . . . . . . . . . . . . . . . . . . 2-14
REAR SUSPENSION . . .. . . . . . . . . • . . • • . . . . . . • • . . • . 2-14
CHASSIS BDL TS AND NUTS . •..•••• • .•.•.• _ •. • . .• 2-15
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for aU the required periodic service work necessary
to keep the motorcycle operating at peak performance and economy . Travelilng distances are expressed in terms of hours.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe condit ions.
PERIODIC MAINTENANCE CHART
Interval
Item
Cylinder head bolts and nuts, cylinder nuts,
exhaust pipe bolts and muffler connections
Initial 5 Hours Every 30 Hours Every 60 Hours
T
T
T
Valve clearance
I
-
I
Spark plug
-
I
A
Spark arrester
-
C
C
Air cleaner
Inspec t each time the motorcycle is ridden and
clean as necessary
De -compression lever
I
I
I
Engine oil and oil filter
A
-
A
Engine oil hoses
I
I
I
Engine oil strainer
C
-
C
Carburetor
I
I
I
I
I
I
Fuel line
Replace every 4 years
Clutch
Drive c hain
Brakes
I
I
I
Clean, lubricate and inspect each time the
motorcycle is ridden
I
I
I
I
I
I
Brake hoses
Repla ce every 4 years
I
Brake flu id
I
I
Replace every 2 years
Tires
Inspect tire pressure and damage each time
t~e motorcycle is ridden
Spoke nipples
Inspect each time the motorcycle is ridden
I
I
-
Rear suspension
I
-
I
Chassis bolts and nuts
T
T
T
Steering
I
Front fork
I : Inspec t and adjust , c lean , lubricate or replace as necessary
R : Replece
T : Tighten
C : Clean
I
PERIODIC MAINTENANCE AND TUNE·UP PROCEDURES 2·2
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each warking part of the
motorcycle.
Major lubrication points are indi cated below.
l!J Clutch cable _ _---,
mClutch lever holder
mFront wheel bearing
mSide stand pivot
I bearing
Throttle cable
Throttle grip holder
mSteering stem
bearing
m
:
m;Grease
Motor oil
[i]
Swingarm pivot
bearing
r!l Odometer gear box
NOTE:
• Before lubricating each part clean off any rusty spots and wipe off any grease, oil, dirt or grime.
•
Lubricate exposed parts which are subject to rust, with motor oil or grease .
2-3 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
MAINTENANCE AND TUNE-UP
PROCEDURES
This section describes the servicing procedures for each item
of the Periodic Maintenance requirements .
CYLINDER HEAD BOLTS AND NUTS,
CYLINDER NUTS, EXHAUST PIPE BOLTS AND
MUFFLER CONNECTIONS
Tighten Initial 5 Hours and Every 30 Hours
CYLINDER HEAD AND CYLINDER
• Remove the frame covers, seat and fuel tank .
• Disconnect the spark plug cap and breather hose.
• Disconnect the de-comp o cable. IRefer to page 3· 2 .)
• Remove the upper side of engine mounting bolts and
cylinder head cover. IRefer to pages 3·3 and 3 -7 .1
• First loosen and retighten the four bolts CD and two nuts
® to the specified torque with a torque wrench sequentially in diagonally with the engine is cold.
Tightening torque
<D:
Bolt
35 - 40 N -m 13_5 - 4_0 kg-m , 25.5-29.0 Ib-It)
Nut @ : 23 - 27 N 'm 12.3 - 2 .7 kg-m. 16.5 - 19. 5Ib-It)
• After firmly tightening the cylinder head bolts and nuts.
tighten the two cyli nder nuts @ to the specified torque .
Tightening torque
Nut @ : 23 - 27 N 'm 12.3 -2.7 kg-m. 16.5 - 19.5 Ib -ft!
• When installing the cylinder head cover. apply SUZUK I
80ND No. 12078/ 121 5 to the mating suriace.(Refer to
page 3-45. )
EXHAUST PIPE AND MUFFLER
• Tighten the exhaust pipe bolts @). muffler connection bolt
® and muffler mounting bolts to the specified torque.
®
TIghtening torque
Bolt @ :18 - 28 N ' m 11.B - 2.8 kg-m . 13.0 - 20.0 Ib-It)
Bolt ®: 18-28 N'm 11.8- 2 .B kg -m. 13.0 - 20.0 Ib-It!
Bolt @ :23-28 N'm 12.3-2.B kg-m. 16.5 - 20.0 Ib-It)
PERIODIC MAINTENANCE AND TUNE·UP PROCEDURES 2·4
VALVE CLEARANCE
Inspect Initial 5 Hours and Every 6 0 Hours
Excessive valve clearance results in valve noise and insuffi·
cient valve clearance results in valve damage and reduced
power. At the distances indicated above. check and adjust
the clearance to the specification.
The procedure for adjusting the valve clearance is as follows:
NOTE:
Valve clearance is to be checked when the. engine is cold.
Bach intake and exhaust valves must be checked and adjusted when the piston is Bt Top - Dead- Center (T.D ,C.)
on the compression stroke.
• Remove the frame covers, seat, fuel tank and ignition coil.
• Remove the spark plug and valve inspection caps, intake
and exhaust.
NOTE:
Before adjusting the valve clearance, check or adjust the decompression lever clearance,
V alve clea rance sp ecification s
IN .: 0 .0 5 - 0 .10 mm 10 .00 2- 0 .004 in )
EX .: 0 .08 - 0 .13 mm 10 .003 - 0 .005 in )
• Drain engine oiL (Refer to page 2 -7.1
• Remove the T,D.C. inspection plug CD and magneto cover
cap ® on the magneto cover.
• Turn the crankshaft counterclockwise with the box
wrench to set the piston at T.O.C. on th e compression
stroke . (Turn the crankshaft until the engraved line @ on
the magneto rotor is aligned with t he center of hole on
the magneto cover.)
• Insert the thickness gauge into the clearance between
the valve stem end and the adjusting screw on the rocker arm .
09900 -2 0803 : Thick ness gauge
09917 -14910 : V alve adju st driver
• If clearance is off the specification. bring it into the specified range with the special tools .
• Securely tighten the lock nut after adjustment is com pleted .
CAUTION:
Both right and left valve clea rances, should be as closely
set as possible.
NOTE:
Make sure to re -check (he de-compression lever play, after
valve clearance adjustment is made.
• Reinstall the removed parts and add engine oil.
2·5 PERIODIC MAINTENANCE AND TUNE·UP PROCEDURES
SPARK PLUG
Inspect Every 30 Hours and Replace Every 60 Hours
The plug gap is adju sted to 0 .8 - 0.9 mm (0 .03 - 0 .04 in ).
The gap is co rrectly adjusted wi th a thickness gauge. When
ca rbon is deposited on the spa rk plug . rem ove the carbon
deposit s with wire or pin . If the electrodes are extremely
worn or burnt , replace the plug. Also replace th e plug if it
has a broken insu lator, d amaged thread. etc.
NGK DPR9EA-9 or NIPPON DENSO X27 EPR-U9 as listed in
the table should be used as the standard plug . However. the
heat range o f th e plug should be selected to meet the requirem ent s of speed, actual load. fuel, et c. If the plug need
to be replaced , it is recommended that the standard plug
listed in the table be select ed. Remove the plug and inspect
the insulator. Proper heat range would be indicated if it in·
sulator was light brown in color. If it is blac kened by carbon, it should be replaced by a hot type NGK OPR8EA-9 or
NIPPON DENSO X24EPR-U9.
NOTE:
To ch eck the spark plug, first make sure that the fuel tank
contains unleaded g8soline, and after a test ride if the plug
is sooty with carbon or burnt white, replace it.
NOTE:
Confirm the thread size and rea ch when replacing the plug.
" the reach is too short, carbon will be depois ted on the
screw portion of the plug hole and engine damage may
reslut.
NOTE:
" R n t ype spark plug is installed for some specifica tions. uR "
type spark plug has a resistor 10cBted at the cen ter electrode
to pre ven t radio noise.
Clean Every 30 Hours
~PPQN DENSQ
REMARKS
DPRBEA·9
X24EPR· U9
If the standard
plug Is apt to
get wet, reo
place 1t with
this hot type
plug .
DPR9EA·9
X21EPR·U9
Standard
NGK
. .'
~ r· ~­
SPARK ARRESTER
I
0 .8 - 0 .9 mm
10.03-0,04 inl
I
• Remove th e drain bolt .
• Start the engi ne and rev it to blowout the accumulated
carbon particles .
• Stop the engine. and install the drain bolt securely.
WARNING :
Only clean the spark arrester in an open area away from combustible materials. Exhausted hot carbon particles can start
a fire .
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-6
AIR CLEANER
Inspec t each t ime the motorc ycle is rdden and clean
as necessary
If the air cleaner is clogged with dust, int ake r es istance will
be increased with a resul ta nt decrease in power output and
an in crease in fuel consumptio n .
Check and clean the element in the following manner:
• Remove the left frame cover.
• Remove the air cleaner case cover.
• Remove the element.
• Separate the polyurethan foam element CD from the e l e ~
m ent frame @ .
• Fill a washing pan of a proper size with nonflammable
cleaning solvent . Immerse the element in the c leaning solvent and wash it c lea n .
• Squeeze the c leaning so lvent o f the washed elem en t by
pressing it between the palms of bot h hands.
• Immerse the element in motor oil , and squeeze the oil out
of the elemen t leaving it sligh tl y wet wi th oil.
NOTE:
Do not t wist or wring the element because it will tear or the
individual cells of the element will be damaged.
CAUTION:
In spect the element ca refully for rips. torn sea m s, etc . If any
damage is noted. replace the element .
• Reinst all the clea ned or new c leaner element in the
reverse order of removal.
Nonflammable cleaning
solvent ~
!
lJLJ ,.
DE-COMPRESSION LEVER
Inspect Initial 5 Hours and Every 30 Hours
~,i'---In co rrect adjustment o f th e lever clea rance may res ult in
starting difficulties or engine damage. Check th e lever clearence and if necessary, adjus t as follows :
• Adjust the valve c learan ce. (Refer t o page 2-4 .)
• Loosen both lock nuts @ on the ca ble adjuster @.
• Locate the adjuster @ to provide the speci fied lever clearance ® as shown in photograph .
• Tighten both lock nuts @.
De -compression lever clearance ®: 1 - 2 mm
(0 _04 - 0 _08 inl
,,'
..
SAE
1QW/4 0
OIL
2-7 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
ENGINE OIL, OIL FILTER AND OIL STRAINER
Replace (Change) oil and oil filter Initial 5 Hours and
Every 60 Hours
Clean oil strainer Initial 5 Hours and Every 60 Hours
The oil should be cha nged while the engine is hot .Oil filter
replacement at the above int ervals should be done together
with engi ne oil change .
• Amove the engine under cover.
• Keep the motorcycle upright. supported by jack or block.
• Place a"n oil pan under the frame head pipe and the engine.
• Rmove the engine oil drain plugs (CD and 0 1and oil filler
ca p @ to drain e ng ine oil.
• Remove the oil filter cap @ by removing the three bolts.
• Remove the old filter ®. and install th e new one.
• Replace th e filter cap @) and tighten the bolt s securely.
NOTE:
Before installing the oil filter and filter cap. check to be sure
that the spring ® and new O-rings (<2) and @ ) are installed
correctly.
• Remove the oil strainer ®.
• Clean the oil strain er ® at th e above intervals.
• Tighten the oil strainer ® t o the specified torque.
Tightening torque :25 - 30 N ·m
12.5-3 .0 kg-m . 18 .0 - 21-5 Ib -ftl
• Tighten the oil drain plugs KD and 0 ) sec urely. and add
fresh oil through the oi l filler. The engine w ill hold about
1 900 m l of oil.
Use API classi fi cation of SE or SF oil with SAE 10W/ 40
viscosity .
• Install t he fill er cap @ .
• Sta rt up the engine and allow it t o run for 3 minutes at
idling speed.
• Stop th e eng ine w ith the engine stop switch and wa it
one minute. then check th e oi l level by rem ovi ng the oil
level gauge @ . If the level is below m ark " F" . add oil
to that level.
NECESSARY AMOUNT OF ENGINE OIL
Oil change : 1 700 ml 11 .8 / 1 _5 US/lmp qtl
Filter change : 1 900 ml (2 .0 / 1.7 US /Imp qt)
Overhaul engine: 2100 ml (2.2/ 1 .8 US /Imp qt)
(
PERIODIC MAINTENANCE AND TUNE·UP PROCEDURES 2·8
CARBURETOR
Inspect Initial 5 Hours and Every 30 Hours
THROTTLE CABLE ADJUSTMENT
A twin throttle cable system is used in this motorcycle . Ca ·
ble CD is for pulling and cable @ is f or returning. To adjust
the cable play ,adjust the returning cable first and then ad just the pulling cable.
Returning Cable Play
The returning cable adjuster should have 2 - 3 mm
(0.08 - 0 . 12 in) of clearance as shown in the illustration .
If the adjustment is necessa ry . carry out the pro cedure
below:
• Loosen the lock nut ® .
• Turn adjuster
to obtain the clearance @ of 2 -3 mm
®
10.08 - 0 .12 inl .
• Tighten the lock nut @ securely.
Pulling Cable Play
The pulling cable play @ should be 0 . 5 - 1 .0 mm
(0.02 - 0 .04 in). If the adjustment is necessary, ca rry out
the procedure below :
• Turn the handlebar all the way to the left .
• loosen lock nut @.
• Turn adjuster ® to obtain a cable play of 0.5 - 1.0 mm
10.02 - 0 .04 in).
• Tighten lock nut ® securely.
• Make sure that the clearance of © is less than 1.0 mm
(0 .04 in ) when th e throttle grip is fully opened .
WARNING :
After the adjustment is completed. check that handlebar
movement does not raise the engine idle speed and that the
throttle grip returns smoothly and automatically .
AI OLE RPM {Idling adjustmentl
NOTE:
Make this adjustment when the engine is hot.
• Start up the engine and set its speed at anywhere be·
tween 1 300 and 1 500 rl min by turning the throttle stop
screw 0.
• Turn in or out the pilot screw ® within 112 turn from the
standard setting . and se t it when the engine speed is at
the highest possible level.
• After thi s adjustment. recheck the idling speed and ad·
just to between 1 300 and 1 500 rl min with throttle stop
screw if necessary .
•
.'
2·9
FUEL LINE
Insp ect Initial 5 Hours and Ev ery 30 Hours
Replace Ev ery 4 years
Inspect the fuel line for damage and fuel leakage.
If any defects are found. the fuel line must be replaced .
CLUTCH
In spect Initial 5 Hours and Every 3 0 Hours
• Loosen the lock nut <D and turn the adjuster ® fully in.
• Loosen the cable lock nut @ and adjust the play of the
cable with the adjuster @ until play of the clutch lever
isl0 - 15mm.
Clutch lever play ® : 10 - 15 mm(O.4 - 0. 6 in)
• Tighten the lock nuts
((D and @).
NOTE:
Minor adjustment can be made by the adjuster @ after
loosening the lock nut <D. A t the same intervals. lubricate
the clutch cable with motor oil.
DRIVE CHAIN
Clean. lub ricat e and ins pect each tim e the
mot orcycle is red den
Visually inspect the drive chain for the listed below possi·
ble defects . (Lift the rear wheel and place a jack or block
under the engine, and turn the rear wheel slowly by hand
with the transmission in NEUTRAL.
• Loose pins
.. Damaged rollers
I'
Dry or rusted links
I'
Kinked or binding links
I'
Excessive wear
.. Missing Q· rings
If any defec ts are found , the drive chain must be replaced .
CHECKIN G
• Remove the cotter pin
(For U.S.A . and Canada) .
• Loosen the axle nut @.
• Tension the drive chain fu ll y by turning the right and left
chain adjusters 0.
• Count ou t 21 pins (20 pitches) on the chain and meas·
ure the distance between the two points. If the distance
exceeds following limit, the chain must be replaced .
®
Service Limit: 3 19. 4 m m (12 .5 7 in )
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 1-10
ADJUSTING
• Turn both chain adjusters CD until the chain has 25-40
rnm of slack at the middle between en gi ne and rear
sprockets. The number @ on both chain adjusters must
be at the same position to ensure that the fro nt and rear
w heels are correctly aligned. Place the motorcycle on the
side stand for accurate adjustment,
Drive chain slack: 25 - 40 mm 11 .0 - 1 .6 in)
• Afte r adjusting the drive chain slack, tighten the axle nut
to the specified torque .
Tightening torque
Rear axle nut: 85 - 115 N-m
(8_5 - 11 _5 kg -m . 61.5 - 83_0 Ib-It)
CLEANING AND LU8RICATING
• Wash the chain with kerosene . If the c h ain tends to ru st
faster , the intervals must be sho rtened.
CAUTION :
Do not use trichlene . gasoline or any similar fluids : These
fluids have too great a dissolving power for this chain and .
what is more important. can damage the " 0 " rings (or seals)
confining the grease in the bush -to-pin clearance. Remem ber. high durability c omes from the presence of grease in
that clearance .
• After washi ng and drying the chai n. oil it with a
heavyweight m o tor oil.
CAUTION :
Do not use any oil sold commercially as " drive chain oil " .
Such oil can damage the "0" ring s (or seals).
The standard drive chain is DAIOO OJ .0 .520VC5 or
TAKASAGO RK520S0 SUZUKI recommends that the
above-mentioned standard drive chain be used for the
replacement .
BRAKES
In spect Initial 5 Hours ·and Every 30 Hours
Replace hoses Every 4 years
Replace (change) fluid Every 2 years
BRAKE FLUID LEVEL
• Keep the motorcycle upright and place the handlebar
straight .
o
25 - 40 mm
' 1.0-1 .6 in)
2-11 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
• Check the brake fluid level by observing the upper (only
for fea f brake ) and lower (both fron t and rear brake) limit
lines on the brake fluid reservoirs.
• When the level is below the lower limit tine, replenish with
brake fluid th at meets the follow ing specificatio n .
Specification and classification : DOT 4
99000 -23110 : SUZUKI BRAKE FLUID
WARNING :
The brake system of this motorcycle is filled with a glycolbased brake fluid . Do not use or mix different types of fluid
such as silicone-based and petroleum-based . Do not use any
brake fluid taken from old. used or unsealed containers .
Never re -use the brake fluid left over from the last servicing
and stored for long periods .
WARNING :
Brake fluid . if it leaks. will interfere with safe running and
immediately discolor painted surfaces.
Check the brake hoses for cracks and hose joints for leak age before riding .
BRAKE PADS
Wearing condition o f brake pads can be c hecked by observ ing the groove ill (front and rear calipers ) marked on the pad .
When the wear exceeds the limit mark , replace t he pads w ith
new ones. (Refer to pages 6 -6 and 6 -23.)
BRAKE LEVER PLAY
Adjust the front brake leve r playas follows.
• Loosen the lock nut ®.
• Turn the adjuste r @ in or out to obtain the correct play
®
Brake lever play @: 0 - 0 .3 mm (0 - 0 .01 in)
• Tighten the loc k nut @.
BRAKE PEDAL HEIGHT
• Loosen the lock nut @) and stopper bolt @.
• Loosen the lock nut ®, and rotate push rod (2) to locat e
b rake pedal 5 mm below the top f ace o f the foo trest .
• Reti ghten the lock nut ® to secure the push rod (2) in
the proper position .
• Tighten the stopper bolt ® so that the clearance bet ween
the st opper bolt and stopper is zero.
• Tighten th e lock nut 0 securly .
Brake pedal height @: 5 mm 10.2 inl
Rear
Front
Grooved
limit lirH!!
PERIOOIC MAINTENANCE ANa TUNE·UP PROCEDURES 2·12
BLEEDING AIR FROM TH E BRAKE flUID CIRCUIT
Air trapped in the flu id circuit acts like a cushion to abso rb
a large p roportion of the pressure developed. by the mast er
cylinder and thus interferes with the full braking performance
of the brake caliper . The presence of air is indicated by
"sponginess" of the brake lever and also by lack of braking force . Considering the danger to which such trapped air
exposes the machine and rider, it is essential that. after remounting the brake and restoring the brake system to the
normal condition. the brake fl uid ci rcuit be purged of air in
the following manner:
• Fill up the master cylinder reservoir to the upper end of
the inspection window (for front brake) and upper line
(for rear brake) . Replace the reservoir cap to prevent entry of dirt.
• Attach a pipe to the caliper bleeder valve, and insert the
free end of the pipe into a receptacle .
• Squeeze and release the brake lever several times in rapid
successio n, and squeeze the lever fu ll y without releasing it. Loosen the bleeder valve by turning it a quarter
of a turn so that the brake fluid runs into the receptacle:
this will remove the tension of the brake lever causing
it to touch the handlebar grip. Then , close the valve , pump
and squeeze the lever, and open the valve . Repeat this
process until the fluid flowing into the receptacle no
longer contains air bubbles .
NOTE:
Replenish the brake fluid reservoir as necessary while bleeding the brake system.
Make sure that there is always some fluid visible in the
•
reservo".
• Close the bleeder valve . and disconnect the pipe . Fi ll the
reservoir to t he upper end of the inspection window (for
front b rake) and upper line (for rear brake) .
• Rear brake : Differences between fron t and rear are that
the master cylinder is actuated by a pedal.
Bleed er v alve
Tightening torqu e: 6 - 9 N 'm
(0 .6 - 0 .9 kg-m . 4 .5 - 6 .5 Ib-Itl
CAUTION :
Handle the brake fluid with ca re: the fluid reacts chemical ly with paint. plastics. rubber materials. etc .
.""'if
••
2·13 PERIODIC MAINTENANCE AND TUNE·UP PROCEDURES
TIRES
••
Inspect tire pressure and damage each time the
motorcycle is redden
TIRE TREAD CONDITION
Operating the motorcycle with excessively worn tires will
decrease riding stability and consequently invite a danger·
ous situation. It is I:lighly recom mend ed to replace tire when
the remaining depth of tire tread re aches the follow ing
specification .
Tire tread depth limit
Front & Rear: 4 .0 mm 10.16 in)
TIRE PRESSURE
If the tire pressure is too high or too low, stee ring will be
adversely affected and tire wear increased . Therefore. main·
tain the correct tire pressure for good roadability or shorte r
tire life will result.
Cold inflation tire pressure is as follows .
FRONT
REAR
kPa
kg /cm 2
psi
kPa
kg/cm2
pSI
100
1.00
14
100
1.00
14
CAUTION :
The standard tire fitted on this motorcycle is 80 /100-21 51 M
for front and 110/100-18 64M for rear. The use of tires other
than the those specified may cause instability . It is highly
recommended to use a SUZUKI Genuine Tire .
SPOKE NIPPLES
Inspect each time the motorcycle is ridden .
Check t o be sure that all nipples are tight, and retighten them
as necessary with a special tool.
09940-60133:Spoke nipple wrench
Tightening torque:2 - 4 N'm 10 .2 - 0.4 kg-m . 1 .5 - 3.0 Ib-ftl
PERIODIC MAINTENANCE AND TUNE·UP PROCEDURES 2·14
STEERING
Inspect Initial 5 Hours and Ev ery 60 Hours
Steering should be adjusted properly for smooth turning o f
handlebar and safe running . Overtight steering prevents
smooth turning of the handlebar and too loose steering will
cause the handlebar to vibrate .
Check that there is no play in the front fork assembly by
supporting the motorcycle so that the fron t w heel is off the
ground, with the wheel straight ahead , grasp the lower fork
tubes near the axle and pull forward . If play is found . per·
form steering bearing adjustment as described in page 6 - 19
of this manual.
FRONT FORK
Inspect Initial 5 Hours and Every 60 Hours
Inspect the front fork oil leakage, scoring or scra tches on
the outer surfa ce of the inner tubes. Replace any defective
parts, if necessary.
REAR SUSPENSION
•
Inspect Initial 5 Hours and Ev ery 60 Hours
Inspect the shock absorber for oil leakage and check that
there is no play in the swing arm assembly .
2·15 PERIODIC MAINTENANCE AND TUNE·UP PROCEDURES
CHASSIS BOLTS AND NUTS
Tighten Initial 5 Hours and Every 60 Hours
The nuts and bolts listed below are important sa fety parts . They must be retightened when neces·
sary to the specified torqu e with a torque wrench . (Refer to page 2- 16 for the locations of the following nuts and bolts on the motorcycle.
Item
(i)
@
@
@
N 'm
kg-m
lb·"
80 - 100
20 - 31
20-31
30-40
8.0 - 10.0
2.0 - 3 . 1
2.0 - 3 . 1
3 .0 - 4 .0
58.0 - 72.5
14.5 - 22.5
14. 5-22.5
21.5 - 29.0
30 - 40
50 - 80
6- 8
3 .0 - 4 .0
5.0 - 8 .0
0 .6 - 0 .8
21.5 - 29.0
36.0-58.0
4.5 - 6 .0
18 - 28
6- S
20 - 31
1.8- 2 .8
0 .6 - 0 .S
2.0 - 3. 1
13.0 - 20.0
4 .5- 6 .5
14.5 - 22.5
2.0 - 2.5
0 .6 - 0 .S
1 .8 - 2.8
4.4 - 6 .6
14.5 - 18.0
4 .5 - 6 .5
13.0 - 20.0
Front footrest bolt
20 - 25
6- S
18-28
44 - 66
Swing arm pivot nut
61 - S4
6. 1 - S.4
32.0 - 47 .5
44.0 - 68.0
48 - 72
4 .8 - 7. 2
34.5 - 52.0
84 - 120
60 - S6
84 - 120
8.4 - 12.0
6 .0-S.6
8.4-12.0
60.5 - 87.0
43.5 - 6S.5
60.5 - 87 .0
85 - 115
2- 4
8 .5 - 11.5
0 . 2 - 0.4
61 .5 - 8 3.0
1.5 -3. 0
8 - 12
15 - 20
0 .8 - 1.2
6 .0- 8 .5
11.0-14.5
Steering stem head nut
Front fork upper clamp bolt
Front fork low er clamp bolt
Front fork cap bolt
® Front fork damper rod bolt
® Front axle shaft
Q) Front axle pinch nut
® Handlebar clamp bolt
® Front brake ma ster cyli nd er mounting bolt
@i
@
@
@
@
@
Front brake ca liper mounting bolt
Brake hose union bolt (Front & Rear)
Air bleeder valve (Front & Rear)
Brake disc mounting bolt (Front & Rear)
Shock absorber mounting nut
@ (Upper & Lowe r)
@ Rear cushion rod mounting nut
@ Rear cushion lever nut (Frontl
@ Rear cushion lever nut (Center)
® Rear axle nut
® Spoke nipple
® Rea r brake ma ster cylinder mounting bolt
@ Rear brake rod lock nut
1.5 - 2.0
PERIODIC MAINTENANCE AND TUNE·UP PROCEDURES 2·16
ONTENT ; . . - - - - - - - - - - - ,
ENGINE COMPONENTS REMOVABLE WITH THE
ENGINE IN PLACE . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . 3- 1
ENGINE REMOVAL ANO REMOUNTING • .•• . ••........ 3· 2
ENGINE OISASSEMBLY . . . . . . . . . . . . . . . . • • . . .. .... . 3· 6
ENGINE COMPONENTS INSPECTION AND
SERVICING . ..... .. ... . .. . .. .. ..... . .....••. . ... 3 - 14
CYLINDER HEAD COVER . . . . . . . . . . . . . .... •..•.... 3 · 14
ROCKER ARM ... ...... . . . . . . . . . . . . . . . . • . . . . . . . 3-15
CYLINDER HEAO . . ..• . . . . . . . . • . . . . . . . . . •. . . . . . . 3·16
VALVE . . . . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . ... 3-16
CAMSHAFT . . . . . . . . . . . • . . . . . . . . . ... . . . • . . . . . . . 3-22
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . •.. ... . . . .. 3-23
PISTON . . . . . . . . . . . • . .. . . . • . . . . . . . • • . . . . . . •.. . 3-23
CONROD . . . . . . . . . • . . . . . . • . . . . . . . . . . . . . . . . . . .. 3-26
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -26
CLUTCH . . ... . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . 3 -27
TRANSMISSION. . • . . . . . . • . . . . . • . . . . . • • • • • . • . . . 3 · 28
CRANK BALANCER SHAFT AND GEARS . . . . . . . . . . ... 3·31
CRANKCASE BEARINGS .. • .. • . •• . . .... .•. ... .... 3 · 31
ENGINE REASSEMBL Y . . . . . . . . . . . . . . . ... ••. .... ... 3·32
OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 3·32
CRANKSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-32
BALANCER SHAFT AND GEARS . ..•. . . . . . . . . . . ...• 3·33
OIL
PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -33
GEARSHIFT CAM AND FORKS • •..•..........•••.• 3 · 34
OIL PUMP AND OIL SUMP FILTER . •.. . .• ...•.• .•.• 3-35
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -36
CAM CHAIN AND PRIMARY DRIVE GEAR • ...• .• ..•• 3·37
KICKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
CLUTCH . ..... .. . . . . . . . . . . . . . . . . . . . . . . .. • .. ... 3-40
OIL FILTER . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 3-41
MAGNETO . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . .. .. 3-42
PISTON RING AND PISTON . .•..••. .. . . . • . . . . . . . • . 3 · 42
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . .. 3-43
CYLINDER HEAD .. .... . . . . . . . • . . . . . . . . . . . . ..... 3-44
CA MSHA FT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-44
CYLINDER HEAD COVER . .•...•.••....••••.••..•• 3-45
CAM CHAIN TENSIONER ADJUSTER • ... •. .• .•..... 3-46
OIL
PIPE . . . . . . . . . . . . . . . . . . . . . . . .. . • . . . . . . • . . . 3-47
MAGNETO COVER • . . ....•.•.... . • . . . . . . • . . . . . . . 3 · 48
3·1 ENGINE
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE
The parts listed below can be removed and reinstalled without removing the engine from the frame .
Refer to the page listed in this section for removal instruction .
ENGINE LEFT SIDE
Re fer to page
Engine sprocket.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3· 3
Magneto cover . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . .
3· 6
Magneto rotor ..... .......................... .
Magneto coil ........... .. . . . . . . . . . . . . . . . . . . . .
3· 8
3· 13
ENGINE CENTER
Refer to page
Cylinder head cover . . . . • . . . . . . . . . . . . . . • . . . . . . . .
3· 7
Camshaft . . . . . . . . . . . . ....... .. . . . . . . . . . .... , .
3· 7
Cylinder head . . . . . . . . . . . . . . . . . _ . . . . . . • . . . . . . . .
3· 7
Cylinder . . . . . . . . . . .. • . . . . . . . . . . . • . . . . . . . . . . . .
3· 7
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . .
3· 8
Cam drive chain . . ..... . . . . . . . . . . . . . . . . . . . ... . .
3· 10
ENGINE RIGHT SIDE
Refer to page
Oil fi lter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2· 7
Clutch cover . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .
3· 8
3- 8
Clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary driven gear assembly . . . . . . . . . . . .....• . .. .
3· 9
Oil pump driven gear . . . . . . . . . . . _ . . . . . . . • . . . . __ .
3· 9
Kick shaft assembly . . _ .. _ . _ .... __ . . . . . . . . . . . . _ .
3- 9
Gearshift shaft . . _ ... _ ... . ..... _ . . . . . . . . . ..... .
3· 9
Primary drive gear . .. _ .. _ .... _ • _ .. _ .• _ ... _ .... .
3- 10
ENGINE REMOVAL AND REMOUNTING
ENGIEN REMOVAL
Before taking the engine out of the frame, thoroughly clean
the engine with a suitable cleaner.
The procedure of engine removal is sequentially explained
in the following steps.
• Remove the left and right frame cavers.
• Remove the seat by removing the two bolts.
• Turn the fuel cock lever to "OFF" position .
• Disconnect the fuel hose.
• Remove the fuel tank by removing the four mounting
bolts.
• Remove the engine under cover by removing the four
bolts .
• Drain engine oil. (Refer to page 2-7.J
• Loosen the muffler clamp bolt CD.
• Remove the exhaust pipe by removing the exhaust bolts
@.
• Disconnect the de-compression cable @ and cylinder
head breather hose .
• Remove the high tension cord clamp.
• Disconnect the spark plug cap.
• Disconnect the magneto lead wires @ .
• Loosen the lock nuts ® and disconnect the throttle cables (pulling cable ® and returning cable <V).
• Remove the carbu rator by loosening the clamp screws.
3·3 ENGINE
• Disconnec t the clutch cable along with the release arm .
• Disconnec t the crankcase breather hose .
• Remove the oil hose connector mounting bolts CD.
• Remove the gea rshi ft lever, engine sproc ket cover and
left footrest .
• Remove the engine oil hose connecter mounting bolts I@
and @ I.
• Remove the engine sprocket with the drive chain by
removing the circlip .
• Remove the kick lever.
• Remove the engine mounting bolts and brackets.
• Remove the engine from the leh side of the frame .
ENGINE 3-4
ENGINE REMOUNTING
Remount the engine in the reverse order of engine removal.
• In stall the brackets. spacers , bolts and nut properly as
shown in the illustration.
NOTE:
The engine mounting nuts are self-locking nut. Once the nut
has been removed, it is no longer of any use. Be sure ( 0 use
new nuts and tighten them to the specified torque.
.....
T\9hl ... 1ng IOfq...
co.. ,..
• Apply T HREAD LOCK SUPER" 1303 " 199000· 320301
• Install th e oil pipes, to the crankcases co rrec tly.
CAUTION :
Replace th e O ~ ri n gs w ith new ones t o prevent oil leak age.
• Tighten the oil pipe securing bolts ® and union bolt @
to the specified torqu e.
Tighte ning to rqu e
Bolt ® : B - 12 N' m 10 .B - 1 .2 kg ·m . 6.0 - B.5 Ib·ftl
Bolt @ : 2 0 - 25 N 'm 12 .0 - 2 .5 kg ·m .14.5 - 1B .0 Ib·ltl
ITE M
N ·m
Ob-h
37 - 4 5
3.7- 4. 5
27 .0-325
80- 72
6 .0-7. 2
43 .5 - 52.0
18- 28
1.8- 2 .8
13.0 - 20.0
3·5
• After remounting the engine. following adjustments are
necessary.
• De ~co mpres sion cable play IRefer t o page 2-6.1
• Clutch cable play (Refer to page 2 -9.1
• Drive chain sla ck IRefer to page 2- 10,l
• Idling speed (Refer to page 2-8.)
• Throttle cable play (Refer to page 2-8.1
• Pour 2.1 L 12.2/ 1.8 US/Imp qt) of engine 011SAE l OW/40
graded SE or SF into the frame after overhauling engine.
• Start up the engine and allow it to run for 3 minutes at
idle speed. About one minute after stopping engine,
check oil level with filler gauge.
If the level is below the " F" mark. add oil until the leve l
rea ches the " F" mark.
Engine oil capacity
Change
: 1 700 ml 11.8/ 1.5 US/imp qtl
Filter change
: 1 900 mI12 .0 / l.7 US/Imp qt)
Overhaul
: 2 100 ml (2 .2 / 1 .8 US/Imp qt)
L
ENGI NE 3·6
ENGINE DISASSEMBLY
• Remove the oil pipe .
• Remove the crankcase breather pipe .
• Loosen the bolt <D and remove the chain tensioner mounting bolt.
,/
• Remove the valve in spec tion caps (Intake and Exhaust) .
• Remove the spark plug .
• Remove the magneto cover .
• Rotate the mangeto rotor until the " T" line ® on the ro-
tor is aligned with index mark ® on the crankcase.
NOTE:
When removing the cylinder head cover, the piston must
be at top dead center on the compression stroke.
3·7 ENGINE
• Remove the de-compo shaft return spring by removing
the nut CD.
• Loosen the cylinder head cover bolts in the ascending order numbers and remove the cylinder head cover.
NOTE:
When removing the cylinder head cover, do not remove the
de-compo shaft set bolt 0 .
• Remove the camshaft end cap @ .
• Flatten the lock washers and remove the camshaft
sprocket bolts 0,
• Remove the camshaft and sprocket.
NOTE:
• The cam chain tensionerse t bOlt @ istoberemovedonly
when disassembling the engine.
.. Do not drop the camshaft drive chain, pin and sprocket
into the crankcase.
• Remove the Coring ® .
• Loosen the cylinder head bolts diagonally .
• Remove the cyl inder head by removing the two nuts 0.
NOTE:
It is difficult to remove the cylinder head, gently pry it off
while tapping the finless portion of the clinder head with a
plastic hammer. Be careful not to break the fins .
• Remove the cam chain guide ®.
• Remove the cylinder by removing the two nuts @.
•
ENGINE 3·8
• Place a clean rag over the cylinder base to prevent the
piston pin circlips from dropping into crankcase. Remove
the piston pin circlips with long-nose pliers .
• Remove the piston pin with a proper drift .
• Loosen the magneto rotor nut with a 27 mm box-end
wrench .
• Remove the magneto rotor with the special tooL
099 3 0 -34960: Rotor remover
• Remove the key
CD.
• Remove the clutch cover.
• Remove the clutch spring mounting bolts diagonally.
• Remove the pressure plate along with the clutch release
bearing and rack .
• Remove the several c lutch drive and driven plates.
3·9 ENGINE
• Fl atten the lock washer and remove the clutch sleeve hub
nut with the special tool.
09920· 53710: Clutch sleeve hub holder
• Remove the washer
bly <y.
<D and primary driven gear assem ·
• Remove the spacer @ and washer @.
• Remove the kick id le gear ® by removing the circlip .
• Remove the kick shaft assembly ®.
• Remove the oil pump driven gear Q) by removing the
eire lip.
• Remove the pin @.
CAUTION:
Do not remove the oil pump No .1 before separating the
crankcase.
• Remove the gearshift shaft ®.
• Remove the cam driven gear @) by removing the cam
guide ®.
ENGINE l ·10
• Remove the cam stopper CD and cam stopper plate ®
by removing the bolt.
• Remove the spacer @ .
• Remove the primary drive gear by removing the nut with
the special tool.
09910-20115 : Conrad holder
CAUTION ;
This nut has left· hand thread .
• Remove the cam chain and key 0.
• Remove the crankcase securing bolts .
• Separate the crankcase, right and left with th e special
tool .
09920·13120 : Crankcase separating tool
NOTE:
Fit the crankcase separs ting tool. so that the tool plate ;s
parsllel with the end face of the crankcase.
The crankshaft and transmission components must remain
in the left crankcase half.
3·11
• Rem ove the gea rshift f ork shafts and gea rshift forks.
• Rem ove th e gea rshift cam.
• Rem ove the driveshaft assembly and coun tershaft assem b ly.
• Remove t he oil pipe.
• Rem ove t he p lat e CD and bala ncer driven gear @ .
• Re m ove t he ba lace r s haft w ith th e s pecia l tools.
09930-30102 : Sliding shaft
09930-30141 : Attachment A
• Remove the ba lance r drive gea r .
• Rem ove t he c ran kshaft with the specia l tool.
09920· '3120: Crankshaft remover
(Crankcase separating tool)
ENGI NE 3·12
• Remove the oil pump No.2.
• Remover the inner rotor <D and outer rotor ®.
• Remove the pin @.
• Remove the oil pump No. 1.
• Remove the retainer.
•
• Remove the oil seals and bearings.
3·13 ENGINE
• Remove the oil filter cap.
• Rem ove the oil filter.
• Remove the Q-ring.
CAUTION :
The removed O-ring should be replaced with new one.
• Remove the magneto coil.
E~GINE
ENGINE COMPONENTS INSPECTION AND SERVICING
CYLINDER HEAD COVER SERVICING
CAUTION:
Be sure to identify each removed part as to its locBtion. and
lay the parts out In groups designated as " Exhaust " and " 'nlet". so that each will be festored to the original location
during assembly.
• Remove the de-comp o cable bracket CD.
• Remove the de-comp o shaft @ .
• Remove the intake and exhaust rocker arm shaft set bolts.
• Remove the intake and exhaust rocker arm shafts with
a 6 mm bolt.
CYLINDER HEAD COVER DISTORTION
After removing sealant from the fitting surface of the cylinder
head cover, place the cylinder head cover on a surface plate
and check for distortion with a thickness gauge . Check
points are shown in photograph.
Service Limit : 0 .05 mm 10.002 in)
If the distortion exceeds the limit. replace the cylinder head
cover .
3·14
ROCKER ARM SHAFT 0 .0.
Measure the diameter of rocker arm shaft with a micrateter.
Standard : 11 .973 - 11 .984 mm(0 .4714 - 0 .4718 in)
09900 · 20205 : Micromete r (0 - 25 mm)
ROCKER ARM 1.0.
When checki ng the valve rocker arm , the inside dia meter
of the valve rocker arm and wear of the camshaft contacting surface should be checked.
Standard : 12.000 - 12.018 mm (0.4724 - 0.4731 in)
09900 · 20605 : Di al calipers
ROCKER ARM AND SHAFT REASSEMBLY
• Apply SUZUKI MOLY PASTE to the rocker arm shafts.
99000· 25140 : SUZUKI MOLY PASTE
• Insert the rocker arm sha fts with their threaded hole end
positioned outside .
• Tighten each rocker arm shaft bolts to the specified
torque .
Tightening torque: 25 - 30 N 'm
(2.5 - 3 .0 kg· m. 18.0 - 21 .5Ib·lt)
NOTE:
Use new g8sket on the set bolt CD.
DE·COMP. SHAFT REASSEMBLY
• ApplV SUZUKI MOLY PASTE to the de·comp. shaft.
99000·25140 : SUZUKI MOLY PASTE
• After inserting the de-compo shaft. tighten its bolt to the
specified torque .
Tightening torque : 8 - 12 N-m
(0 .8 - 1.2 kg·m .6 .0 - 8 .5 Ib·lt)
NOTE:
Use new gasket ® on the set bolt.
ENGINE 3·16
CYLINDER HEAD SERVICING
• Compress the valve sp rings w ith the specia l too ls.
• Remove the va lve cotters.
09916· 14510 : Valve spring compressor
09916-14910 : Attachment
09916-84510 : Tweezers
• Remove the valve sp ring ratainer. inner spring and outer
spnng.
• Remove the va lves.
• Remove the o il seal, and remove the spring seat.
NOTE:
Removal of valves completes ordinary disassembling work.
If valve guides have to be removed for replacement after
inspection related parts, carry out the steps shown in valve
guide servicing.
CYLINDER HEAD DISTORTION
Decarbon the combustion chamber .
Check the gasketed surface o f the cylinder head for distor+
tion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest
reading at any position of the straightedge exceeds the limit,
replace the cylinder head .
Service Limit : 0 .05 mm 10.002 inl
VALVE FACE WEAR
Measure th e thickness (1)and, if the thickness is found to
have been reduced to the limit. replacle th e valve .
NOTE:
Visually inspect each valve for wear of its seating face.
Replace any valve with an 8bnormally worn face.
Service Limit : 0 .5 mm 10.02 inl
3·11 ENGINE
VALVE STEM RUN OUT
Support the valve with "V" blocks. as shown. and check
its runout with a dial gauge. The valve mu st be replaced if
the runout exceeds the limit.
Service limit : 0 .05 mm 10 .002 in)
09900· 20701 : Magnetic stand
09900-20606 : Dial gauge (11100 mm!
VALVE HEAD RADIAL RUNOUT
~ace the dial gauge at right ang les to the valve head, and
measure the valve head radial fun out.
If it measures more than limit. replace the valve.
Service Limit : 0 .03 mm 10.001 in)
VALVE GUIDE-VALVE STEM CLEARANCE
Measure the clearance in t wo direction s. " X " and "Y" perpendicular to each other, by rigging up the dial g8uge as
shown. If the clearance measured exceeds the limit specified below , then determine wheth er the valve o r the guide
should be replaced to reduce the clearance to w ithin the
stand ard range:
Standard
IN .
0 .010 - 0 .037 mm
(0.0004-0.00 1 5 in!
EX.
0 .030 - 0.057 mm
(0.0012 - 0 .0022 inl
I
Limit
I
0 .35 mm
10.014 in!
0 .35 mm
10.014 in!
•
VALVE STEM WEAR
If the valve stem Is worn down to the limit, when m easured
with a micrometer, and the clearance is found to be in ex·
cess o f the limit indica ted previou sly, replace the valve , if
the st em is within the limit, then replace the guide. After
replalcing valve o r guide, be sure to re·c heck the clearance .
Valve stem 0 .0 .
Standard
IN .: 4 .975 - 4 .990 mm (0.1959 - 0 .1965 in!
EX .: 4 .955 - 4 .970 mm (0. 1951 - 0.1957 in!
09900· 20205 : Micrometer (0 -25 mm)
ENGINE 3·18
VALVE GUIDE SERVICING
• Remove the valve guide with the special tool.
09916 44310: Valve guide remover
• Ae-finish th e valve guide holes in cylinder head with a
10. 8 mm reamer and handle.
09916·34580: 10.8 mm reamer
09916·34541 : Handl.
• Fit a ri ng to each va lve guide. Be sure to use new rings
and valve guides. Rings and valve guides removed in dissassembly must be disca rded.
• Lubrica te each valve guide and drive the guide into the
guide hole with a valve guide installer .
09916·44310 : Valve guide installer and remover
• After fining valve guides, re-finish their guiding bores with
a 5 .0 mm reamer and handle . Be su re to c lean and oil
the guides after reaming .
09916 -34570 : 5 .0 mm reamer
09916· 34541 : Handl.
<D.
• Install the valve spring seat
Be careful not to confuse
the lower sea t with the sp rin g retainer ®.
] ·19 ENGINE
• Lubricate each stem seal with engine oil .and install the
seal.
CAUTION:
Install the new stem seals.
VALVE AND SEAT CONDITION
VALVE SEAT WIDTH
Coat the valve seat with prussia" blue uniformly. Fit the
valve and tap the coated seat with the valve face in a rotat·
ing manner, in order to obtain a clear impression o f the seating contact. In this operation , use the lapper to hold the valve
head.
The ring-like dye impression left on the valve face must be
continuous-without any break. In addition , the width of the
dye ring. which is the visualized seat "width ", must be wi·
thin the specifica tion .
,
V alve sea t width
STD . ® : 0 .9 - 1 .1 mm 10 .035 - 0 .043 inl
If ei ther requirem en t is not met, co rrec t the seat by se r vicing it as follows .
VALVE SEAT SERVICING
The valve seats for both intake and exhaust valves are an·
gled to present two bevels . 15° and 45 °
INTAKE SIDE
EXHAUST SIDE
45 ·
N· 116 or N· l22
N· 1160rN· 122
15 ·
N· 1160rN· 12 1
N· 116 or N· 121
09916· 20610 : Valve seat cutter head (N · 121)
09916·20620 : Valve seat cutter head (N· 122)
09916·24420 : Valve seat cutter head (N · l 1 61
09916· 24311 : Solid pilot IN -l00· 5 .01
I
ENGINE 3·20
NOTE:
The valve seat contact area mus t be inspected alter each
cut.
1 . In sert wi th a s light rotation, the solid pilot that gives a
snug fit. The shou lder on the pilot should be about 10
mm (0.39 in) from the va lve guide.
2 . Using th e 45 0 cutter. deseale and clea nup the sea t with
one or two turns.
3 . Inspect the seat by the previous seat width measurement
procedu re. If the sea t is pitted or burned, additional sea t
conditioning with the 4 5° c utter is required .
CAUTION :
Cut the minimum amount necessary from the seat to pre·
vent the possibility of the valve stem becoming too close
to the rocker arm for correct valve contact angle .
If the con tac t area is too low or too narrow, u se the 45 0
cu tter to raise and widen the contac t area. If the contac t
area is too high or to o wide, u se the 15 0 cutter to lower
and narrow the con tac t area .
4 . After the desired sea t positon and width is achieved, use
the 4 5 0 cu tter ve ry lightly to clean up any burrs c au sed
by the previous cutting operations. DO NOT use lapping
compound aher the final cu t is made. The finished valve
seat should have a velvety smooth finish and not a highly polished or sh iny fin ish. This will provide a soh surf ace for the final seating o f the valve which will occu r
during the first few seconds of engine operation .
S . Clean and assemble the head and valve co mpon ents. Fill
the intake and exhaust ports with gasolin e to check for
leaks. If any leaks occur, inspect the valve seat and face
for burrs or ot her things that cou ld prevent the valve from
sealing .
COnl ltC:1 e ree 100 lo w
end 100 netr o w o n face
of lI'al..,,,
WARNING :
Always u se extreme caution when handling gasoline.
NO TE:
Be sure to adjust the valve clearance after reassembling the
engme.
VALVE STEM END CONDITION
lnspec the valve stem end face for pitting and wear. If pitting or wear of the stem end face are present, the valve stem
will not
end may be resurfaced, providing that the length
be reduced to less than 1.8 mm (0.07 in) . If thi s length becomes less than 1 .B mm (0.07 in). the valve must be
repl aced . Aher installing a valve whose stem end has been
ground o ff as above , check to ensure that the face @ o f
,
t he valve stem end is above the co tters @'
<D
Contac t a rea 100 high
e nd 100 wide on lece of
"'81..,e
Cf a
,ill.
,.'
• ••
3-1 1 ENGINE
VALVE SPRING
Check the springs for strength by measu ring their f ree
lengths and also the force required to compress them . If the
limit indicated below is exceeded by the free length read·
ing or if the measured force does not fall within the range
specified, replace both the inner and outer springs as a set.
Valve s pring fre e length
Service limit
INNER : 35 .0 mm 11 .38 in)
OUTER : 37 .8 mm 11 .49 in)
5.3 - 6.5 kg
(],
Valve spring tension
Sta nda rd
INNER : 6 .3 - 6 .5 kg/28.0 mm 111 .7 - 14.3Ibsl l .10 in)
OUTER : 13.1 - 15.1 kg/31 .5 mm 128 .9 - 33 .3 Ibsl l .24 in)
VALVE AND VALVE SPRING REASSEMBLY
• Insert the valves, with their stems coated with (SUZUKI
MOLY PASTE) all around and along the full stem length
withou t any break .
Similarly oil the lip of the stem seal.
99000-25140 : SUZUKI MOLY PASTE
CAUTION :
Whe n inserting eac h valv e. t a ke care not to d a m age th e lip
of th e stem seal.
• Install the valve springs. making sure that the close-pitch
end <D of each spring goes in fjrst to rest on the head.
The coil pitch of both inner and outer springs vary: the
pitch decreases f rom top to bottom. as shewn in t he illustration.
• Fit a valve spring retainer, compress the springs with a
valve spring compressor and fit the cotter halves to the
stem end .
09916 -14510 : Valve spring compressor
09916 -14910 : Attachment
09916-84510 : Tweezers
I
28.0 mm
ENGINE 3-22
CAMSHAFT
Inlet opon
The camshaft should be checked for runout and also for wear
of cams and journals if the engine has been noted to produce
abnormal noise or vibration or to lack ou tput power. Any
of these malconditions could be caused by a worn camshaft .
T. O.C
(B. T.D.CI
Elfhausl close
IA. T.D.C.'
Inlol do h
(A.B.O.C.1
CAMSHAFT CAM WEAR
Worn-down cams are often the ca u se of mi stimed valve
operation resulting in reduced output power. The limit of cam
wear is specified for both intake and exhaust cams in terms
of cam height 8>. which is to be measured with a micrometer. Replace the camshaft if found it worn down to the limit.
Cam height
Height <Ell
Service Limit
Intake cam
33.13 mm 11.3043 in)
33.16 mm 11 .3055 in)
Exhaust cam
Val ve lIming
diagram
Exhaus t open
B. O.C.
!B.B.O.C.I
o
09900· 20202 : Mic rometr (25 - 50 rnm)
CAMSHAFT JOURNAL WEAR
Determine whether each journal is worn down to the limit
or not by measuring camshaft journal oi l clearance with the
camshaft installed . Use plastigauge to read the c learance ,
which is specified as follows.
Camshaft journal oil clearance
Service Limit : 0 .150 mm (O .0059 in)
• Tighten the cylinder head cover bolts evenly and diagonally to the specified torque .
Tightening torque : 8 - 12 N'm
10 .8 - 1 .2 kg ·m. 6 .0 - 8 .5 Ib·lt)
09900 -22301 : Plastigauge
If the camshaft journal oil clearance measured exceeds the
limit, measure the ou tside diameter of camsh aft. Replace
ei ther the cylinder he ad set or the camshaft if the clearance
is incorrect .
Cam shaft journal 0 .0 .
Standard
Right side
I Left side
21 .959 - 21.980 mm 10.8645 - 0 .8654 in)
17 .466 - 17.484 mm 10.6876 - 0 .6883 in)
09900-20205 : Mic rometer 10 - 25 mm)
NOTE:
To properly measure the oil clearance
with plastigauge. all gasket material
must be ramoved from fitting surfaces
of cylinder head and cover. Do not apply SUZUKI BONO No. 120781 1215
until after the oil clearance has been
determined.
3-23 ENGINE
CAMSHAFT RUNOUT
Measure the runout with a dial gauge. Replace the camshaft
if the ru n out exceeds the limit.
Service limit : 0 .10 mm (0 .004 in)
09900· 20701 : Magnetic stand
09900·20606 : Dial gauge 11 / 100 mm}
CAM CHAIN 20-PITCH LENGTH
Pull the ch ain tight to remove any slack, then using venier
calipers. measure the 20-pitch (2 1 pins) length o f cam chain.
If it measures more th an the limit replace the cam cha in .
Service Limit : 128.9 mm (5 .07 in)
CYLINDER DISTORTION
Check the gasketed su rface of the cylinder for distortion w ith
a straightedge and thickness gauge, taking a clearance reading at severa l places as indicated . If the largest reading at
any pasitan of the straightedge exceeds th e limits. repl ace
the cylinder .
Service limit : 0 .05 mm (0 .002 in)
CYLINDER BORE
Measure the cylinder bore diameter at six places . If anyone
of the measurements exceeds the limit. overhaul the cylinder
and replac e the piston wi t h an ove rsize. or replace th e
cylind er.
Service Limit : 79 .075 mm (3.1132 in)
09900·20508 : Cylinder gauge set
PISTON DIAMETER
Using a micrometer, measure the piston ou t side diameter
at the place 15 mm (0.6 in) from the skirt end as shown
in Fig. If the measurement is less than limit, repla ce the
piston .
\
Service Limit : 78 .880 mm (3 .1055 in)
Piston oversize : 0 .5 . 1 .0 mm
09900-20204 : Micrometer (75 - 100 mm)
I 15 min
* 10. 6 inl
ENGINE ) ·14
PISTON-CYLINDER CLEARANCE
As a result o f the previous measuremen t , if the piston t o
cylinder clearance exceeds th e limit. overhau l the cyli nder
and use and oversize piston , or replace both cylinder and
piston .
Service Limit : 0 .120 rnm (0 .0047 inl
PISTON RING-GROOVE CLEARANCE
Using a thickness gauge, measure the sid e clearance o f the
1st and 2nd rings. If any of the clearances exceeds the limit .
replace both piston and piston rings .
Piston ring-groove clearance
Service Limit
1st : O,1aO mm (0.0071 inl
2nd: 0 .150 mm 10 .0059 inl
09900·20803 : Thickness gauge
Pis ton ring groove width
Standard
, 5t and 2nd : 1.01 - 1 .03 mm (0 .040 - 0 .041 in)
Oil : 2 .01 - 2.03 mm 10.079 - 0 .080 inl
Piston ring thickness
Standard
151 and 2nd : 0 .97 - 0 .99 mm 10 .038 - 0 .039 inl
NOTE;
Using a soft-metal scraper. decarbon the crown of the
piston. Clean the ring grooves similarly.
PISTON RING FREE END GAP AND
PISTON RING END GAP
Before installing piston rings, measure the free end gap of
each ring using vernie r calipers.
Next. fit the ring in the cylinder. and measure each ring end
gap using a thickness gauge.
If any ring has an excess end gap, replace the ring .
Piston ring free end gap
Service limit
1 st : 8 .2 mm (0 .32 in)
2nd : 8 .9 mm (0.35 in)
09900-20101 : Vernier calilpers
3-25 ENGINE
Piston ring end gap
Service limit
1st and 2nd : 0.70 mm (0.028 in)
09900 -20803 : Thickness gauge
OVERSIZE RINGS
OVERSIZE PISTON RINGS
The following two types of oversize piston ring s are used.
They bear the following identification numbers.
0.5 mm o.S.
Piston ring
0 _5 mm O_S _
1.0 mm 0.5.
1st
50
100
2nd
50
100
OVERSIZE Oil RINGS
The following two types of over size oil rings are used , They
bear the following iden t ification marks .
SIZE
MARK
Standard
Nil
0.5 mm 0.5.
Painted red
1.0 mm 0.5.
Painted ye llow
OVERSIZE RAil
Just measure out side diameter to identify th e side rail as
there is no m ark or number on it.
PISTON PIN AND PIN BORE
Using a ca liper gauge , measure the piston pin bore inside
diameter, and using a micrometer mea sure the piston pin
out si de diameter. If the difference between the these two
measurements is more than the limits, replace both piston
and piston pin .
PISTON PIN BORE
Service Limit: 20.030 mm (0 .7886 in)
PISTON PIN 0_0 _
Service Limit: 19.980 mm (0 .7866 in)
09900 -20605 : Dial caliper
09900-20205 : Micrometer {O - 25 mml
I
1.0",", os.
all 'in9 .paoo'
ENGINE 3-26
CONROD SMALL END I.D.
Using a cali per gauge, measure the con rad small end insdie
diameter.
Service limit : 20 .040 mm (0 .7890 in)
If the conrad sma ll end bo re inside diameter exceeds the
limit. replace conrad.
CON ROD DEFLECTION AND CON ROD
BIG END SIDE CLEARANCE
Wear on the big end of the conrad ca n be estimated by
c hecking the movement of th e small end of the rod . This
method can also check the ext en t of wear on the conrad 's
big end .
Service limit : 3 .0 mm (0 .12 in)
09900· 20701 : Magnetic s tand
09900· 20606 : Dial gauge (1 / 100 mm)
09900·2 1304 : V· block
Push the big end of the co nrad to one side and measure the
side clearance with a thickness gauge .
Standard : 0 .10 - 0 .55 mm (0 .004 - 0 .022 in)
Service Limit : 1 .0 mm (O .04 in)
09900· 20803 : Thickness guage
Where the limit is exceeded . replace cranksh aft assembly
or reduce the deflec tion and the side clea rance to within the
limit by replacing the worn parts -conrod . big end bearig
and crank pin etc.
CRANKSHAFT RUN OUT
Support the crankshaft with " V" blocks as shown , with the
two end journal s resting on th e blocks,
Position the dial gauge, as shown , and rotate the crankshaft
slow ly to read the runout.
Correct or replac e the crankshaft if the runout is greater than
the limit.
Service Limit : 0 .05 mm 10.002 in}
3·27 ENGINE
CLUTCH DRIVE PLATE
Measure the thickness and claw width of each drive plate
with vernier calipers. Replace drive plates found to have
worn down to the limit.
Thickness
Claw width
Standard
Service Limit
2.72 - 2 .88 mm
10.107-0.113 inl
15.8 - 16.0 mm
10.62-0.63 inl
2.42 mm
10.095 inl
15.2 mm
10.60 inl
Measuring thickne ss
0 9 9 00-20 101 : V ernier calipers
M easuring claw width
CLUTCH DRIVEN PALTE
Measure each driven plate for distortion with a thic kness
gauge.
Replace driven plates which exceed the limit.
Se rvice limit : 0 .10 mm (0 .004 in )
09900 -20803 : Thickness gauge
Measuring distortion
CLUTCH SPRING FREE LENGTH
Measure the free length of each coi l spring with a vernier
calipers, and determine the elastic strength of each. Replalce
any spring not within the limit.
Service Limit : 29 .5 m m 11.1 6 in )
0 99 00·2010 1 : Ve rnie r calipe rs
Measuring c lutch spring
CLUTCH RElEASE BEARING
In spect the release bearing for any abnormality. particularly c racks. to decide whether it ca n be reused or should be
repla ced . Smooth engagement and disengagement of the
clu tch depends much on the condition of this bearing .
,
ENGINE 3·28
CLUTCH RELEASE PINION AND RACK
Rotate the clutch release pinion by hand to inspec t for a
smooth rotation . If a large resistance is felt to rotation, inspect the pinion and rack for damage or wear. If the defect
is found , replace them as a set.
TRANSM ISSION
DISASSEMBLY
• Disassemble the transmission gears as shown in the illustration.
CD Low driven gear
® Top driven gear
@ 4th driven gear
@ 3rd driven gear
® 5th driven gear
® 2nd driven gear
CD Driveshaft
® Countetshaft/Low drive gear
® T op drive gear
@ 4th/ 3rd drive gear
® 5th drive gear
@ 2nd drive gear
3·29 ENGINE
GEARSHIFT FORK-GROOVE CLEARANCE
Using a thickness gauge. c heck the shifting fork clearance
in the groove o f its gear.
The clearance for each of the th ree shi fting forks plays an
improtant role in the sm oothness and posi tiveness o f shih·
ing action .
Shift fork -Groove clearance
Standard
: 0 . ' - 0 .3 mm (0 .004 - 0 .012 in'
Service Limit : 0 .5 mm (0 .020 in)
Checking clearance
If the clea rance c hecked is noted to exceed th e limit speci·
fied . repla ce the fork or its gear , or both .
Shift fork groove width
Stand ard : 5 .0 - 5 .1 mm (0 ,197 - 0 .200 in)
Shift fork thick ne ss
Standard : 4 .8 - 4.9 mm (0 .189 - 0 .193 in)
Checking groove width
09900-20803 : Thickness gauge
09900 -20101 : V ernier calipers
Chicking t hickness
REASSEMBLY
Assemble the countershaft and driveshaft. in t he reverse order of disassembly . Pay attention to fol lowing points:
NOTE:
In reassembling the transmission. atten tion must be given to the locations and posi tions of washers
and circlips. The c ross sectional view given here will serve as 8 reference for correc tly mounting
the gears, washers and eirclips.
CAUTION:
• Never reuse a circlip . After a circlip has been removed from a shaft, the removed circlip should
be discarded and a new circllp must be installed .
• When installing a new circlip. care must be taken not to expand the end gap larger than required
to slip the c irclip over the shaft.
• After installing a circlip , always insure that it is completely seated in its groove and securely fitted.
NOTE:
Before installing the gears, coa t lightly moly paste o r engine oil to the drivesh8ft and counrershaft.
99000 -25140 : SUZUKI MOLY PASTE
• When installing a new circlip , pay attention to the di r ec ~
tion of the circlip. Fit it to the side where the thrust is
as shown in figure .
Thrust
I
Countershaft
3-31 ENGINE
BALANCER SHAFT AND GEARS
CD Crank balancer shaft
® Bearing , L
@ Bearing ,A
@ Key
® W asher
® Balancer driven gear
o Driven gear inner race
® Pin 13 pes I
,
•
® Spring (6 pes)
CD,
®
When installing the pins
springs
and inner race @
to the balancer dri ven gear @ . set the pins
t o the sym·
<D
metrical position , and align the punched marks ® as
shown in the illustration.
CRANKCASE BEARINGS
Inspect the play of the crankcase bearings by hand while
they are in the right and left crankcases . Rot ate each cran kcase bearing inner race by hand to inspect for abnormal noise
and smooth rotation . Replace the bearing if there is anything
unusual.
NOTE:
When reassembling the bearing retainer, appl y a small quantity of THREAD LOCK SUPER "1303/ 1322 " to the bearing
retainer screws.
99000-32030 : THREAD LOCK SUPER " 1303" (U .S.A .)
99000-32110 : THREAD LOCK SUPER " 1322" (Others)
Plav
ENGINE 3·32
ENGINE REASSEMBLY
Reassembly is generally performed in the reve rse order to
disassembly. but there are a number o f reasse mbling steps
th at demand or deserve detaited explana tion or empha sis .
These steps will be laken up for respective parts an d com -
ponents .
NOTE:
Apply engine 0;1 to each runn ing and sliding part before reas·
sembling.
OIL SEALS
• Fit the respective oil seals .
• Coat SU PER GREASE " A" to the lip of each oil sea l.
99000·25030 : SUZUKI SUPER GREASE " A " (U .S .A .)
99000·25010 : SUZUKI SUPER GREASE" A " (Others I
CAUTION :
Replace the oil seaJ.s w ith new ones ev ery disassembly to
pre ve nt oil leakage
CRANKSHAFT
<D Bearing . A
® Thrust washer
® Pin
@) Key
® Cranksha ft . R
® Conrod
(1) Bearing
® Crank pin
® Crankshaft . L
@l Bearing . l
® Balancer drive gear
3-33
• Decide the width between the webs referring to the figure
below when rebuilding the crankshaft .
STO width between webs : 60.0 ± 0 . ' mm
12.362 ± O.004 in)
JlIe
H
~
• When mounting the c rankshaft to the crankcase. it is
necessary to pull its left end into the c rankcase w ith the
special tool.
09910·32812: Crankshaft installer
CAUTION :
Never fit the crankshaft into the crankcase by tapping it with
a plastic hammer. Always use the special tool. otherwise
crankshaft alignment accuracy will be affected .
BALANCERSHAFT AND GEARS
• When installing the balan cer drive gear and driven gear.
align the three punched marks.
OIL PIPE
Install the oil pipe to the crankcase .
NOTE:
Use the new O·rings.
~
ENGINE 3·34
GEARSHIFT CAM AND FORKS
:~
CD Gearshift shaft
® Gearshift cam
@ Return spring
@ Fork shaft No.1
@ Gearshift fork No .2
® Gea rshift arm stopper
@ Cam driven gear securing bolt @ Gearshift fork No . 1
® Cam driven gear
® Fork shaft No .2
@ Gearshift cam stopper plate
Q) Cam guide
@ Gearshift fork No .3
® Spring
® Pin
® Gearshift pawl
® Gearshift cam stopper spring
. : Apply THR EAD LOCK SU PER " 1303/1 322 "
•• : Apply THREAD LOCK SUPER " '303 "
@ Gearshift cam
• After installing the countershaft assembly and driveshaft
assembly into th e left crankcase. fit the gearsh ift forks
CD • ® and @ into the gearshift fork grooves .
<D For 4th driven gear (No. 1)
® for Top driven gear INo . 21
@ For 3rd drive gear (No . 3)
NOTE:
Three kinds of gearshift forks. <D. ® and @ Breused. Th ey
reassemble each other very closely in external appearance
and configuration.
Carefully examine the illustration for correct installing posi·
tions and directions.
3·35 EN GINE
OIL PUMP AND OIL SUMP FILTER
CD Oil pump No . 1
@ Oil pump dri ven gear
® Outer rotor
o Inner ro tor
® Oil pump No.2
® Oil sump filt er
• Before mounting the oil pump . apply engine oil to the sliding surfaces of the case, outer rotor, inner rotor and shaft .
• Install the oil pump No .1.
• Inst all the pin <D .
• When in stalling the inner rotor ®. align the groove of inner rotor with pin
<D.
CAUTION:
When installing the outer rotor @ . the pun che d ma rk on the
outer rotor must face to the inside IOil pump No .1 side ).
Oil pump No. 1
• Apply engine oil to the rotors .
• Install the oil sump filter.
ENGINE J·J6
CRANKCASE
When reassembling the crankcase pay attention to the following points:
• Remove sealant material on the mating surfaces of right
and left halves of crankcase and thoroughly remove oil
stains .
• Fit the new O-ring G) and dowel pins @ on the left half
as shown in Fig ,
• Apply engine oil to the conrad big end of the c rankshaft
and all parts of the transmission gears.
• Apply SUZUKI BOND No. 12078/ 1215 uniformly to the
mating surface of the right and left crankcases as shown
in the illustration, and assemble the cases within few
minutes .
99104· 31140 : SUZUKI BONO No. 1207B IU .S .A .)
99000·31110 : SUZUKI BONO NO .1 21 5 IOthe,s)
left c ra nkcase
Right crank case
00
• Tighten the crankcase bolts to the specified torque.
Tightening torque : 9 - 13 N'm
10.9-1 .3 kg·m. 6.5 - 9.5Ib·ft)
• After the c rankcase bolts have been tightened. check if
crankshaft. countershaft and drives haft rotate smoothly .
• If a large resistance is felt to rotation . try to free the shafts
by tapping the shahs with a plasti c hammer.
00
3·37 ENGINE
• TIghten the batancershah bolt to the specified torque with
the special tool.
Tightening torque : 40 - 60 N 'm
14.0 - 6 .0 kg-m. 29 .0 - 43 .5 Ib-Itl
09910-201 15 :Conrod holder
CAM CHAIN AND PRIMARY DRIVE GEAR
• Engage the cam c hain to the sp rocket .
• Install the key CD to the c rankshaft.
• When installing the primary drive gear , al ig n the key CD
with the groove of gea r.
• Tig hten the primary drive gea r nut to the 'Specified torque with the special tool.
Tightening torque : 60 - 80 N' m
(S ,0 - 8 ,0 kg-m, 43 ,5 - 58 ,0 Ib-Itl
09910·20115 : Conrad holder
NOTE:
This nut has lefr-hand thread.
CAM DRIVEN GEAR AND GEARSHIFT SHAFT
• Inst all the spacer ® ont o the gea rshift cam .
• Apply a small quantity of THREAD LOCK SUPER " 1303"
to the gearshift stopper bolt @ . and tighten it to the speci·
fied torque .
99000·32030 : THREAD
LOCK SUPER " 1303"
,
Tightening torque: 15 - 23 N 'm
(1 .5 - 2 ,3 kg-m , 11.0 - 1S.5Ib-ftl
• Install the gearshift pawls into the ca m driven gear. The
large shou ld er (}must f ace to the out side as show n in
the illustration.
ENGINE ] ·38
• Apply a small quantity of THREAD LOCK SUPER
" 1303/ 1322" to the cam pawel lifter securing screws
<D and cam driven gear securing bolt ®.
99000-32030 : THREAD LOCK SUPER " 1303· ' IU .S .A .)
99000-32110 : THREAD LOCK SUPER " 1322" IOthe,,)
Tightening torque
BOlt @ : 8-12N·mI0 .8 - 1.2kg-m. 6 .0 - 8 .Slb-h)
• Fit the sp ring to the gearshift shaft co rrec tly .
• Install the gearshift shaft. Match the cen ter teeth of t he
gear on the gearshift shaft with the center teeth on the
cam driven gear as shown in Fig.
,
KICK STARTER SHAFT
CD Kick starter shaft
® Kick drive gear
@ Kick starter pawel
@ Return spring
® Spring guide
• Apply THREAD LOCK SUPER " 1 303/1322"
•• Apply THREAD LOCK SUPER " 1303"
3·39 ENGINE
• Apply a small quantity THREAD LOCK SUPER " '30 3"
to the ki ck stopper bolts and tighten th em.
99000· 32030 : THREAD LOCK SUPER " 1303"
• When installing the kick starter pawel , align the punched
mark CD on the kick starter pawel with line ® an the kick
s tarter shaft .
• When installing the kick return spri ng, hook part @ of
return spring in to the hole of crankcase and turn it 1/ 2
turn counterclockwise with plilers and fit part ® of return
spring into the hole of the kick shaft. In stall the spring
gu ide .
I
• When installing the oil pump driven gear, align the pin
® with the pin groove ® .
• Install the circlip 0 .
ENGINE 3·40
CLUTCH
CD Clutch release arm
® Oil seal
@ Clutch release pinion
@ Clu tch pressure plale
® Release bearing
® Clutch release rack
(1) Clutch driven plate
® Clutch drive plate
® Lock washer
@ Clutch steeve hub
® Primary driven gear
@ Space r
• After installing the primary driven gear assembly and
clutch sleeve hub onto the countershaft. tighten the
clutch sleeve hub nut to the specified torque with the special tool and torque wrench.
09920 -53 71 0 : Clutch sleeve hub holder
•
Ti ghte ning t orqu e: 40 - 60 Nom
14.0 - 6 .0 kg -m . 29 .0 - 43 .5 Ib ·l t)
• After tightening the clutch sleeve hub nut, be sure to lock
the nut by firmly bending the tongue of the lock washer .
3-41 ENGINE
• Tighten the clutch spring mounting bolts diagonally with
the special tool.
09910-20115: Conrad holder
• Fit the two dowel pins CD to the cra n kcase and attach
new gasket.
CAUTION:
Use a new gasket to prevent oil leakage .
,
• Engage th e teeth of clutch re lease rack w ith those of pinion gear at the clutc h cover side , and replace clutch cover.
Make surenthat the rack and pinion gear engage positively .
To install cover, t ap tightly w ith plastic hammer, and tighten the bolts .
• Fit the new gaskets @ (4 pes) t o the clut ch ca ble hold er
bolts as shown in th e illustration .
Oil FilTER
• Before in stalling the oil filter, check to be su re that the
O-rings , @ and @ . and spring ® are install ed correc tly .
CAUTION:
Replace the O-rings , with new ones to prevent oil leakage .
ENGINE 3-42
MAGNETO
• Fit the key CD in the key slot on the c rankshaft , then in ~
stall the magneto ro tor.
CAUTION ,
Degrease the tapered portion of the magneto rotor and also
the crankshah .
• Apply a small quantity o f THREAD LO CK SUPER
"130311305" to the threaded part of nut.
99000 - 32030 , THREAD LOCK SUPER " 1303" IU .S.A .I
99000 - 32100 , THREAD LOCK SUPER " 130S" IOthersl
• Tighten the nut to the specified torque with a 27 mm boxend wrench .
Tightening torque : 120 - 140 N'm
112.0 - 14.0 kg · m . B7 .0 - 101 .Slb-ftl
Oil RING
Install the spacer @ into the oil ring groo\le first. Then in stall both side rails @ . on, on each side of the spacer . The
spacer and side rails do not have a specific top or bottom
when they are new. When reassembling used parts , insta ll
them in their original place and direction .
TOP RING AND 2ND RING
Top ring and 2nd ring differ in the shape o f ring face . Top
and 2nd rings have the letter " A" and " RN" marked on the
top .
Top ring : " R" mark
2nd ring : " RN " mark
~
0>,
Top ring
NOTE:
Be sure to bring the marked side to top when filting them
to the piston.
2nd ring
:::
3-43 ENGINE
Position the gaps of the three rings as shown.
Before inserting piston into the cylinder . check that the gaps
are so located .
EX
I
• 2nd ring
• I
c
. . .
• UP\MII' .ide till
side ..;'
• Top r;ng
PISTON
The following are reminders for piston installation:
• Rub a small quantity of SUZUKI MOLY PASTE onto the
piston pin .
• Plac;;e a clean rag over the cylinder base to prevent the
piston pin circlips from dropping into the crankcase.
• When fitting the piston. turn arrow mark <D on the piston
head to exhaust side
• Fit the piston pin circlips with long-nose pliers .
CAUT ION :
Use n ew pis ton pin circlip to prevent circ lip f ailure which
will occur with a bent one.
CYLINDER
Before mounting the cylinder. oil the big end and sma ll end
of the conrad and also the sliding surface of the piston .
• Fit the dowel pins to the c rankcase and attach new
gasket.
CAUTION :
To prevent oil leakage. d o not use the old gas ket again. always u se new one.
• Hold each piston ring with properly position , and insert
the piston into th e cylinder .
NOTE:
When mounting the cylinder, keep the camshaft drive chain
® taut. The camshaft drive chain must not be caught between cam drive chain sproket and crankcase when crank. rotate d.
I
shaft IS
NOTE:
There is a ~oJder for the bottom end of the cam chain guide
cast in the crankcase. 8e sure that the guide ® is inserted
properly or binding of the cam chain and guide may result.
• Fit the dowel pins to the cylinder and attach t he new
gasket.
CAUTION :
Use a new cylinder head gasket to prev ent oil leakage. Do
not use t he old gasket.
IN · Spec.
ENGINE 3·44
CYLINDER HEAD
• With the head snug ly seated on the cylinder, secu re it
by tightening the bolts diagonally . Tighten eac h bolt to
the speci fi ed t orque.
Tightening torque :
35 - 40 N' m 13. 5 - 4.0 kg-m . 25.5 - 29.0 Ib-Itl
• After tightening the cylinder head bolts to the spec ific ation, tighten the cylinder head nuts and cylind er base
nuts.
Tightening torque :
23-27 N'm 12.3 - 2.7 kg ·m . 16 .5 - 19. 5 Ib·ltl
CAMSHAFT
• Align " T" mark CD on the magneto rotor w ith the index
mark ® on th e crankcase keepi ng the c amshaft drive
chain pulled upward.
CAUTION:
If crankshaft is turned without drawing the camshaft drive
chain upward. the chain will be caught between crankcase
and cam chain drive sprocket. I
NOTE:
Apply grease on the cam sprocke t loca ting pin and install
the p in into the camshaft.
• Install the C-ring into the its groove of t he cylinder head .
3-45 ENGINE
• Engage the chain on the cam sprocket with the locating
pin hole CD two o'clock position .
NOTE:
Do not rotate the magneto rotor while doing (Ms. When the
sprocket is not positioned correctly. turn the sprocker. When
installing the camshaft into the cam sprocket; pay attention
not to dislodge the locating pin or it may fa/l into the
crankcase.
• Align the engraved line mark ® on the camshaft so it is
parallel with the surface of the cylinder head.
• Fit the lock washer
so that it is covering the locating
pin .
• Apply THREAD LOCK SUPER" 1303" to the cam sprock-
®
et bolts and tighten them to the specified torque .
99000-3 2030 : THREAD LOCK SUPER " 1303"
Tightening torque: 14 - 16 N 'm
(1 .4 -1. 6 kg-m . 10.0 - 11 .5 Ib-It)
• Bend up the washer tonque positively to lock the bolts.
• Apply SUZUKI MOLY PASTE to the camshaft journals and
cam faces _
99000-25140 : SUZUKI MOLY PASTE
CYLINDER HEAD COVER
• Thoroughly wipe off oil from the fitting surfaces of
cylinder head and cover.
• Fit the two dowel pins to the cy linder head .
• Unilormly apply SUZUKI BOND No. 1207B/ 1215 to the
cylinder head cover surface.
99 104-3 1140 : SUZUKI BONO No. 1207B (U .S.A .)
9 9000-3 1110 : SUZUKI BOND No . 1215 (Others)
ENGINE 3-46
NOTE:
00 not apply SUZUKI80ND No. 1207811215 (0 (he cam ·
shaft end cap.
• Install the dowel pins.
• Fit the four new gaskets CD to the head cover bolts correctlv_
CAUTION:
Use new gaskets to prevent oil leakage.
NOTE:
When tightening the cylinder head cover bolts, the piston
must be at top dead center on the compression s troke.
• Lightly tighten the cylinder head cover bolts sequential+
IV in the ascending order of numbers, and then if every·
thing is satisfactory . tighten securely with a torque
wrench to the specified torque .
Tightening torque : 8 - 12 N -m
10.8 - 1 .2 kg · m. 6 .0 - 8 .5 Ib·lt)
CAM CHAIN TENS lONER ADJUSTER
Install the cam chain tensioner adjuster following the procedure be low .
• Apply SUZUKI MOLY PASTE to the push rod @.
99000· 25140: SUZUKI MOLY PASTe
• Unlock the ratchet mechanism @ and push in the push
rod @ al1 the way before mounting th e chain ten sioner.
• Install a new gasket and the cam chain tensioner to the
cylinder block with two bolts (@) and @ L and tighten
them to the specified torque as shown in the illustration .
Tightening torque :
801t @) : 8-12 N 'm 10 .8 - 1.2 kg·m. 6 .0 - 8.5 Ib·lt}
Bolt ® : 9 - 13 N'm 10.9 - 1.3 kg·m. 6 .5 - 9 .5Ib·lt}
CAUTION:
Always use a new gasket and O-ring ® to prevent oil
leakage.
3·47 ENGINE
• In sert the sp ring into th e ca m chain tensioner and
tighten the spring holder bolt CD to the specitied
torque.
Tightening torque : 7 - 9 N' m
10 .7 - 0 .9 kg·m. 5 .0 - 6 .5 Ib· lt}
VALVE CLEARANCE
• Check and adjust the va lve c learance . (Refer to page
2·4}
VALVE INSPECITON CAP
• Before installing the valve inspection caps, coa t the
re spective O-rings with grease.
CAUTION :
Replace the respective C-rings with new ones.
OIL PIPE
• Set the oil pipe ® to the cushion. and bend the
clamp as shown in the itlustration.
@ : Clamp
@) : Cushion
® : Slit of cushion
• Tighten the union bolts
® to the specifi ed torque .
Tightening torque : 18 - 23 N 'm
11 .8 - 2 .3 kg ·m , 13 .0 - 1 6 .5 }b· lt}
CAUTION:
When tightening the union bolts , use the stoppers (5 rnm
and 9 mml as shown in the illustration .
CAUTION :
Use new gaskets CD to prevent oil leakage .
inl
9mm
(0.35 in' ________"
ENGINE 3·48
MAGNETO COVER
• Install the stator, clamp pick4UP coil and grommet correctly . (Refer to page 7- 10.)
• Fit the two dowel pins and new gasket.
• Fit the new gaskets <D to the magneto cover bolts as
shown in photo .
ON TENT
FUEL COCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
CARBURETOR. . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . .
4-2
CONSTRUCTIONS. . . . . . . . . • . . . . . . . . . . . . . . . . . . .•
4-2
SPECIFICA TIONS . . . . . . . . . . . • . . . . . . • . • • . . • . . . . .•
4·3
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
4-4
DISASSEMBL Y. . . . . . . . . . . . . . . . . . . . • • . . . . . . . • . . . 4 -4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
4-6
REASSEMBLY ANO REMOUNTING. . • • • . . • . . . • . . . ..
4·7
LUBRICA TION SySTEM. . . . . . . . . . . . . . . . . . .. . . . . . . .
4-7
OIL PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 · 7
ENGINE LUBRICA TION SYSTEM CHART. • . . . . . . . . . •.
4·8
4-' FUEL AND LUBRICATION SYSTEM
FUEL COCK
I
''OFF ''
"ON"
INSPECTION AND CLEANING
If the fuel strainer is darty w ith sed iment o r rust , fuel will
no t flow smoothly and loss in engine power may resul t.
Clean the fu el strainer in the following manne r :
• Turn the fuel cock to OFF posi ti on.
• Di sconnect t he fu el hose.
• Turn th e fuel cock to " RES " position and drain fue l.
• Remove the fuel cock assembly by rem ov ing the bolt s.
• Clean the fuel stra iner with compre ssed air.
WARNING :
• Gasoline is very explosive . Extreme care must be taken .
• Gaskets and O -rings must be replace d with new ones to
prevent fuel leakage.
" RES"
fUEl AND LUBRICATION SYSTEM 4-2
CARBURETOR
CONSTRUCTIONS
CD Carburetor lOp cap
® ThroWs valve lever
@ Throttle valve bracket
@) Jet needle
® Thro ttle valve
® Needle jet
CD Throttle s top screw adjuster
® Thro ttle lever sha ft
® Accelerating lever
@ Accelerating rod
® Accelerating plunger
@ Pilo t screw
@ Pilot je t
@ M ain jet
@ Needle valve
@ Float
® Drain plug
@ Starting plunger
4-3 FUEL AND LUBRICATIDN SYSTEM
SPECIFICATIONS
ITEM
SPECIFICATION
MIKUNI TM33SS
Carbureto r type
1.0. No .
1400
Bore size
Fuel level
33 mm
1 400 + 100 r/min
o ± 0 .5 mm (0 :t 0.02 in)
Roat height
14. 2 + 1.0 mm 10. 56 ±0.04 inJ
Idle r/ min
IM .J .J
#132 . 5
Main air jet
IM .A .J .J
0 .9 mm
Jet neeale
IJ .N .J
5FP96-3rd
Needle jet
IN .J .I
P-B
Cu t·away
IC. A.I
1. 5
Pitot jet
IP.J.I
#37 . 5
By-pass
IS.P.I
0 .8 mm
Pilot outlet
(P.O.I
0 .6 mm
Valve seat
IV.S.I
1 .8 mm
Starter jet
IG .SI
#50
Pilot screw
(P.S.I
1 .0 turn back
Pil ot air jet
IP.A.J.I
1.0 mm
Main jet
Throttle cab le play (pulling cable)
1.0. No. LOCATION Q)
0.5 - 1.0 mm 10 .02 - 0 .04 inl
FUEl AND LUBRICATION SYSTEM 4-4
REMOVAL
• Remove the ca rbu retor. (Ref er to page 3 ~ 2 . 1
DISASSEMBLY
• Remove the throttle cabl e holder.
• Remove the top cap .
• Remove the throttle lever shaft .
• Remove the throttle valve assembly .
4-5 FUEL AND LUBRICATION SYSTEM
®
• Separate the throttle lever arm CD and throttle valve
by removing the bolts with a 2 .5 mm hexagon wrench.
• Separate the jet needle @ and throttle valve 0 .
• Remove the float chamber .
• Remove the accelerating plunger and spring.
.,
• Disconnect the float pin and remove the float with nee-
dle valve .
CAUTION :
When removing the float pin , be careful not to damage the
carburetor body .
• Remove the main jet and palte .
FUEL AND LUBRICATION SYSTEM 4-6
<D
• Remove th e needle jet
from the bore side .
• Remove the pilot jet ® and pilot screw @.
• Remove the starter plunger assembly ® .
CAUTION :
00 not attempt to di sassemble the four screws ® this pa rt
@ is not serviceable
INSPECTION
Check following items for any damage or c logging .
• Pil o t jet
.. Needle valve
• Main jet
• Starter jet
.. Main air jet
• Gasket
• Pilot air jet
• Throttle shaft sea l
..
Pilot outlet and by-pass holes
• Needle jet air bleeding hole
• Accelerating nozzle
• Float
NEEDLE VALVE
If foreign matter is caugh t between the valve seat and the
needle. the gasoline will continue fl owing and cause it to
overflow . If the sea t and needle are worn beyond the permissible IiImits, similar trouble will occur. Conversely. if the
needle sticks, the gasoline will not flow into the float cham·
ber. Clean the float chamber and float parts with gasolilne .
If the needle is worn as shown in the illustration. replace
it together with a valve seat . Clean the fuel passage of the
mixing chamber with compressed air.
FLOAT HEIGHT ADJUSTMENT
To check the float height. invert the carburetor body , with
the float arm kept free . measure the height ® while float
arm is ju st in contact with needle valve with cali pers.
Bend the tongue Q) as necessa ry to bring the height ® to
this valve .
Float height @: 14.2±1 .0 mm 10 .56 + 0 .04 in}
09900· 20101 : Vernier calipers
n
-rA
INCO RRECT
'r-
'('CORRECT
®
4-7 fUEL AND LUBRICATION SYSTEM
REASSEMBLY AND REMOUNTING
Reassemble and remount the carburetor in the reverse ord er of removal and disassembly , and following adjus tments
are necessary after remounting the carburetor .
.. Throttle cable play (Refer to page 2-8 .)
~ Idling adjustment (Refer t o page 2-8 , )
LUBRICATION SYSTEM
OIL PRESSURE
Check the oi l level with oil level gauge of the oil filler cap .
(Refer to page 2-7.1
Check the oil pressure in the following manner:
• Remove the engine under cover . (Refer to page 3- 2.)
• Remove the oil pressure inspection plug CD.
• Install the oil pressure gauge @ in the pasitan in the il lustration .
• Connec t an electric ta chometer to the engine .
• Warm up the engine as follows.
Summer approx. 10 min . at 2 000 r/min .
Winter approx . 20 min . aat 2 000 r/min.
• After the warming up operation , increase the engine
speed to 3 000 r/min , and read the oil pressure gauge .
NOTE:
Engine 011 must be warmed up to 60°C (140 °F) when check ~
ing the oil pressure.
09915 -74510 : Oil pressure gauge
Oil pressu re specification
Above 40 kPa , 10.4 kg /cm2 , 5. 7 psi).
Below 140 kPa , (1 .4 kg/cm2, 19.9 psi)
at 3 000 r/min . Oil temp . at 60 0 C 1140 0 F)
If the oil pressure is lower or higher than the specifications ,
several causes may be considered.
* Low oil pressure is usually the result of a clogged oil filter,
oil leakage from the oil passageway, damaged oll sea l,
a defective oil pump or a combin ation o f these items.
* High oil pressure is usually caused by a engine oi l which
is to o heavy a weight , a clogged oil passage, improper
installAtion of the oil filter or a combination of these items.
FUEl AND LUBRICATIDN SYSTEM 4·8
ENIGNE LUBRICA nON SYSTEM CHART
IL__~CA~M~CH~A~IN__~I ~~~~~~
FRAME I
..
",
,
ARM
ICYLINDER WAll I
",
,,
,
I IN. & tEX. CAM FACE I
,,,
fll
OIL
r.-
~
i ~~J'
OIL HOS E
CYLINDER HEAD
r ,= CYLINDER
CYLINDER
CRA NK S",H"A:..:
FT,-",=-="'-.-
for coo
OIL FILTER
CLUTCH COVER
LEFT
OIL HOSE
PRIMARY
PLATES
...., '
..
OIL
fORKS
ORIFICE
'"
"
CRAN",K-== co
.
,,,
'oo
CRANKCASE,R
CLUTCH COVER
.
4-9 FUEL AND LUBRICATION SYSTEM
ONTENT
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . .
5- 1
DISCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..
5-1
INSPECTION . ... • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
5- 1
• •
5- 3
INSPECTION . .. . . . . . • . . . • • • • • • • • • • • • • • • • • • • • • •
5- 3
LAMPS • . .... . • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
5-4
ENGINE STOP SWITCH . . . . . . . •.. ... . . . • . • • . . . . .
5- 4
LIGHTING SYSTEM • . . ••. . .. .. •...... . • • . . . . . ..
• •
5-1 ELECTRICAL SYSTEM
IGNITION SYSTEM
DISCRIPTION
The capacitor discharged ignition system consists of a magneto. COl unit. ignition coil and spark plug .
The electrical energy generated by t he magneto charges the capacitor . This energy is released in
a single surge at the specified ignition t iming point. and current flows throug h the primary side o f
the ignition coil. A high voltage cu rrent is induced in the secondary windings of the ignition coil resulting
in strong spark between the spa rk p lug gaps.
r----- B, - -- - - - - - - - - r-- w -----BI - - -- - - -
...
-
------<0
COl un it
G --Pick -up coil
-
----,
_ _
To Ihe headlight,
} regulator and l allllgh l
Magneto
INSPECTION
MAGNETO COIL
• Disconnect the pick-up coil and power source co il lead
w ires of the magneto.
Measure the resistance between the lead wires with a pocket
t ester .
M agneto coil resistan ce
Pick -up coil : 1S0 -2700 IG - SII
Pow er source coil : 250 - 3700 CW - Brl
09900·25002 : Poc ket t est er
WIRE COLOR
BI : Blu e
Br : Brown
G : Gree n
W : W hite
Engine stop swit ch
"
BIW - - coil
ElECTRICAL SYSTEM 5-2
IGNITION COil
Chec king with electro te s ter
• Remove t he ign ition coil from the frame .
Test the ignition coil for sparking performance. The test connect ion is as indica ted. M ake su re t hat th e three- need le
spa rki ng distance is at leas t 8 m m. If no sp arking or orange
color spa rking occurs wi th th is mu ch gap , th en it is d efective and must be replalced.
STD Spark performance : 8 mm (0 .3 in)
09900 -28106 : Electro tes te r
Checking with pocket tester
Ignition coil resistance
Primary (Terminal-Ground) : 0 .1 - 1 .0 n
Secondary (Terminal-plug cap) : 12 - 22 kn
n
kO
COl UNIT
• Rem ove th e frame cove rs and seat.
• Disco nnect the COl uni t lead w ires .
Check the cont inuity and measure t he resist ance va lues w ith
a pocket tes ter.
09900-25002 : Pocket tester
Unit : Approx . kO
(±) Probe of tester t o :
1"-.1
S,
S(W
SI
W IBI
SlY
W
G
0-100 - 24 eo 020 80 - 120
W
90
'<0"•
S, 80 - 180
~ 1 36-12 56- 120
1 2- 5 1 50
••
7-14
a
SI
2 - 5 2- 5
6 - 17
0
24 - 5 4
9
•0 G 1 3 - 24 1 2 - 24 7 - 14
D
W/SI 8- 24 8- 22 2 - 6 14- 2 7
28 12 ~
3
"-"
SlY
CD
S(W 2 - 5 2 - 5
a 7 - 14
6 - 17
---
~
~
~
~
~
~
~
~
~
~
~
WI RE COLOR
-- Blue
SI
S,
-- Bro wn
-- Green
G
W
White
S / W -- Black wit h W hite t racer
S l Y -- Black with Yellow t racer
W I B I : White w ith Blue tracer
NOTE:
A s capacitors, diodes, etc. are used inside this COl unit, the resis tance values will defter when an
ohm me ter other than SUZUKI p ocket tes ter is used.
NOTE:
Rem ove the spark plug and place the spark plug on the cylinder head cover kick the engine and check
the sparks o f the spark plug. If no sp arking at spark plug gap, replace the COl unit or inspec t the
magneto coils, ign ition coils and spark plug. If the m agne to coils, ignition coils and spark plug checked
are correct, the COl unit m ay be fault y, repla ce the COl uni t with a new one.
5·3 ElECTRICAL SYSTEM
LIGHTING SYSTEM
REGULAT OR
MAGNETO
HEADLI GHT
.-+-.
TAI LLIGHT
INSPECTION
LIGHTING PERFORMANCE CHECK
• Connect the probes o f the pocket t ester to t he tailli ght
lead w ires (Y and 8 IW )'
• Set the tester knob to th e A C v olt range 2 5 V.
• Connect a tachometer and start the engine.
Check that the voltmeter reads as follows.
12 - 14V IACI at 5 000 r/min .
If the voltage checked is incorrect. check the m agnet o coil
or regula tor.
Lighting coil output check .
• Discon nect the lighting coil lead wire co upler.
• Co nnect a tac hometer and s tart th e engine.
Chec k that the vo ltm eter reads as foll ow s.
More than 75V (Ae) at 5 000 r/min
If the voltage checked is incorrect, replace the magneto coil.
ELECTRICAL SYSTEM 5·4
Regulator check
• Rem ove t he frame cover an d seat .
• Disconnect t he lead wires.
Check the continuit y and measure the resist ance values w ith
a pocket tes te r.
09900-25002 : Pocket tester
Unit : Approx. kO
<±> Probe af tester to :
CD
.o. CD
-.
(D-o
~.
~
"--
®
0_
®
7
LAMPS
HEADLIGHT
TAILLIGHT
ENGINE STOP SWITCH
Inspec t the engi ne st op swit ch f o r co ntinuity wi th a pocke t
tester.
09900 -25002 : Pocket tester
COLOR
POsmON
BIY
O FF
ON !push)
W IRE CO LOR
B I W : Black w ith W hite tracer
B / Y : Black wi th Yellow tr acer
B/W
ONTENT
FRONT WHEEL. . . . . . . . . . . . . . . . . . . . . . . •....•.... . 6- 1
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6- 1
INSPECTION ANO DISASSEMBLY .. .... . .. .. .•.... . 6- 2
REASSEMBLY AND REMOUNTING . .. . . . ... . .•..... 6- 3
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .... 6- 5
BRAKE PAD REPLACEMENT . . . . . •.. ... . . .••• • .... 6- 6
CALIPER REMOVAL AND DISASSEMBLY . . . . . . • .... . 6- 6
CALIPER AND DISC INSPECTION . • .. . .. . . . . . . ..... 6- 7
CALIPER REASSEMBLY AND REMOUNTING . . . . . . . . . . 6- 8
MASTER CYLINDER REMOVAL AND DISASSEMBLY . . .. 6- 8
MASTER CYLINDER INSPECTION . ..... ... .. . . . . . . . 6- 9
MASTER CYLINDER REASSEMBLY AND
REMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 6 - 9
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 6 - 10
REMOVAL ANO DISASSEMBLY . . . . . . . • . . . . . . • .. ... 6 - 10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . .. 6- 12
REASSEMBLY AND REMOUNTING ... . •... . •••... . . 6 - 13
ADJUSTMENT . .. . . . . . . . . . .. .... . . ... •. .. . . . . . . 6-15
STEERING STEM . . . . . . . . . . . ..... . . .. •. .... .•.... 6-16
REMOVAL AND DISASSEMBLY .. .. .•. ... . .. . .•.... 6-16
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
REASSEMBLY AND REMOUNTING .. .. . . • . . . . . . . . . . 6-18
REAR WHEEL . . . . . . . . . .. . .... . .... . . . . .. . ...... . 6-20
REMOVAL . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-20
INSPECTION AND DISASSEMBLY . ... .•.•......• . .. 6-21
REASSEMBLY AND REMOUNTING . . ....•. . ....•. . . 6-21
REAR BRAKE . . . . . . . . . . . . . . . ... . . . . .... . . . . . . . . . 6-23
BRAKE PAD REPLACEMENT . . . . . . . .. .. •.....••. . . 6-24
CALIPER REMOVAL AND DISASSEMBLY .. . . . . . . • . . . 6-24
CALIPER AND DISC INSPECTION . . . ... . • . . . . . . . . . . 6 -25
CALIPER REASSEMBLY AND REMOUNTING . ... .. .... 6-25
MASTER CYLINDER REMOVAL AND DISASSEMBLY . . . . 6-26
MASTER CYLINDER INSPECTION . . . . . . . . . . . . . ..... 6-27
MASTER CYLINDER REASSEMBLY AND
REMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . 6-27
REAR SWINGARM AND SUSPENSION . .... . .. .•. ..... 6-28
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-29
INSPECTION AND DISASSEMBLY . .....• . .• . . . ... . . 6-30
REASSEMBL Y AND REMOUNTING . ..... . . • . .. •.... 6-32
REASSEMBLING INFORMA TION . .... . .. . •• .. . . . . . . 6-33
6·1 CHASSIS
FRONT WHEEL
•
G : Apply SUZUKI Super grease "A " :
Tightening torqu e
ITEM
<D
(J)
@
®
N ;m
50 - 80
2- 4
6- 8
18 - 28
k g-m
Ib-ft
5.0 - 8.0
0 .2 - 0.4
0 .6 - 0 .8
1.8 - 2 .8
36.0 - 58 .0
1.5- 3 .0
4 .5- 6 .0
13.0 - 20.0
99000· 25030 IU.S.A .I
99000-25010 (Others)
Th 1303ITh 1324 :
Apply THR EAD LOCK SUPER " 130311324"
99000· 32030 : THR EAD LOCK SUPER " 1 303 "
IU . S.A . I
99000· 32 120 : THR EAD LOCK SUPER " 1324 "
(Others)
REMOVAL
• l oosen the front axle holder nuts and axle shaft.
• Support the motorcycle wit h jack or block, and keep the
fron t wheel off the ground.
• Draw out the axle shaft and remove the front wheel.
NOTE:
Do not operate the brake lever while dismounting the fron t
wheel.
CHASSIS 6·1
INSPECTION AND DISASSEMBLY
WHEEL BEARING
Inspect the play of beari ng inner ri ng by hand while mounted in the wheel.
Rotate th e inner ring by hand to inspect if any abnormal noise
occurs or rotating smoothly.
Replace the bearing if there is anything unusual.
• Drive out the both bearing with the special t ool in the foll woing procedures.
09941 -50110 : Bearing remover
• Insert the adapte r into the bearing .
• After inserting the wedge ba r from the opposit side, lock
the wedge bar in the s lit of the adapt er.
• Drive out the bearing by knocking the wedge bar.
CAUTION :
The removed bearing should be replaced with new ones .
AXLE SHAFT
Check the axle shaft runout with a dial gauge and replace
it if the runout exceeds the limit.
Service limit : 0 .25 mm (0 .010 in)
09900-20606 : Dial gauge (1 1100 mml
09900-20701 : Magnetic stand
09900·21304 : ' V ' block set
WHEEL RIM
Make sure that the wheel rim runout does not exceed the
service limit when checked as shown .
As excessive funou t is usua lly due t o worn or loose wheel
bearings and can be reduced by replacing the bearings. If
bearing replacement fails to reduce the runout . replace the
wheel.
Service limit: 2.0 mm (0.08 in)
(Axial and Radial)
Play
r= ~ Play
6·3 CHASSIS
SPOKE NIPPLE
Check to be sure that all nipples are tight. and retighten them
as necessary with the special tool.
Tightening torque : 2 - 4 N ' m
10 .2 - 0 .4 kg-m . 1.5 - 3 .0 Ib-hl
09940·60113 : Spoke nipple wrench
TIRE
Refer to page 2· 13.
Service Umit : 4 .0 mm (0 .16 inl
REASSEMBLY AND REMOUNTING
Reassemble and remount the front wheel in the reverse order
of removal and di sassembly . and also carry out the follow-
ing steps;
• Install the wheel bearing wi th the special tools .
09924-84510: Bearing installer set
09924-84521 : Bearing installer set
CAUTION :
First install the wheel bearing for left side .
l eft s ide
left side
Righi s ide
•
Right side
CHASSIS 6-4
• When installing the odometer gear box. align the two
drive pawls CD with the two recesses ® of the wheel hub.
CAUTION :
After touching the odometer gear box @ to the stopper @ .
tighten the axle shah .
• When remounting the axle holder on the front fork, first
tighten the holder nuts for upside as shown in the illu s-
tratio n .
6·5 CHASSIS
FRONT BRAKE
Thl
Tightening torque
ITEM
(j)
®
®
@)
SG : Apply SUZUKI Silicone grease 199000-25100 1
Th1342: Apply THREAD LOCK "1342"
199000-320501
®
®
(i)
N' m
6- 9
20 - 25
20 - 3 1
6- 9
15 - 20
20 - 25
15 - 20
kg·m
0 .5 - 0.8
2.0 - 2.5
2.0 - 3. 1
0 .6 - 0.9
1.5 - 2.0
2.0 - 2.5
1.5 - 2 .0
lb·1t
4.5 - 6.5
14.5 - 18.0
14.5 - 22.5
4 .5 - 6 .5
11.0 - 14.5
14 .5 - 18.0
11 .0 - 14. 5
CHASSIS 6-6
BRAKE PAD REPLACEMENT
• Slightly loosen the pad mounting bolts CD to facilitate later
disassembly.
• Remove the caliper by rem oving the caliper mounting
bolts @ _
NOTE:
Do not operate the brake lever while dismounting the caliper_
• Remove the brake pad by removing the pad mounting
bolts.
CAUTION:
Replace the brake pad as a set, otherwise braking perfor manee will be adversely affected.
• Reassemble and remount the caliper. (Refer to page 6 -5,)
CALIPER REMOVAL AND DISASSEMBLY
• Remove the brake hose and catch the brake fluid in a
suitable receptacle.
CAUTION:
Never re-use the brake fluid left over from the last servicing
and stored for long periods.
• Remove the caliper.
• Remove the pads by removing the mounting bolts.
• Remove the caliper holder.
• Place a rag over the piston to prevent popping up . Force
out the pistons with a air gun .
CAUTION :
00 not use high pressure air to prevent piston damage .
• Remove the dust seals and piston seals .
6-7 CHASSIS
CALIPER AND DISC INSPECTION
Inspect the caliper cylinder bore wall for nicks. scratches
or other damage .
Inspect each piston for damage and wear .
Inspect each rubber part for damage and wear.
Check the disc for wear with a micrometer . Its thickness
can be checked with disc and wheel in place . Replace the
disc if the thickness exceeds the service limit.
Service Limit : 3 .0 mrn (0 .1 2 in )
09900-20205 : M icrometer (0 - 25 mml
With the disc mounted on the wheel. check the disc for face
run out with a dial gauge , as shown .
Replace t he disc if the runout exceeds the service limit.
Service Limit : 0 .30 mm (0 .012 in)
09900-20606 : Di81 g8Ug8 (1/100 mm l
09900-20701 : Magnetic sta nd
CHASSIS 6·8
CALIPER REASSEMBLY AND REMOUNTING
Reasse mble and rem ount the ca liper in the reve rse ord er o f
remova l, and also ca rry out the following steps:
CAUTION :
W ash the caliper c om ponents with fre sh brak e fluid before
reasse mbly.
Nev er use cleaning solvent or gasoline to w ash them .
A p ply brake fluid to the ca liper bore and piston to be in se rt -
ed into the bo re .
• Reassemble and remount the caliper. (Refer to page 6- 5 .1
WARNING :
Bleed air ah er reassembling t he caliper. IRefer t o page 2· 1 2 .)
MASTER CYLINDER REMOVAL AND
DISASSEMBLY
• Remove th e brake lever cover and brake lever by rem oving the m ount ing bolt and nut.
NOTE:
Wh en removing the brake lever, do not lose the spring.
• Place a c lot h undermea th the u nion bolt on the m aster
c ylinder to cat ch spilled drops of b rake fl uid , Un screw
the un ion bolt and disconnect th e brake hose/m aster
cylind er joint.
CAUTION :
Complet ely wipe off any brake fluid adh erin g to any part of
motorcycle. The fluid react s c hemicall y with paint. pla stics.
rub ber m aterials. etc.
• Remove the m aster c ylinder .
6-9 CHASSIS
• Remove the reservoir cap and diaphragm.
• Drain brake fluid .
• Remove the dust boot.
• Remove the ci rclip with the special tool.
09900-06108 : Snap ring pliers
• Remove the piston/primary cup with return spring.
MASTER CYLINDER INSPECTION
Inspect the master cylinder bore for any scraatches or other
damage.
Inspect the piston su rface for scratches or o th er damage.
Inspect the primary cup and dust boot for wear or damage .
MASTER CYLINDER REASSEMBLY AND
REMOUNTING
Reassemble and remount th e master cylinde r in th e reve rse
order of removal and disassembly, and also carry ou t the
following steps.
CAUTION:
Wash the master cylinder components with fresh brake fluid
before reassembly . Never use cleaning solvent or gasoline
to wash them .
Apply brake fluid to the cylinder bore and all the internals
to be inserted into the bore .
• Reassemble and remount the master cylinder. (Ref er to
page 6-5.)
• When remounting the master cylinder on th e handlebar,
first tighten the clamp bolt for upside .
CAUTION:
Bleed air after reassembling the master cy linder. (Refer to
page 2 -121.
CHASSIS 6·10
FRONT FORK
Tightening torque
ITEM
N'm
(j)
30 - 40
0
30 - 40
REMOVAL AND DISASSEMBLY
• Rem ove the f ront wheel. (Refer to page 6- 1.1
• Rem ove the caliper moun ting bolts. (Refer to page 6-6 .)
• Rem ove th e front bra ke hose hold er CD and odom et er ca ble guide @.
CAUTION :
Hang the caliper from the motorcycle frame by using the
string . etc. , taking care not to bend the brake hose .
kg -m
Ib·ft
3.0 - 4 .0 21 .5 - 29.0
3.0 - 4 .0 2 1.5 - 29.0
6·"
CHASSIS
• Loosen the front fork upper and lower clamp bolts and
remove the front fork .
NOTE:
Slightly loosen the front fork cap bolt facilitate later disas*
sembly, before loosening the lower clamp bolt.
• Remove the cap bolt and spring .
• In vert the fork and stroke it several times to let out fork
oil.
• Under the condition (inverted condition), hold the fork
for a few minutes .
• Remove the boot.
• Loo sen the damper rod bolt with the specia l too ls.
09940-34520 : T h andle
09940·34530 : Attachment " A"
• Remove the damper rod from the outer tube .
• Remove the dust seal CD.
• Remove the oil seal stopper ring ®.
CAUTION :
The rem ov ed dust seal and oil seal should be replaced .
CHASSIS 6·12
• Sepa rate the inner tube from the outer tube.
CAUTION:
When separating the inner tube from the outer tube . both
antifriction metals may be damaged and must be replaced
with new ones .
• Separate the spring adjuster
<D by rem oving the E-ring @.
INSPECTION
DAMPER ROD RING
Inspect the dam per rod ring for wea r and dam age .
DAMPER ROD BOLT/DAMPING FORCE ADJUSTER
In spect the d amper rod bolt/d amping force adju ster for
dam age or w ear.
INNER TUBE AND OUTER TUBE
In spec t th e inner tube and outer tube sliding surface s for
any scuffing or flaws.
6·13 CHASSIS
FORK SPRING
Measure t he fork spring free length, If it is shorter that the
service limit. replace it .
Service limit : 608 mm (23.9 in)
REASSEMBLY AND REMOUNTING
Reassemble and remount the front fork in the reverse order
of removal and disassembly, and also carry out the follow ing steps:
• Install the front fork . (Refer to pag e 6· '0.)
INNER TUBE METAL
• Install the metal by hand as shown.
CAUTION:
Use special care to prevent damage to the "Teflon" coat·
ed surface of the Anti -friction metal when mounting it .
OUTER TUBE METAL. WASHER AND OIL SEAL
• Install the outer tube metal CD. washer @ and oil seal @
with the special tool.
09940-50113 : Front fork oil seal installer
CAUTION;
Use special care to prevent damage to the " Teflon" coated surface of the anti-friction metal when mounting it .
OIL SEAL STOPPER RING AND DUST SEAL
• Install the oil sea l stopper ring @.
CAUTION:
Make sure that the oil seal stopper ring fitted securely.
• Install the dust seal @ .
DAMPER ROD BOLT/COMPRESSION DAMPING ADJUSTER
• Tighten the damper rod bolt to the specified t orque with
the special tools . (Refer to page 6· 1 0 . )
09940· 34520 : T handle
09940-34530 : Attachment " A "
CAUTION:
Use a new gasket to prevent oil leakage.
I
CHASSIS 6·14
FORK OIL
• Place the front fork vertically with full compressed position .
• For the fork oil , be sure to use a front fork oil w hose viscosity rating meets specifications below .
Fork oil type : Fork oil # 10
99000· 99044· 10G : SUZUKI FORK OIL # 10
• Hold the front fork vertical and adjust the fork oi l level
with the specia l tool.
Oil level : 145 mm 15.7 in)
09943-741' 1 : Fork oil level gauge
NOTE:
When adjusting the 011 level. remove the fork spring and compress the inner tube fully.
FORK SPRING
• Install the fork spring as shown in pho tog raph .
NOTE:
Close-pitch end of spring should position bottom.
FRONT FORK REMOUNTING
• When inst alling the front fork assembly, align the line
on the inner tube to the upper surface of the steering stem
<D
upper bracket @.
6-15 CHASSIS
ADJUSTMENT
Afte r installing the front fork . adjust the spring pre-load and
damping force as follows .
SPRING PRE-LOAD ADJUSTMENT
The re are four grooved lin es on the side of th e adjuster . Position 0 provides the maximum spring pre-load and position
5 provides the minimum spring pre -load .
Standard setting: 3
DAMPING FORCE ADJUSTMENT
Slowly turn in the adjuster and find out the adjuster is seat ed. From th at position , turn bac k and find out first click that is , -position then turn back and count th e specified position as shown below.
Standard setting: Max .- 7
WARNING :
Be sure to adjust the spring pre-load and damping force on
both front fork legs equally.
POSItion 6
CHA SSIS 6·16
STEERING STEM
Tightening torque
G : Apply SUZUK I S UPER GREASE " A"
99000-2 5030 IU.S .A.)
99000· 250 10 tO thers)
REMOVAL AND DISASSEMBLY
• Remove the fron t w heel. (Refer to page 6- 1.1
• Remove the front fork . (Refer to page 6- 10 .1
• Remove the fron t fender.
ITEM
N' m
(j)
18 - 28
80 - 100
20 - 31
20 - 3 1
®
®
@I
Ib· ft
kg ·m
1.8 - 2.8 13.0 - 20.0
8 .0 - 10 .0 58.0 - 72 .5
2.0 - 3. 1 14 .5 - 22. 5
2.0-3. 1 14.5 - 22 .5
6·11 CHASSIS
• Disconnect the headlight lead wires .
• Remove the headlight housing with headlight by remov·
ing the screw.
• Remove the two brake hose guides.
• Remove the odometer bracket with the odometer and
cable .
• Remove the throttle grip case and throttle grip .
• Remove the engine stop switch and clutch lever holder .
• Disconnect the de-comp o cable .
• Remove the handlebar .
• Remove the steering stem upper bracket by removing the
nut .
• Remove the steering stem nut with the special tool.
09940-14920 : Steering nut socket wrenc h .
NOTE:
Hold the steering stem lower bracket by hand to prevent
it from falling .
CHASSIS 6·1B
• Remove th e up per bearing .
• Rem ove th e upper bearing race and lowe r bearing race
with th e specia l tools.
09941 -54911 : Bearing outer race remover
09941 -74910 : Steering bearing remover and installer
• Rem ove t he lower bea ri ng w ith th e specia l t oo l.
09941 -8451 a : Bearing remover
CAUTION :
The removed bearing should be replaced with a new one.
INSPECTION
In spect t he removed p arts for t he foll ow in g abno rma li ti es.
.. Hand lebar dis tortion
.. Handlebar cla mp wear
.. Race wea r and brinelting
.. Abn ormal n oise of bearing
.. Dis tortion of stee rin g st em
REASSEMBLY AND REMOUNTING
Reasse mble and remount th e st ee rin g st em in the reverse
order o f rem oval and disasse mbly . Pay attention t o the fol-
lo w ing po ints:
BEARING RACES
• Press in t he upper and lowe r bearing races w ith th e special too l.
09941 -34513 : Steering outer race installer
BEARING
• Press in t he lower bea rin g w it h the specia l tool.
09941 -74910 : Steering bearing installer
6·19 CHASSIS
STEERING STEM NUT
• Tighten the steering stem nut with the specia l tool to th e
specified torque (4 0 - 50 Nom , 4.0 - 5.0 kg-m.
29.0 - 36.0Ib-ttl .
09940·14920 : Steering nut socket wrench
• Turn the steering stem bracket about five or six times
to the left and right until it locks in position so that the
taper roll er bearings wi ll be seated properly.
• Turn back the stem nut by 1/4 - 1/ 2 turn .
NOTE:
This adjustment w ill vary from motorcycle to motorc ycle.
CAUTION:
After performing the adjustment and installing the steering
stem upper bracket. "rock" the front wheel assembly forward and ba ckward to ensure that there is no play and that
the procedure wa s accomplished correctly.
Finally c heck to be sure that the steering stem moves free ly from left to right with its own weight . If play or stiffness
is noticea ble. readju st the steering stem nut.
HANDLEBAR
• Set the handlebar to match its punched mark CD to the
matin g face of the holder.
• Secu re the each hand lebar clamp in su ch a way that the
clea rances ® ahead and beh ind the handlebar are
equalized .
1/ 4 - 112 tum
CHASSIS 6·20
REAR WHEEL
Th1303!
Tightening torque
ITEM
G)
®
@
N'm
85 - 115
2- 4
18 - 28
kg-m
Ib·ft
8.5 - 11.5 61.5 - 83.0
0 .2 - 0.4
1.5-3.0
1.8 - 2.8 13.0 - 20.0
G : Apply SUZUKI SUPER GREASE" A"
99000~ 25030 (U .S. A .) 99000-2501010thers)
Th1303/ 1324 : Apply THREAD LOCK SUPER
" 1303/1324"
99000-32030 : THREAD LOCK SUPER " '303"
(U .S.A .)
99000-32120 : THREAD LOCK SUPER " '324"
REMOVAL
• Remove the cotter pin . (For U.S.A. and Canada)
• Remove the axle nut.
• Support the motorcycle with jack or block, and keep the
rear wheel off the ground.
• Remove the axle shaft and disengage the drive chain from
the rea r sprocket.
• Remove the rear wheel.
(Others)
6·21 CHASSIS
INSPECTION AND DISASSEMBLY
Play
WHEEL HUB BEARING
Inspect the play of the wheel hub bearings by hand whi le
mounted in the wheel hub.
Rotate the inner ring by hand to inspect if any abnormal noise
occurs or rotating smoothly.
Replace the bearing if there is anything unusual.
Play
• Remove the bo th bearings with a appropriate bar .
CAUTION:
The removed bearing should be replaced with new ones .
•
REAR SPROCKET
In spect the sprocket teeth for wear. If they are worn as illu strated, repla ce the sprocket and drive chain.
--'-
-- -
Normal wear
AXLE SHAFT . ...•.•. . .... •...
WHEEL RIM . . . . . . . . .... . .... .
TI RE . . . . . . . . . . . . . . . . . . . . . . . .
Service limit : 4 .0 mm 10.16 inl
SPOKE NiPPLE . . ... • .... ..• .. •
Refer to page 6 ·2.
Refer to page 6 -2 .
Refer to page 2-13
Refer to page 6 -3 .
REASSEMBLY AND REMOUNTING
• Reassemble and remoun t the rear wheel in the reverse
order o f removal·and disassembly, and also carry out the
following steps:
• Reassemble and remount the rear wheel. (Refer to page
6 -20 .)
. _. Excessive w ear
CHASSIS 6·11
• Ins t all the wheel bearing with the specia l tools.
09924-84510 : Bearing installer
09924 -84521 : Bearing installer
CAUTION :
First install the wheel bearing for right side.
Left side
Left side
Right side
Right side
•
CD Bearing installer set
@ Wheel bearing !RJ
@ Wheel bearing ILl
@ Spacer
NOTE:
When installing the wheel bearings, use the removed b earing ®
and special tool.
• After remounting th e rear wheel , adj u st the drive chain
slack . (Refe r to page 2- 10 .)
6·23 CHASSIS
REAR BRAKE
SG : Apply SUZUKI SI LICONE GREASE (99000-25 100)
Th 1342 : Apply THREAD LOCK " 1342" (99000-32050)
Tightening torque
ITEM
CD
®
@
0
®
®
I (fJ
N 'm
kg-m
Ib-ft
8-12
0 .8 - 1.2 6 .0- 8 .5
20 - 25
2.0 - 2.5 14. 5 - 18 .0
15 - 20
1.5 - 2.0 1 1.0 - 14.5
15 - 20
1.5 - 2.0 11. 0 - 14.5
6- 9
0 .6 - 0 .9
4 .5 - 6 .5
20 - 25
2.0 - 2.5 14.5 - 18.0
10 - 15 1 1.0 - 1.5 17 .0- 11 .0
CHASSIS 6·24
BRAKE PAD REPLACEMENT
• Remove the rear wheel. (Refer to page 6·20.1
• Remove the caliper cover.
NOTE:
Do not operate the brake while dismounting the rear wheel.
• Remove th e brake pads by removing the pads mounting
bolts.
CAUTION :
Replace the brake pad as a set , otherwise braking performance will be adversely affected.
• Reassemble and remount the caliper . (Refer to page
6- 23.)
CALIPER REMOVAL AND DISASSEMBLY
• Remove the rear wheel. (Refer to page 6· 20.)
• Remove the caliper cover .
• Disconnec t the brake hose and catch the brake fluid in
a suitable rece ptacle .
• Remove the caliper.
• Remove the caliper holder.
• Remove the pads by removing the mounting bolts .
• Place a rag over the piston to prevent popping up. Force
out the piston with a air gun.
CAUTION :
00 not use high pressure air to prevent piston damage .
• Remove the dust sea l and piston seal.
6·25 CHASSIS
CALIPER AND DISC INSPECTION
Inspect the caliper bore wall for nicks, sc rac hes or o th er
damage.
Inspect the piston for damage and wea r.
Inspect each ru bber part for damage and wea r.
DISC THICKNESS IRefer to page 6 -7 .1
Service limit : 3 .5 mm 10.14 in)
DISC RUNOUT IRefer to page 6 -7 .1
Service limit : 0 .3 mm (0 .012 in)
CALIPER REASSEMBLY AND REMOUNTING
Reassemble and remount the caliper in the reverses order
of removal and disassembly. and also carry out the follow ing steps :
• Reassemble and remo unt the caliper. (Aefer to page
6-23 .1
CAUTION:
Wash the caliper components with fresh brake fluid before
reassembly .
Never use cleaning solvent or gasoline to wash them.
Apply brake fluid to the caliper bore and piston to be insert-
ed into the bore.
WARNING :
Bleed air after reassembling the caliper. {Refer to page 2· '2.1
CHASSIS 6·26
MASTER CYLINDER REMOVAL AND
DISASSEMBLY
• Remove the reservoir tan k mounting bolt.
• Remove the co tter pin and p in .
• Place a cloth u nde rn eath the union bolt on the m aster
cylinder to cat ch spilled drop s o f brake f lu id . Unscrew
t he union bolt and di sco nnect the brake hose/m aster
cylind er joint.
CAUTQN :
Completely wipe off any brake fluid adhering to any part of
motorcycle . The fluid reacts chemically with paint. plss t lics, rubber materials. etc.
• Remove t he connector by removing t he c irclip
t he special tool.
<D with
09900 -06108 : Snap ring pliers
• Rem ove th e O-rin g @.
• Remove the dust boot.
• Remove the circlip wi th the s pecia l tool.
09900·06108 : Snap ring pliers
• Rem ove the rod @. piston/prim ary cup @) and spring ®.
6·27 CHASSIS
MASTER CYLINDER INSPECTION
In spect the c ylind er bore w all for any sc ratc hes or other
damage.
Inspect the piston surface for scra tc hes or oth er dam age.
Inspect the prim ary cup for d amage.
MASTER CYLINDER REASSEMBLY AND
REMOUNTING
Rea ssemble and remount the m ast er cy lind er in the reve rse
ord er o f rem ova l and di sasse mbly. and also ca rry oul the
follo wing steps:
CAUTION :
Wash the master cylinder components with fresh brake fluid
before reassembly . Never use cleaning solvent or gasoline
to wash them . Apply brake fluid to the cylinder bore and
all internals to be inserted into the bore .
• Reassembl e and remount the m aster cyli nd er . (Refer to
page 6- 23.)
CAUTION:
Bleed air after reassembling the master cylinder . (Refer to
page 2-' 2.1
CHASSIS 6·28
REAR SWINGARM AND SUSPENSION
G
ITEM
(j)
®
®
G : Apply SUZUKI SUPER GREASE " A"
99000-25030 (U .S.A.I
99()()()'25010 fOthers)
@
®
TIghtening torqu e
N 'm
kg-m
48 - 72
60 - 96
84 - 120
84 - 120
61 - 94
Iboft
4 .8 - 7.2 34.5 - 52.0
6 .0 - 9 .6 3.5 - 69.5
8.4 - 12 .060.5 - 87.0
8.4 - 12.0 60.5 - 87.0
6. 1 - 9.4 44 .0 - 68.0
6·29 CHASSIS
REMOVAL
• Remove the rear wheel. IRefer to page 6· 20. )
• Remove the chain guide.
• Remove the rear brake hose with caliper from the hose
guides .
CAUTION :
Ha ng the caliper from the motorc ycle frame by using the
string etc., taking care not to bend the brake hose .
• Remove the fender.
• Remove the rear shock absorber reservoir tank by loosening the clamps .
• Remove the rear shock absober upper mounting nut and
bolt.
• Remove the chain roller.
• Remove the cushion rod nut and bolt.
• Remove th e rear swinga rm with suspens ion by removing the swingarm pivot shaft.
CHASSIS 6-30
• Remove the chain buffer.
• Remove the chain case.
• Remove the suspension mounting nut and bolt.
• Remove the shock absorber with the reservoi r tank .
INSPECTION AND DISASSEMBLY
Inspect the shock absorber for oil leakage or other damage.
REAR SWINGARM
Inspect the swing arm bearings by hand while mounted in
the swing arm . Rotate the bearing spacer to inspect for abnormal moise and smooth rotation.
Replace the bearing if there is anything unusual.
In spect the dust seals. If they are found to be damage,
replace them with new ones.
• Remove the dust seals and spacars .
• Remove the bearings with the special tools .
09923 -74510 : Bea ring remover
09930 -30102 : Sliding shaft
6·31 CHASSIS
CAUTION:
00 not attempt to remove the bolts, right and left . Swingarm is not disassembly .
CUSHION LEVER
Inspect the respective cushion lever bearings by hand while
they are in the cushion lever.
Rotate each bearing spacer to inspect for abnormal noise
and smooth rotation. Replace the bearing if there is anything
unusual. Inspect the dust seals . If they are found to be
damaged, replace them with new ones .
• Remove the dust seals and spacers .
• Remove the bearings with the specia l tools and proper
tool.
09923-74510: Bearing remover
09930-30102 : Sliding shaft
Inspect the swingarm pivot shaft runout with the dial gauge.
The swingarm pivot shaft must be replaced if the runout exceeds the limit.
Service Limit : 0 .3 mm 10.01 in)
09900-20606 : Dial gauge I I ' I 00 mmJ
09900-20701 : Magnetic stand
09900-21304 : V-block
CHASSIS 6·32
REASSEMBLY AND REMOUTING
Reassemble and remount the rear suspension in the reverse
order o f remova l and disasse mbl y. and also carry out the
foll owing steps .
• Reassem ble and rem ount the fea f suspensio n. (Refer to
pages 6 -2B. and 6-33.1
• Install the cushion lever and swing arm bearings with the
special tool and proper socket w rench .
09924·84510 : Bearing installer
NOTE:
When ins talling the bearing, th e s tamped mark on the bearing ;s positioned outside.
SHOCK ABSORBER SPRING PRE-LOAD
ADJUSTMENT
Using the universal c lamp w rench, adjust the spring tension
o f the shock absorber by turning the spring pre-load adjust er
ring as follows .
Standard spring pre-set length : 269.2 mm 110 .6 inl
09910 -60611 : Universal clamp wrench
CAUTION :
After adjusting the pre-load. tighten the spring adjuster lock
ring sec urely .
SETTING TABLE
Spring length
STO
: 269.2 mm 110.6 inl
Softer: 274 .2 mm (10 .8 in)
Stiffer: 261.2 mm (10.3 in)
Damping force adjuster (STD)
Compression: Max . - 2
Rebound
; Max . - 2 .5
6·33 CHASSIS
REASSEMBLING INFORMATION
LettMnd
I
R'uht hand
I
•
."
ITEM
®
N·m
48 - 72
......
48 - 1. 2
"'.
34.S- 52.0
<II>
'16 - 72
4 8 - 1.2
34 5- 52.0
C>
84 - 120
8 4- 12.0
60 5- 87.0
0)
60- 96
80- 9.6
43.5- 69.5
<E>
84 _ 110
8.4 - 12.0
60.6- 87.0
fi
en _9"
6. 1- 9.4
44.0-68.0
.-
CHASSIS 6·34
Rear
absorber
tank
Protrusion of tank
Bracket
VIEW A
ONTENT
TROUBLESHOOTING. . . . . . • . . . • . . . . . . . • • . • • . • . . . . . . .. 7- 1
WIRING DIA GRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 8
WIRE, CABLE AND HOSE ROUTING . . . . . . . . . . . . • . . . . . ... 7- 9
SPECIAL TOOLS . .. . ..... . . . . . ... . . . .. . . • . . .. .. ... .. 7-13
TIGHTENING
TORQUE .. . ... . . . . . . . . . . . . . . . . .. ... .. .. 7- 15
SERVICE DATA . • ...•.... . .•
0
•
•
•
•
••••
•
•
••••••••••
••
•
7-18
)·1 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
Complaint
Engine will not
s tart . or is hard
to start .
1. Valve clearance ou t of adjustment.
2. Worn valve guides or poor seating of valves .
3 . Valves mistiming .
4 . Piston rings excessively worn .
5. Worn -down cylinder bore .
6. Improperly adjusted de-compression cable .
7. Poor seating of spark plug
Plug not sparking
1. Fouled spark plug .
2. Wet spark plug.
3. Defective ignition coil.
4. Open or short in high-tension cord .
5. Defective pick-up coil or COl unit .
No fuel reaching the carburetor
1. Clogged hole in the fuel tank cap .
2. Clogged or defective fu el cock .
3. Defective carburetor float valve.
4. Clogged fuel hose
5. Clogged fuel filter.
Engine stal1s
easily
Adjust.
Repair, or replace.
Adjust.
Replace.
Replace, or rebore.
Replace .
Retighen
Clean .
Clean and dry .
Replace.
Replace .
Replace .
Clean.
Clean or replace.
Replace .
Clean.
Replac e.
6 . Defect ive ignition coil.
Clean.
Replace.
Replace.
Clean .
Adjust.
Replace.
excessive valve chatter
1 . Valve clearance too large .
2. Weakned or broken valve springs.
3. Cam shaft journal worn and burnt .
4. De-compression cable play Is maladjusted .
Adjust
Replace.
Replace.
Adjust.
Noise appears to come from piston
1. Piston or cylinder worn down .
2. Combusion chamber f ouled wi th carbon.
3. Piston pin or piston pin bore worn .
4 . Piston rigns or ring groove worn .
Replace .
Clean.
Replace.
Replace .
Noise seems to come from timing chain
1. Stretched chain.
2. Worn sprocket .
3. Tension adjuster not working
Replace .
Replace .
Repair or replace.
1. Fouled spark plug
2. Defective pick-up coil or CDI unit.
3 . Clogged fuel hose.
4 . Clogged jets in carburetor
5. Valve clearanc e out of adjustment.
Noisy engine .
Remedy
Symptom and possible causes
SERVICING INFORMATION 7-2
Complaint
Symptom and possible causes
Noisy engine.
Noise seems to come from clutch
1. Worn splines o f counlershah or hub.
2. Worn teeth o f clutc h platos.
3. Distorted clutch pls les. drive and driven .
4. Worn/ Damaged clutch release bearing
5. Clut ch dampers weakened .
Remedy
Replace.
Replace.
Replace.
Replace.
Replace the primary driven
gear.
Noise seems to come from crankshaft
1 . Rattling thrust washer due t o wear.
2. Big-end bearings worn and burnt .
3. Journal bearing worn and burnt.
4. Thrus t clearance too large .
Noise seoms to come from transmission
1 . Gears wom or rubbing .
2. Badly worn splines.
3. Primary gears worn Of rubbing .
4 . Badly worn bearings.
Slipping clutch .
1. Clutch control out of adjustment or loss of play.
2. Weakened clu tch springs .
3. W om or distorted pressure plate.
4. Distorted clutch plates, driven and drive.
Dragging c lutch .
1. Clu tc h c ontrol out o f adjustment or t oo much play .
2. Some clutch springs weakened while others are not .
3. Distorted pre ssure plate or clutc h plates.
Transm ission will
not shift .
Transmission will
not shi ft back .
Transmission jumps
out of gear.
Engine Idles poorly.
1. Broken gearshift cam.
2. Dist orted gearshift f ork s .
3. W orn gearshift pawl.
,.
Broken return spring on gearshift shaft .
2. Gearshift fork s hafts are rubbing or st icky,
3. Dist orted or worn gearshift fork s .
1. Worn shi fting gears on d rivesha ft or countorsh eh .
2. Distorted or worn gearshift f ork s .
3. Weakened cam stopper spring o f gearshift c am .
4. Worn gearshift pawl.
1. Valve clearance out o f adjustment .
2. Poor seat ing o f valves .
3. Defective valve guides.
4. Spark plug gap too wide.
5. Defec tive ignition coil.
6 . Defecti ve pick-up coil or COl unit .
7. Float-chamber fuel level out of adjustment in caburator,
8. Clogged jets in carburetor.
Replace.
Replace .
Replace .
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Replace.
Replace.
Replace.
Adjust.
Repl ace.
Replace.
Replace.
Replace.
Replace.
Replace.
Repair.
Replace ,
Repl ace.
Replace .
Replace .
Replace .
Adjust.
Repair or replace .
Replace.
Adjust or replace.
Replace.
Replace.
Adjust,
Clean or adjust.
7·3 SERVICING INfORMATION
Complant
Engine run s
poorly In high speed rang e.
Remedy
Symptom and possible causes
1 . Valve spring weakened.
2. Valve t iming out of adjustment.
3. Spark plug gap too narrow.
4 . Clogged jets in carburetor
5. De fective ignition coil.
6. Defective pick·up coil or COl unit.
7 . Float-chamber fuel level too low.
a. Clogged air cleaner elemen t.
9. Clogged f uel hose, re sul t ing in inadequat e fuel
supply to carburato r.
Replace.
Adjust.
Adjust or replace.
Clean or adjust.
Replace .
Replace .
Adjust.
Clean or replace.
Clean and prime.
1. Too muc h engine oil in the engine.
Check with oil level
2. Worn pist on rings or cylinder.
3. Worn valve guides.
4 . Cylinder walls scored 01 scuffed.
5. Worn valve stem s.
6. Defective stem seal.
7. Worn oil ring or side rail.
gauge , drain out excess oil.
Replace.
Replace.
Rebore or repla ce.
Replace .
Replace.
Replace.
Engine lacks power.
1 . loss of valve clearance .
2. Weakened valve springs .
3 . Valve timing out of ad just ment .
4. Worn piston rings or cylinder.
5. Poor seating of valves.
6. Spark plug gap incorrect .
7. Clogged jets in carburator .
a. Float-chamber fu el level out of adjustment.
9. Clogged air cleaner elem ent.
10. Sucking air fr om intake pipe .
11 . Too much engine oil .
1 2 . Def ecti ve pick-up coill CDI unit fig nition coil.
Adjust.
Replace.
Adjust.
Replace.
Repair.
Adjust or replace.
Clean .
Adjust.
Clean.
Retighten or replace.
Drain out excess oit.
Replace
Engine overheat s.
1. Heavy carbon deposit on piston crown.
2 . Not enough oil in the frame .
3. Defective oil pump or dogged oil circuit.
4 . Fuel level too low in f loat chamber .
5. Suck air from intake pipe.
6. Use incorrect engine oil .
Clean.
Add oil.
Replace or clean.
Adjust.
Retighten or replace.
Change.
Dirty of hsavoy
exhaust smoke.
SERVICING INFORMATION ) ·4
CARBURETOR
Complaint
Trouble w ith
s la n ing .
Sympto m and pos sible c aus".
l. Starter jet is c logged.
2. StarUtI pipe is clogged .
3. Air leaking from a joint between starter body and
carbunnor .
4. Starter plunger is not operating properly .
Idlin g o r lo w -s peed
trouble .
l. Pilot jet . pilot air jet are clogged or loose.
2. Improperly set pilot air screw.
3. Pilot outlet or by-pass Is clogged.
4. Staner plunger is not fully closed.
5. Incorrect float height .
M edium- or hig h-
l. Main jet or main aIr jet Is clogged .
s peed trouble .
2. Needle Jet is clogged .
3. Throttlo valve is not operating properly.
4. Filter is clogged.
5. Incoreet float height
Overflo w lind fu el
level fluc tuat ions.
1. Needle valve is worn or damaged .
2. Spring in needle valve Is broken .
3. Floa l Is not working properly.
4. Foreign matter has adhered to needle valve.
5. Fuel level is too high or low .
6. Clogged carburator air vent hose.
Rem edy
Clean.
Cleen.
Check starter body and
carburetor for t ighten8SS,
adjust and replace gasket .
Check and adjust.
Check snd clean.
Adjust.
Check and clean.
Check and adjust.
Adju st .
Check and clean.
Check and clean.
Check throttle valve fOf
operation.
Check and clean.
Adjust .
Replace .
Replace.
Cheek and adjust .
Clean.
Adjust float height .
Clean.
ELECTRICAL
Complaint
Symptom and possible causes
No sparking or
1. Defective ignition coil.
poor sparking .
2. Defective sprak plug .
3 . Defective pick-up coil or COl unit.
4. Defective magneto .
Spark plug soon
become fouted
with carbon .
1. Mixture t oo rich.
2. Idling s peed set too high .
3. Incorrect gasoline .
4 . Dirty element In air cleaner.
5. Spark plug too cold .
Spark plug
1. Worn piston rings
become fouled
too soon.
2. Piston or cylinder worn.
3. E){cessive clearance of valve stems In valve guides.
4 . Worn stem oil seals.
Spark plug alectrodes overheat
or bum .
Bulb doe, not light .
1 . Spark plug too hoI.
2. The engine overheats.
3 . Defec tive pick·up coil or COl unit .
4 . Spark plug loose.
5. M ixture too lean.
1. Blown bulb.
2. Open or short in lead wires. or loose lead connections.
3. Shorted, grounded or open mangeto lighting coil .
Remedy
Replace.
Replace.
Replace .
Replace .
Adjust carburetor.
Adjust carburetor.
Change.
Clean .
Replalee by hot type plug .
Replace.
Replace.
Replace.
Replace.
Replace by cold type plug .
Tune up.
Replce.
Retighten .
Adjust carbotetor
Replace.
Repair. replace or retighten.
Replace.
SERVICING INFORMATION J.6
CHASSIS
Complaint
Symptom and possible causes
Remedy
Handling feels too
1. Steering slem nut overtightened.
Adjust.
heavy .
2. Worn roller bearing or race In sl eering stem.
3. Distorted s teering s lem.
4. No t enough pressure in lires.
Replace.
Steering oscillat ion .
1. loss o f balance between right end lell suspensions .
2. Bent front fork .
3. Bent front axle or crooked tire .
4 . Loose st eering stem nUl .
5. Worn or incorrect tires or wrong tite pressure.
Wobbly front wheel.
1. OiSloned wheel.
2. Worn fr ont wheel bearings.
3. Oef ective or incorrect t ire .
4 . Loose nul on axle .
5. loose nuts on rear shock.
6. Worn swingarm bearings.
Front suspension
too soft.
Front suspension
100 stiff.
1. Weaknend springs.
2. Not enoug h fork oil.
3. W rong weight fork oil.
1. FOlk oil too viscous.
2. Too much fork oil.
3. Front 8xle bent .
4. Fork t ubes not adjust ed evenly in forks st em and
Replace .
Adjust.
Adju st.
Repair or repetee.
Replace .
Adjust.
Adjust or rep/ace.
Replace.
Replace .
Replace .
Retighten.
Retighten.
Replace.
Replace .
Refill.
Replace.
Replace.
Drain excess oil.
Replace.
Adjust.
steering st em head
Noisy f ronl
lUlpentlon .
Wobbly rear wheel.
1. Not enough fork oil ,
2. l oose nuts on suspension .
1. Distort ed wheel rim .
2. Worn-down rear wheel bearings or swingarm bearings,
3. Defective or incorrec t t ire.
4. Worn swingarm bearings.
5. loosen nuts on rear suspention.
6. loosen nut on axle.
Rear suspension
100 soft.
Resr suspension
too stiff.
Noisy reer
suspenskln .
1. Weakened spring .
2. Rear suspension adjuster improperl y set.
3. Oil leakage o f rear shock absorber .
1. Rear suspension adjuster Im properl y set .
2. Shock ebsorber shah bent.
3. Swlngarm bent .
4. Worn swingsrm bearings.
1. loose nut on rear suspension ,
2. Worn swingarm bearings.
Refill.
Retighten.
Replace.
Replace.
Replace .
Replace.
Re t igh ten .
Retighten.
Replace .
Reset .
Replace.
Ad just.
Replece .
Replace.
Repl ace.
Retighten .
Replatce.
7-7 SERVICING INFORMATION
BRAKES
Complaint
Poor braking .
Ins ufficient brake
powe r.
Sympto m and po••ible causes
1 . Not enough brake fluid in the reservoir.
Refill to level mark .
2. A ir Happed in brake fluid circuit.
3. Pads worn down.
4 . Too much play on brake lever.
Replace.
Adjust .
1 . Leakage of brake fluid from hydraulic system.
2. Worn pads .
3. Oil adhesion on engaging surface of pads .
4 . Worn d isc .
5 _ A ir entered into hydraulic system.
Brake aquealUng.
Repair or replace.
Replace .
Clean disc and pads .
Replace .
Bleed air.
Repair surface with
2_ Tilted pad.
3. Damaged wheel bearings .
4. loose Iront wheel axle or rear wheel axle.
sandpaper .
Modify pad fitting .
Replace.
nghten to specified torque .
S- Worn pads .
7 _ Clogged return port of master cylinder.
8 . Wrongly fixed pad shim. ret'ainer or spring .
9 _ Caliper binding on caliper axles .
1 . Air enlered into hydraulic system.
2. Insufficienet brake fluid .
3. Improper quality of brake fluid.
Lea kage of brake
fl uid .
Bleed air out .
1 • Carbon adhesion on pad surface.
6 . Foreign material in brake fluid.
Excessive brake lever
stroke .
Rem edy
'- Insufficient t ightening 01 connection joints.
2. Cracked hose.
3. Worn piston andlor cup.
Replace.
Replace brake fl uid.
Disassemble and clean
master cylinder .
Set correctly .
Clean and lubrica te.
Bleed air.
Replenish fluid to specified
level; bleed air .
Replace with correct fluid.
TIgh t en 10 speci fied torque .
Replace .
Replace piston andlor cup .
-Z
-o
: ll
IGNITION COil
G')
~
G')
:ll
~
S
HEADLIGHT
TAILLIGHT
I
ENGINE STOP SWITCH
C.O.!. UNIT
MAGNETO
REGULATOR
.,
--<
..
~
"z
z'"
-
....
-....
~
WIRE COLOR
81 : Blue
Br : Brown
G:
Green
W : While
o
Y : Yellow
B/W: Black with White tracer
BIY: Black with Yellow tracer
W/BI: White with Blue tracer
~
o
z
7·9 SERVICING INFORMATION
WIRE, CABLE AND HOSE 'ROUTING
Pass through the magneto lead wire
under the frame.
Clamp
Pass through the wiring harness under
unit lead wire.
through the COl unit lead wire
the frame.
COl unit
Clamp
Taillight I~,d wire
Clamp
Clamp
Clamp
Clamp
stop switch
switch
Odometer
;ne.,op
To the headlight
VI EW A
w ire
harness
Pass through the magneto lead wire over
the air cktaner
Magneto lead wire
Magneto lead wire
Clamp
harness
- t- Drive chain roller
Clamp
•
•
SERVICING INFORMATION 7-10
oad wire
coil
Magneto lead wire
VIEWA
coil
Spark plug cap
COl
unit
7·11 SERVICING
Brake hose gUid~e::, Front brake hose
Clutch cable
....-Throttle cables
lever
De-comp. cable
I cable guide
eo
_5°
Brake lever
De-camp. lever
cable
Throttle cable (pulling
Throttle cable
::::~Throttle cable guide
cable guide
Throttle
C-- Clutch cable
(pulling
- -
De-comp. cable
NOTE:
Make sure that the de-compo
Cable is not touch (he fuel
tank after mounting the fuel
tank.
Cable
Odometer c"ble- - --
Cable
•
SERVICING INfORMATIO N 7·12
Pass through the brake hose in fron of the
throttle cable. clutch cable and de·
camp .cable.
25 - 30"
Hose guide
When tighten the brake hose clamp. align
the boHom ® of the thick hose tube with
bottom of
After touchmg the brake hose union to
the stopper, tighten the union bolt to the
specified torque.
Inside
After touching
brake hose union to
the stopper, t ighten the union bolt to the
...
specified torque.
Forward
•
Reservoir lank hose
After touching
brake hose
Ihe st~. tighten the union bolt 10 the
spectfted torque.
1· 13 SERVICING INFORMATION
SPECIAL TOOLS
C , ,ffiR;p~
09900·06107
09900·06 I 08
Ii
09900·09003
09900·2010 1
09900· 20508
09900· 20605
•
09900· 20204
09900· 20606
1
09900·20701
09900· 20803
09900· 21304
09900·22301
09910· 201 I 5
09910· 32812
09910-60611
Universal clamp
099 16· 149 10
09916· 20610
09916· 20620
Valve lifter
Valve seet cutter
Valve seat cutter
:!!!:..!s:!;ta!!n~d~-+~~~
09900· 25002
"---+~ = ~_--+~1~
09915· 74510
09916·145 10
09916·21110
09916· 24311
09916·34541
09916· 34570
Valve seat cutter
Valve seat cutter
1
Valve guide re8mer
Valve guide reamer
SERVICING INFORMATION ) ·1 4
099 1 6-34580
09916-44310
Valve guide reamer
(10.8 mm)
Valve guide re mover and installer
09920- 53710
Clutch sleeve hub
09920- 131
09916-845 10
Tweezers
10
09930-34960
Magneto rotor
Attachment
remover
09940-50113
Front fork oil seal
insta ller
09940-60113
Spoke nipple
w rench
09941 -74910
Steering bearing
installer
09941-845 10
remover
Valve
driver
1
in st aller
holder
09930-30141
09917 · 14910
Crankcase separatorl
cranksha ft remo ver
09930-30 102
Sliding shaft
09940- 1 4920
Steering stem nut
socket w rench
09940-34520
T handle
09941 -34513
09941 -50 11 0
09941 -54911
Steering race
inst aller
Wheel bearing
remover
Bearing outer race
09943-74111
Front fork oil level
09940-34530
Attachment " A"
remover
TIGHTENING TORQUE
ENGINE
ITEM
N·m
kg-m
Ib·h
Cylinder head cover bolt
8 - 12
0 .8 - 1 .2
6 .0 - 8 .5
Camshaft sprocket bolt
14 - 16
1.4 - 1 .6
10.0 - 11.5
Cylinder head bolt
35 - 40
3 .5 - 4 .0
25.5 - 29.0
Cylinder head nut
23 - 27
2.3 - 2. 7
16.5 - 19 .5
Cylinder base nut
23 - 27
2.3 - 2 .7
16.5 - 19.5
Rocker arm shaft bolt
25 - 30
2 .5 - 3 .0
18.0 - 21 .5
Balancer shaft bolt
40 - 60
4 .0 - 6 .0
29.0 - 43.5
Primary drive gear nut
60 - 80
6 .0 - 8 .0
43.5 - 58.0
Magneto rotor nut
120 - 140
12.0 - 1 4 .0
87 .0 - 101 .5
Clutch sleeve hub nut
40 - 60
4 .0 - 6 .0
29.0 - 43.5
Gearsh ift arm stopper
15 - 23
1.5 - 2 .3
11 .0 - 16.5
Gearshift cam driven gear bolt
8 - 12
0 .8 - 1.2
6.0 - 8 .5
Cam chain tensioner spring holder bolt
8 - 12
9 - 13
7- 9
0 .8 - 1. 2
0 .9 - 1.3
0 .7 - 0 .9
6 .0 - 8 .5
6 .5 - 9 .5
5 .0 - 6 .5
Engine oil drain plug (On the crankcase)
18 - 23
1.8 - 2 .3
13.0 - 16.5
Engine oil drain bolt (on the frame)
15 - 20
1.5 - 2.0
11 .0 - 14.5
Crankcase bolt
9 - 13
0 .9-1 .3
6 .5 - 9 .5
Oil pipe union bolt
18 - 23
1.8- 2 .3
13.0 - 16.5
Oil gallery plug
20 - 25
2.0 - 2 .5
14.5 - 18.0
Oil straine r
25 - 30
2 .5 - 3 .0
18.0 - 21.5
Oil hose union bolt
25 - 30
2 .5 - 3 .0
18 .0 - 21.5
Oil check bolt
8 - 12
0 .8-1 . 2
6.0 - 8 .0
Oil hose bolt (on the crankcasel
8 - 12
0 .8 - 1.2
6 .0 - 8 .5
Oil hose bolt (on the cylinder head)
8 - 12
0 .8 - 1.2
6 .0 - 8 . 5
Oil hose clamp sc rew
1.5 - 2 .0
0 .15 - 0 .2
1.0 - 1.5
T.D.C. plug
20 - 25
2 .0 - 2 .5
14.5 - 18.0
60 - 72
6.0 - 7.2
43 .5 - 52.0
Engine mounting bolt and nut
(Refer to page 3-4)
37 - 45
27.0 - 32.5
18 - 28
3.7 - 4 .5
1.8 - 2 .8
Exhaust pipe bolt
18 - 28
1.8 - 2 .8
13.0 - 20.0
Muffler con nection boh
18 - 28
1.8 - 2 .8
13.0- 20.0
Muffler mounting bolt
18 - 28
1.8 - 2 .8
13.0 - 20.0
Cam chain tensioner mounting bolt
13 .0 - 20.0
SERVICING INfORMATION 7·16
CHASSIS
N ·m
kg-m
Ib-It
50-80
5.0-8.0
36.0-58.0
6-8
0 .6-0.8
4.5-6.0
Front fork damper rod bolt
30-40
3.0-4.0
21.5-29.0
Front fork lower clamp bolt
20-31
2.0-3. 1
14.5-22.5
Front fork upper clamp bolt
20-31
2.0- 3.1
14.5-22.5
Front fork cap bolt
30-40
3 .0-4.0
21.5-29.0
Steering stem head nut
80-100
8.0-10.0
58.0- 72.5
Handlebar clamp bolt
18-28
1.8-2.8
13.0- 20.0
Front brake master cylinder mounting bolt
6-9
0 .6-0.9
4.5-8.5
Front brake caliper mounting bolt
20-31
2.0- 3.1
14.5- 22.5
Front brake pad mounting bolt
15-20
1.5-2.0
11.0- 14.5
Brake hose union bolt (Front & Rear)
20-25
2.0- 2.5
14.5-18.0
Air bleeder valve (Front & Rear)
6-9
0 .6- 0 .9
4.5- 6.5
Brake disc mounting bolt (Front & Read
18-28
1.8- 2.8
13.0- 20.0
Swingarm pivot nut
61-94
6.1 - 9.4
44.0-68.0
Front footrest bolt
44-66
4.4- 6.6
32.0-47.5
48-72
4.8- 7.2
34.5- 52.0
Rear cushion rod mounting nut
84-120
8.4- 12.0
60.5- 87.0
Rear cushion lever nut (front)
60-96
6.0- 9.6
43.5-69.5
Rear cushion lever nut (Center)
84 - 120
8.4-12.0
60.5 - 87.0
Rear axle nut
85- 115
8.5-11 .5
61.5-83.0
Rear brake pad mounting bolt
15 - 20
1.5- 2.0
11.0 - 14.5
Rear brake master cylinder mounting bolt
8-12
0.8 - 1.2
6.0-8.5
Rear brake rod lock nut
15-20
1.5-2.0
11.0- 14.5
Spoke nipple
2-4
0 .2 -0.4
1.5 - 3 .0
ITEM
Front axle shaft
Front axle pinch nut
Shock abSOrber mounting nut (Upper &
Lowed
1·17 SERVICING INfORMATION
TIGHTENING TORQUE CHART
For other bolts and nuts not listed in the preceding page, refer to this chart:
Bolt Diameter
® Imml
"5
6
8
10
12
14
16
18
Conven tional or " 4 " marked bolt
kg-m
lb-ft
N'm
1- 2
0 . 1 - 0 .2
2- "
I 0 .2 - 0 .4
0.4 - 0 .7
4- 7
10- 16
1.0- 1.6
22 - 35
2.2 - 3. 5
35 - 55
3 .5 - 5. 5
60 - 80
5.0 - 8.0
80 - 130
8.0 - 13.0
130- 190
13.0 - 19.0
Conventional boh
0 . 7 - 1.5
1.5 -3. 0
3 .0 - 5 .0
7.0 - 11 .5
16.0-25.5
25 .5 - 40.0
36.0 - 58.0
58.0 - 94 .0
94 .0 - 137.5
"4" marked bolt
N'm
1.5 - 3
3- 6
8 - 12
18 - 28
40 - 60
70-100
.. 7" marked bolt
kg-m
J
0 . 15 - 0 .3
0 .3 - 0 .6
0 .8 - 1.2
1.8 - 2 .8
4 .0 - 6 .0
7.0 - 10.0
110 - 160
11 .0 - 16.0
170 - 250
200-280
17.0 -2 5.0
20 .0 - 28.0
Ib-ft
1.0- 2.0
2.0 - 4 .5
6.0 - 8 .5
13.0 -20 .0
29 .0 - 43 .5
50.5 - 72. 5
79. 5 - 115.5
123.0 - 181.0
144 .5 - 202.5
"7" marked bolt
SERVICING INFORMATION 1·18
SERVICE DATA
VALVE + GUIDE
V alve
Unit : mm (in)
diam~
I
•
IN .
11.20)
27.
11
EX .
Valve lift
IN.
10.311
EX .
:ciE
, e-;; ' e nCoid}
Va lve guide to
clearance
,e s te m
IN .
10.002 - 0 .004)
EX.
~ .1
IN .
10.0004 - 0 .0015)
10.014)
0 . 05~2)
~
•
EX .
Val ve guide IF .
V alve stem 0 .0 .
•
IN . & EX .
10.1969 - 0 . 1973)
~. 975 - 4 . 990
IN .
.1959 - 0 . 196
- •
EX .
Valve stem funout
Ivi ' ,e h.
,ick
Valve stem end length
lvi l Ie seat
1dti1
Valve head radial runout
IIN'.'~ sJ'~i7g fre e le ngth
0 .002
•
10. 1951-0. 1957)
IN. & EX.
~
IN . & EX.
10.02 )
IN . & EX.
10~
IN. & EX.
10 .0 3 5-6:643)
IN. & EX.
~)
INNER
11 .38)
OUTER
11374~)
Valve spring tension (IN .~
111 .7 ...:~k~S)
INNER
,, : l'
.
I
-
OUTER
at I
128.9 - 33.3 )bs )
1
•
•
I
)·19 SERVICING INFORMATION
CAMSHAFT + CYLINDER HEAD
r----Cam height
Unit : mm (in)
:-------,---:-
IN.
11.3043)
11.3161 - 1.3177)
EX
33.460 - 33 .
f-:,---;-,.,-.,.----:---o:--:--- r - - - ._+-_--'-'
11-'=".
31 73 - 1 . 31 ~_-j_---'- .v,
Camshaft journal oil clearan ce
Right side
10.0013 - 0.0026)
10.0059)
Left side
0 .028 - 0 .
.~--;-,.,-.,.----:-~_;_~~+----r---'cIO . 0011 - 0.
Camshaft journal holder 1.0.
Right side
10.8666 - 0 .8671)
Left side
17 . 5 12 - 17. 525
f-::--,---;---,----~_;::_--+--- _ - - - - ' c10 . 6894_
Camshaft journal 0 .0 .
RighI s ide
Left side
1- :
10.8645- 0.8654)
1 7.466 - 17.484
10.6876 - 0.6883)
Camshaft runout
10.004)
128 .9
I
Rocker arm 1.0 .
arm
IN. & EX .
IN. & EX .
1
1
10.4 724 - 0.4 731)
11.973 - 11 .984
10.4714 - 0 .4718)
Cy linder head dis tortion
10.002)
cover distortion
1
De-compression lever play
10.04 - 0.08)
CYLINDER + PISTON + PISTON RING
~
ITEM
Pi ston to cylinder clearan ce
Cylinder bore
Piston diam .
Unit: mm (in)
STANDARD
LIMIT
0 .055 - 0 .065
10.0022 - 0 .0026)
79 .000 - 79 .015
13. 1102 - 3 . 1108)
78.940 - 78.955
13 . 1079 - 3 . 1085)
0 . 120
10.0047)
79.075
13. 1132)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
Pis ton ring end gap
1 sl
R
2nd
R
1 st
2nd
10.2
Approx . 10.40)
11 . 1
10.44)
0.15 - 0.30
10.006 - 0.012)
0 . 35 - 0 .50
10.0 14- 0.020)
App rox .
78.880
13. 1055)
0.05
10.002)
8 .2
10.32)
8.9
10.35)
0.70
10.028 )
0 .70
10.028)
SERVICING INFORMATION 7·20
.
I
to groove
clearance
1st
10.0071
0 . 150
10.0061
2nd
groove
1st
10.040 - 0.0411
- 1.03
-0.041
2nd
Oil
Piston ring thickness
10.079-0.0801
1st
2nd
10.038-0.0391
20.030
' -_ _ _1----'1.:;::0.7886'-1_
Piston pin bore
10.7872 - 0 .78741
CON ROD + CRANKSHAFT + BALANCER
ITEM
Corod small end 1.0.
STANDARD
20.006 - 20.014
10.7876 - 0.78801
Conrad deflection
Con rod big end side clearance
Conred big end width
Crank web to web width
0 . 10 - 0.55
10.004 - 0.0221
21.95 - 22.00
10.864 - 0 .8661
60.0 + 0.1
12.362 ± 0 .0041
10.78661
Unit: mm (in)
LIMIT
20 .040
10.78901
3.0
10.121
1.0
10.041
0.05
10.0021
10.3
10.411
Crankshaft runout
Balancer spring free length
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 oe, 140 0 FI
STANDARD
1.590135/221
Above 40 kPa 10.4 k9 /em'. 5.7 psil
Below 140 kPa ( 1.4 kg /cm 2, 19 .9 psi)
at 3 000 r/min.
LIMIT
7-21 SERVICING INFORMATION
CLUTCH
Unit: mm (in)
ITEM
STANDARD
10 - 15
10. 4 - 0 .6)
2.72 - 2.88
10. 107 - 0 . 113)
15.8 - 16.0
10.62 - 0.63)
Clutch lever play
Drive plate thickness
Drive plate claw width
LIMIT
2.42
10.095)
15.2
10.60)
0 .10
10.004)
29 .5
11. 16)
Driven plate dis tortion
Clutch sprin g free leng th
TRANSMISSION + DRIVE CHAIN
I
Unit: mm (in) Except ratio
:--- - -
Gear ratios
to groove
I
Shih fork gro ove width
10.020)
5.0- 5. 1
_ _--'1-'0 .-',
' ;'-:
97 - O. 2-,00
" ,)_ _ _ _ _ _ _ _ _--j
Drive chain
10 .189 - 0 . 193)
DAIDO : 0 .1.0. 520VC5
TAKASAG O: RK520S0
Type
~~
1 ~--~~~
20-pitch length
11 .0 - 1.6)
1-22
CARBURETOR
I
ITEM
Carburetor type
SPECIFICATION
MIKUNI TM33SS
I
Bore size
33 mm
I.D _ No
Idle r/min.
Fuel level
Float he~lt
Main jet(M.J.)
Main air jet
14DO
1 400 + 100 rlmin
0+ 0.5 mm (0 + 0 .02 in)
14.2 ± 1.0 mm 10_56 ± 0_04 inl
#132_5
IM ,A ,J,I
IJ ,N,I
IN ,J ,I
ICAI
IP,J ,I
IB,P,I
(P ,O,)
IV ,S,)
IG ,S,)
IP,S,)
IP,A ,J ,)
Jet needle
Needle jet
Cut-away
Pilo~t
0 . 9 mm
5FP96-3rd
P-B
1.5
#37 , 5
0 .8 mm
By-pass
Pilot outlet
Valve seat
Starter jet
Pi lot screw
Pilot air jet
Throttle cable play
(pulling cable)
0.6 mm
1.8mm
#50
' .0 turn back
1.0 mm
0 , 5- 1 ,0 mm 10 ,02-0,04 inl
ELECTRICAL
ITEM
Ignition timing
Spark plug
Spark performance
Ignition coil resistance
M agneto coil resistance
Unit: mm (in)
SPECIFICATION
I
30 o B.T . D.C. above 4 300 rl min
ND ,: X27EPR-U9
Type
N ,G ,K ,: DPR9EA-9
0 ,B - O,9
Gap
10,03- 0 ,04)
Over 8 (0 .31 at 1 atm.
Primary
0,1 - 1.00
Secondary
12 - 22kO
Li ghti~
0,1 - 1.50
250-3700
1BO - 2700
Power source
Pick-up
Lighting coil no-load voltage
(when engine is cold)
Regulated voltage
NOTE
5°B. T .D.C . below 2 300 rlmin and
Terminal Ground
Plug cap Term in al
V- B
W - Br
G-BI
M ore than 75 V (AC) at 5 000 r fmin.
,
12 - 14 V at 5 000 r/min.
I
7·23 SERVICING INFORMATION
WATTAGE
Unit : W
ITEM
SPECIFICATION
55
5
Headlight
Taillight
BRAKE + WHEEL
I
Unit: mm (in)
ITEM
Brake leve r play
STANDARD
Rear brake pedal height
Brake disc thickne ss
Front
Rear
0 - 0 .3
10 - 0 .0 1)
5
10.2)
3 .5 + 0.2
10. 138 + 0.008)
4 .0 +
- 0.2
10. 1 57 -+ 0.008)
Brake disc runout
Ma ster cy linder bore
Front
Rear
Ma ster cyli nder pi ston diam.
Front
Rear
Brake caliper cylinder bore
Fra nt
Rear
Brake ca liper pi ston diam .
Front
Rear
Wh eel rim runout
2. 0
10 .08)
2. 0
10 .0 8 )
0 . 25
10.010)
0 . 25
10.010)
Axial
Fron t
Re ar
Tire size
T ire tre ad depth
Front
Rear
Front
Rear
3 .0
10.118)
3 .5
10. 138)
0 .30
10.0 12)
1 1.000 - 11 .0 4 3
10.433 1 - 0.434 8)
12.700 - 12.743
10.5000 - 0 .5017)
10 .957 - 10.984
10.43 14 - 0.4324)
12 .657 - 12 .684
10.4983 - 0.4994)
27 .000 - 27.050
11. 0630 - 1 .0650)
27 .000 - 27.050
11. 0630 - 1 .0650 )
26 .900 - 26. 950
11.059 1 - 1.0610 )
26 .900 - 26.950
11. 0591 - 1.06 10 )
Radia l
Wheel axl e run out
LIMIT
80/ 100· 2 1 5 1M
11 0 / 100- 18 64M
4 .0
10. 16)
4 .0
10. 16)
SERVICING INFORMATION 7·24
SUSPENSION
Unit: mm (in)
ITEM
Front fork stroke
STANDARD
280
(11.0)
LIMIT
608
(23 .9)
Front fork spring free length
145
(5 . 7)
1 000 kPa
Rear shock absorber gas pressure
(10 kg /em' . 142 psi)
Rear shock absorber spring
269.2
pre~ set length
(10 .6)
Rear wheel travel
280
(1 1.0)
Front fork oil level
0 .3
(0 .01 )
Swing arm pivot shaft runout
TIRE PRESSURE
COLO INFLATION
TIRE PRESSURE
FRONT
REAR
•
kPa
kg /cm 2
pSI
100
100
1.0
1.0
14
14
NOTE
) ·25 SERVICING INFORMATION
FUEL + Oll
Use only unleaded gasoline of at least 87
pump octane ( Ii..j:-M method) or 9 1 octane or
higher rated by the research method .
Gasoline containing MTBE (Methyl Tertia ry
Butyl Et her), less than 10% ethanol. or
less t han 5% me thanol with appropriate
coso lve n ts and cor rosion inhibitor is
I .
Fuel type
For U .S.A .
For Canada
i
used
octane or higher.
recommended.
Fuel tank including reserve
reserve
Change
Overhaul
'7' "'-' i
Front fork o~ capacity (each leg)
gasoline IS
For the others
FOREWORD
This chapter descdbes up ~ to - date service procedures which differ from those of
the OR350.
Please refer to the chapters 1 through 7 except for the i tems described in this
chapter.
NOTE:
Any differences between DR350 and DR350S in specifications and service data
are clearly indica ted with the asterisk mark ( .J.
IMPORTANT
All street-legal SUZUKI motorcycles with engine displacemen t of 50ce or grea ter
are subject to Environmental Protection Agency emission regulations. These regulations set specific s tandards for exhaust emission output levels 85 well as particular servicing requirements. This manual includes sp ecific information required to
properly inspect Bnd service DR350S in accordance with all EPA regulations. It is
strongly recommended that the chapter on Emission Control, Pedodic Servicing
and Carburetion be thoroughly reviewed before 8ny type of service work is per·
formed.
Further information concerning the EPA emission regulations and U.S. Suzuki's
emission control program can be found in the U.S. SUZUKI EMISSION CONTROL
PROGRAM MANUAUSERVICE BULLETIN.
ONTENT
VIEW OF DR350S . . . • . . . . . . . . . . . . . . . . . . . . • . . . . . . . . .. 8- 1
SPECIFICA TIONS . . . . . . . . . • . . . . . . . • . . • . a , • • • • • • • • • • • 8- 2
SERVICE DA TA . . . . . . . . . . .. • •.. . . . •... . . .•. . .. . . . . . . 8 - 3
TIGHTENING TORQUE ... .. . .. . .. . . .. . ... . . . . . . . . . . . . B- l1
PERIODIC MAINTENANCE SCHEOULE .•.. . . . . . . • . . . . . . • . B-73
BREAK-IN PROCEDURES..... .. . .. . . . . . . . . . . . . . . . . . . . B-77
ENGINE MOUNTING. . . • . . • . . • . . . . . . . . . . . . • . . . . . • . . .• B-77
KICK IDLE GEAR . ..•• ..••.. .•.•.. .• • •.. .•. .••• . .... • 8 - 18
CARBURETOR . . . . . • . . • . • . • . • . . . • . • . . . . . . . . • . • • . • • . . 8-19
EMISSION CONTROL CARBURETOR COMPONENTS . •.. . ... B-24
IGNITION SYSTEM. • . . . . • • • • • . • . • • • . • . . . • • • • • • . . . . •. B-25
CHARGING SYSTEM • .••.•.•.•.•...•.•.•.•..••••.•..• 8 -27
LAMPS. . . . . . . • . . . . . . . . • . . . • . • . • . . . . . . . . . . • . • . • . • . 8-30
SPEEDOMETER AND TACHOMETER •.•••..•.••••••••••• B-37
SWITCHES. • . . • • • • • . . . . . . . . • • • . • • • • • . • . • • . • • • • • • •• 8-32
SA TTERY • • • • . . . • . . . . . . . • . . . • . . . . . • • . • • • • • • • • • • • •• 8-33
FRONT FORK........ . . . . . .. .. . .. .. . .... . . . . . . . . . . . 8 -36
TROUBLESHOOTING . . ... • . . . . . . . . . ... . . . . . . . ••.•..• . B-37
WIRING DIAGRAM .. . . . . • . . . • . . . . . . . . . . . . ...••.•.. . . 8-38
WIRE, CABLE AND HOSE ROUTING . . •• . . . . . • . . . . . . . . ... B-40
EVAPORA TIVE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . B-45
8·1 OR350S
VIEW OF DR350S
LEFT SIDE
RIGHT SIDE
DRJ5DS 8-2
SPECIFICATIONS
DEMENSIONES AND DRY MASS
Overall length ..... . '2 235 mm 188 _0 inl
Overall width ..... .
885 mm 134.8 in)
Overall height ...... ·1 245 mm (40 .9 in)
Wheelbase . . . . . . .. ·1 435 mm (56 .5 in)
·290 mm (1 1 .4 in)
Ground clea rance .. .
Seat height. ...... .
• 890 mm 135.0 in)
, 118 kg 1260 Ibs)
Dry mass ........ .
ENGINE
Type . . . . . . . . . . . . . Four-stroke . air-cooled .
OHC
Number of cylinders . 1
Bore ...... . ...... 79 .0 mm (3.110 in)
Stroke . . . . . . . . .. . 71.2 mm 12.803 in)
Piston displacement. 349 em l 121 . 3 cu . in)
Compression ratio ... 9 .5 : 1
Ca rburator . . . . . . .. • MtKUNI BST33SS,
single
Air cleaner ........ Polyurethane foam
element
Starter system ..... Primary kick
Lubrication system .. Dry sump
TRANSMISSION
Clutch . . . . . . . . . .. Wet multi-plate type
Transmission ...... . 6-speed constant
mesh
Gearshift pattern .... l -down. 5-up
Primary reduction ... 2.818 (62122)
Final reduction ..... ·3.071 (43 / 14)
Gear ratios , Low .... 2.416 (29 / 12)
2nd __ . _ 1. 733 126115)
3rd . . .. 1.333 124/ 18)
4th .. . . 1.111120/ 18)
5th .... 0.952120/ 21)
TOP .... 0.826119123)
Drive chain ........ TAKASAGO RK520S0
or DAIDO DID,
520VC5. '108 links
ELECTRICAL
Ignition type .... _ ... SUZUKI "PEl "
Ignition timing ....... 5 ° B. T . D . C . below
2 300 rlmin and
30° B.T . D .C . above
4 300 r/min
Spark plug ...... ___ . NGK DPR9EA · 9 or
NIPPON DENSO
X27EPR·U9
Battery . . . . . . . . . . . . • 12V 10.8 kC
13 Ah l/ 10HR
Fuse . . . . . . . . . . . . . . ·15A
CHASIS
Front suspension . . ... Telescopic . coil spring .
oil dampened. spring
preload fully way adjustable. compression
damping force ad justable
Rear suspension ...... Link type suspension
coil spring . gas l oil
damped. spring preload
fully way adjustable ,
compression damping
force adjustable
Steering angle ....... 45 ° (right and left)
Caster . . . . . . . . . . .. . 62 ° 30 '
Trai l . . . . . . . . . . . . . . ·115 mm (4 . 6 in)
Turning radius ....... ·2 .3 m (7 . 2 tt)
Front brake . . . . . . . . . Dis c
Rear brake ....... . . Disc
Front tire size .... . .. "80/ 100-2 1 51P
Rear tire size ........ ·110/ 90- 18 61 P
CAPACITIES
Fuel tank
inc luding reserve .. "9.0 L (2 .4/ 2.0 US/Imp
gal)
'8.0L 12.1/1.8 USllmp
gal) ... California only
reserve . . . . . . . . . *1.5 L (0.4/0 .3 US/Imp
gall
Engine oil, oil chang e . . 1 700 ml fl . 8 / 1.5
USllmp qt)
Front fork oil. ....... "544 ml (18.4/19 . 2
US/ Imp oz)
Specifications marked with asterisks (.) are
py,.I . ":;,,p tn l'IR'1a;nc::
8·3 DR350S
SERVICE DATA
VALVE + GUIDE
Unit : mm (i n )
ITEM
STANDARD
diam .
Valve
Valve cl.
Iwh
, 9I I
to
I
cold}
stem
clea rance
IN .
I
EX.
IN.
11.061
8 .0
10.311
EX .
10.3 11
IN.
1006g~ = g 10
EX.
10.003 -= fo051
0.010 - 0.037
10.0004-0.00151
0 .030 - 0 .057
10.0012 - 0 .00221
- 5 . )12
5.
10. 1969 - 0.19731
4 .975 - 4 .990
(0. 1959 - 0 . 19651
IN.
EX.
I 9I i
ill
IN . & EX .
Va lve stem 0.0.
IN .
. lg~1
10.0141
104i~~1 - 0 . 19571
EX.
Valve stem runout
LIMIT
0 .05
IN . & EX .
•
, headthi( ,ness
IN . & EX .
Valve stem end length
Valve
. 1.
10.03 5 - 0.0431
IN. & EX.
Valve head radial runout
i~
~
ing tension
10~
IN . & EX.
seat
liN . &
10.021
&.EX:
IN . & EX.
0.03
10.001
INNER
~81
OUTER
37 .8
11.491
1 11 .7- 14.'3k~fl l
INNER
I
-
OUTER
at
128 . 9-:-~33
1. mm,I?f~inl
I
DR350S 8·4
CAMSHAFT + CYLINDER HEAD
Unit : mm (in)
--
----
_ -;I:;:N-;-.-t--.......:('313.3~1~6iOl;=:1~'t3~170i7J)-- _---'-I1"",.3043)
16
EX .
.3055)
0.1
Right side
(0.005"",
9)_
--1
Left side
Right side
Left side
1.980
r-R_i9_h_' _5_id_e _ _..:.(0",',;.-8-:-645 - O.865-;-4,--)_ _ _ _ _ _ _ __
Left side
1
76 - 0 .6883)
0 .10
runout
Cam chain 20· pitch length
•
(5 .07)
arm 1.0.
12 .000 - 1
: -_ _!-I_N_._&_E_X_
. _---'(:0:
0 .4724 - 0.4
arm
IN . & EX .
(0.4714 - 0.4718)
Cylinder head distortion
cover
(0.002)
De-compression lever play
CYLINDER + PISTON + PISTON RING
Unit: mm (in)
ITEM
STANDARD
LIMIT
Piston to cylinde r clearance
0 .055 - 0.065
(0.0022 - 0 .0026)
79.000 - 79.015
(3 . 1102 - 3 . 1108)
78.940 - 78 .955
(3 .1079 - 3 . 1085)
0.120
(0.0047)
79.075
(3. 1132)
Cylinder bore
Piston diam .
Measure at 15 mm (O.6 in) from the skirt end.
Cylinder distortion
Piston ring fre e end gap
Piston ring end gap
10.2
151
R
Approx . (0.40)
2nd
R
Approx . (0.44)
151
2nd
11 .1
0 . 15 - 0 .30
(0.006 - 0 .012)
0.35 - 0 .50
(0 .014 - 0 .020)
78.880
(3 . 1055)
0 .05
(0.002)
8.2
(0 .32)
8 .9
(0.35)
0.70
(0.028)
0 .70
(0 .028)
8·5 DR350S
I
ITEM
Piston ring to groove
clearance
+
STANDARD
1st
1st
2nd
Oil
Piston ring thi ckne ss
1 st
2nd
Piston pin bore
Piston pin 0 . 0 .
1.01 - 1.03
(0.040 - 0 .041 I
1.01 - 1.03
(0.040 - 0 .041 I
2 .0 1 - 2 .03
(0.079 - 0 .0801
0 .97 - 0 .99
(0.038 - 0 .0391
0 .97 - 0 .99
(0.038 - 0 .0391
20.002 - 20.008
(0.7875 - 0 .78771
19 .996 - 20.000
(0.7872 - 0 .78741
CONROD + CRANKSHAFT + BALANCER
ITEM
Corod small end 1.0.
Conrod big end width
Crank w eb to w eb width
Crankshaft runout
Balancer spring free length
OIL PUMP
I pressure
20.030
(0 .78861
19 .980
(0.78661
Unit : mm (in )
STANDARD
20.006 - 20.014
(0.7876 - 0 .78801
Conrad deflection
Conrad big end side clearan ce
LIMIT
0 . 180
(0.0071
0 . 150
(0.0061
2nd
Pi ston ring groove width
I
0 . 10 - 0 .55
10.004 - 0 .0221
21.95 - 22.00
(0.864 - 0 .8661
60.0 ± 0 . 1
12. 362 ± 0 .0041
LIMIT
20.040
(0.78901
3.0
(0. 121
1.0
(0.041
0 .05
10.00 21
10.3
10.41)
DR35DS 8·6
CLUTCH
Unit: mm On)
ITEM
Clutch lever play
Drive plate thi ckness
Drive plate claw width
STANDARD
10 - 1 5
(0.4 - 0.6)
2.72 - 2.88
10. 107 - 0 . 113)
15.8 - 16.0
10.62 - 0 .63)
Driven plate distortion
Clutch spring free length
TRANSMISSION + DRIVE CHAIN
LIMIT
2.42
10.095)
15.2
10.60)
0. 10
10.004)
29.5
11. 16)
Unit'• mm (in) Except ratio
ITEM
STANDARD
2 .818162 /22)
'3 .07 1 (43/ 14)
I
2.4 16 (29 / 12)
2nd
1. 733 126/ 1 5)
3rd
1 .333124/ 18)
4th
1.111120118)
I
5th
0 .952 (20/21)
Top
0 .826 (19 /23)
Shift fork to groove clearance
0. 1 - 0 .3
10.004 - 0 .012)
Shift fork groove width
No . 1,No. 2
5.0 - 5. 1
& No.3
10. 197 - 0 . 200)
4 .8 - 4 .9
Shift fork thickness
No.l .No.2
& No .3
10. 189 - 0 . 193)
Dri ve chain
DAIDO : 0 .1.0. 520VC5
Type
TAKASAGO: RK520S0
Link s
'108
LIMIT
Primary reduction ratio
Final reduction ratio
Gear ratios
Low
.
Dri ve chain slack
20' pitch length
25 - 40
11.0- 1.6)
Spe cification marked w ith asterisks (*1 are exclusive to DR350S.
0.5
10.020)
319.4
112.57)
8·7 OR350S
CARBURETOR
SPECIFICATION
U.S.A .
California model only
·MIKUNI BST33SS
33 mm
·1402
""403
• 1 500 ± 100 r /min
"'1.5 ± 0.5 mm
10.06 + 0.02 in!
ITEM
Carburetor type
Bore size
1.0. No
Idle r/min .
Fuel level
*14.6 ± 1 ,0 mm
Float height
Main-.let
Main air jet
Jet needle
Needle jet
Throttle valve
Pilot jet
By -pass
Pilot outlet
V alve seat
Starter jet
Pilot screw
Pilot air jet
IM.J .!
IMAJ .!
IJ.N.!
IN.J .!
IThY!
IP.J .!
IB.P.!
IP.O.!
IV .S.!
IG .S.!
IP.S.!
IP.A .J.!
Throttle cable play
10. 57 ± 0.04 in!
'" # 135
.. 0 .6 mm
·SC016
.. 0·6
.. # 11 5
*# 3'7.5
*0.8 mm, 0.8 mm , 0 .8 mm
·0.8 mm
·1 . 5 mm
·#37 . 5
PRE-SET
·1 .3 mm
·0. 5 - 1.0 mm
10.02 - 0.04 in!
Unit .- mm (in)
elECTRICAL
ITEM
Ignition tim ing
Spa rk plug
Spark performance
Ignition coil resistance
Magneto coil resistance
SPECIFICATION
5 ° B.T .D .C. below 2 300 r/min and
30 o B.T.D.C. above 4 300 r/min
NO .: X27EPR-U9
Type
N .G.K .: DPR9EA-9
0 .8 - 0 . 9
Gap
10.03 - 0.04!
Over 8 (0.3) at 1 atm.
Primary
0 .1 - 1.00
Secondary
12 - 22kO
Cha rgi~
·0. 1 - 1.3 {)
250-370 n
180 - 2700
Power source
Pi ck-up
Charging coil no-load voltage
(when engine is cold)
Regulated voltage
Type designation
Battery
Capacity
Standard
electrolyte S.G.
Fuse size
--------
More than-65 V fAC) at 5 000 r/min .
·13.0 - 15. 5 V at 5000 r/min .
• YT 4L-8S or FT 4L-BS
·12V 10.8 kC 13Ah)f l0HR
*1 .320 at 20°C (68 ° F)
"'15 A
NOTE
Terminal Ground
Plug ca p Terminal
y- y
W - Br
G - B!
DR350S 8·8
WATTAGE
Unit: W
ITEM
Headlight
SPECIFICATION
'60
'55
HI
LO
Position I~h t
T ail /Brake ~ t
Turn signal light
'5121
'2 1
'3
·1.7
T achom eter ~h t
Speedometer I~t
·' .7
Turn sig nal indicator I~ht
~J2!l beam indicator !!aht
Neutral ind icator light
·1 . 7
·1 . 7
'5
License !!2.ht
BRAKE + WHEEl
ITEM
Brake lever play
Unit: mm (in )
STANDARD
I
Rear brake pedal height
Brake disc thickness
Front
Rear
0 - 0 .3
(0 - 0 .0 11
5
(0.21
3.5 + 0 .2
+ 0 .008)
(0. 138 + 0.2
4 .0 + 0.008 )
(0. 15 7 -
Brake disc ru nou t
M aster cylinder bore
Front
Rear
Master cylinde r piston diam.
Front
Rear
Brake calipe r cy linder bore
Front
Rea r
Brake caliper piston diam .
Front
Rear
Wheel rim runout
Axial
Radi al
Wheel axle runou t
Front
RpAr
LIMIT
3 .0
(0.1 18)
3. 5
(0. 138)
0 .30
(0.012)
'12.700 - 1 2.743
(0.5000 - 0 . 5017)
12.700 - 12.743
10.5000 - 0 .5017)
'12 .657 - 12.684
10. 4983 - 0.4994)
12. 657 - 12.684
(0.4 983 - 0.4994)
27.000 - 27 .050
(1.0630 - 1.0650)
'30.230- 30.280
(1.1902 - 1. 1921)
26.900 - 26 .950
(1.0591 - 1.06 10)
'30. 160 -30. 180
( 1.1 87 4 - 1.1882)
2.0
(0.08)
2 .0
10.08)
0 .25
(0.010)
0 . 25
8·9 DR350S
Unit: mm (in)
STANDARD
'80/ 100· 21 5 1P
'l10/ 90· 1851P
ITEM
Front
Rear
Tire size
Tire tread depth
LIMIT
*3 .0
(0. 121
*3 .0
10. 121
Front
Rear
Unit: mm (in)
SUSPENSION
ITEM
Front fork stroke
I
STANDARD
280
111.01
I
'602
123 .71
Front fork sprin g free length
Front fork oil level
LIMIT
·170
(6. 71
1 000 kPa
Rear shock absorber gas pressure
(10 kg/cm2, 142 psi)
Rear shock absorber spring
pre-set length
Rear wheel travel
'272.8
(10. 71
280
(11 .01
Swingarm pivot shaft run out
TIRE PRESSURE
CO LO INFLATION
TIRE PRESSURE
Specic8tion marked with astrisks ( .. ) are exclusive to DR350S.
0.3
10.011
I
NOTE
DR35DS 8·10
FUEl+Oll
NOTE
Fuel type
Use on ly unleaded gasoline of at least 87
pump octane (
method) or 91 octane or
higher rated by the resea rch method .
Gasoline containing MTBE (Methyl Tertiary
Butyl Ether), less than 10% ethanol, or
less than 5 % methanol with appropriate
coso lvents and co rrosion inhibitor is
permissible .
For U.S. A.
Use only unleaded gasoline of at least
octane
m ethod) or 91 octane or
the Researc h Method .
rated
For Canada
gasoline is
For the others
, 9 .0 l
Fuel tank including reserve
12.4/ 2.0 USllmp
,
12. 111.8 USl imp gall
• 1.5
10.4/0 .3
reserve
California only
Change
Filter change
Overhaul
= '
Front fork oil capacity (each leg)
'544 ml
118.4 / 1 9 . 2 ~-,
1 --"-"
o"'
zl_ _ _ _ - - - - - ---1
.. Specifications marked with ast erisk (") are exc lu sive to DR350S.
TIGHTENING TORQUE
ENGINE
N 'm
kg·m
Ib-ft
Cylinder head cover bolt
8 - 12
0 .8 - 1 .2
6.0 - 8 .5
Camshaft sprocket bolt
14 - 16
1.4 - 1.6
10.0 - 11 .5
Cylinder head bolt
35 - 40
3 .5 - 4 .0
25.5 - 29.0
Cylinder head nut
23 - 27
2 .3 - 2.7
16.5 - 19.5
Cylinder base nut
23 - 27
2 .3 - 2.7
16.5 - 19.5
Rocker arm shaft bolt
25 - 30
2 .5 - 3 .0
18.0 - 21 .5
Balancer shaft bolt
40-60
4 .0 - 6 .0
29.0 - 43.5
Primary drive gear nut
60 - 80
6 .0 - 8 .0
43 .5 - 58.0
Magneto rotor nut
120 - 140
12.0 - 14.0
87 .0 - 101.5
Clutch sleeve hub nut
40 - 60
4 .0 - 6 .0
29.0 - 43.5
Gearshift arm stopper
15- 23
1.5 - 2.3
11.0- 16.5
Gearshift cam driven gear bolt
8 - 12
0 .8 - 1.2
6 .0 - 8 .5
Cam chain tensioner spring holder bolt
8 - 12
9 - 13
7- 9
0 .8 - 1.2
0 .9 - 1 .3
0 .7 - 0.9
6 .0 - 8 .5
6 .5 - 9 .5
5.0 - 6 .5
Engine oil drain plug (on the crankcase)
18 - 23
1.8 - 2.3
13.0 - 16.5
Engine oil drain bolt (on the framel
15 - 20
1.5 - 2.0
11.0 - 14.5
Crankcase bolt
9 - 13
0 .9 - 1.3
6 .5 - 9 .5
Oll pipe union bolt
18 - 23
1.8 - 2.3
13.0 - 16.5
Oil gallery plug
20 - 25
2.0 - 2.5
14.5 - 18.0
Oil strainer
25 - 30
2 .5 - 3 .0
18.0 - 21 .5
Oil hose union bolt
25 - 30
2 .5 - 3.0
18 .0- 21.5
Oil check bolt
8-12
0 .8 - 1.2
6 .0 - 8.0
Oil hose bolt (on the crankcase)
8 - 12
0 .8 - 1. 2
6 .0 - 8.5
Oil hose bolt (on the cylinder head)
20 - 25
2 .0 - 2.5
14.5 - 18.0
Oil hose clamp screw
1.5 - 2.0
0 .15 - 0 . 2
1.0 - 1.5
T .O.C. plug
20 - 25
2 .0 - 2.5
14.5- 18.0
ITEM
Cam ch am
.tensloner
.
.
bel Right hand I
mounting
t
Left hand
60 - 72
6 .0 - 7.2
43 .5 - 52 .0
Engine mounting bolt and nut
(Refer to page 8· 17)
37 - 45
18 - 28
3 .7 - 4 .5
1.8 - 2.8
27 .0 - 32.5
13.0 - 20.0
Exhaust pipe bolt
18 - 28
1.8 - 2.8
13.0- 20.0
Muffler connection boh
18 - 28
1.8 - 2.8
13.0 - 20.0
Muffler mounting bolt
23 - 28
2 .3 - 2.8
16.5 - 20.0
DR35DS 8·12
CHASSIS
ITEM
N·m
50 - 80
kg·m
Ib-It
5.0 - 8 .0
36.0 - 58.0
6- 8
0.6 - 0 .8
4 .5 - 6 .0
Front fork damper rod bolt
30 - 40
3 .0 - 4 .0
21.5 - 29.0
Front fork lower clamp boh
20 - 31
2.0 - 3 . 1
14.5 - 22.5
Front fork upper clamp bolt
20 - 3 1
2.0 - 3. 1
14.5 - 22 .5
Front fork ca p bolt
30 - 40
3.0- 4 .0
21.5 - 29.0
Steering stem head nut
80- 100
8 .0 - 10.0
58.0 - 72.5
Handlebar clamp bolt
18 - 28
1.8 - 2.8
13.0- 20.0
Front brake master cylinder mounting bolt
6- 9
0 .6 - 0 .9
4 .5 - 6 .5
Front brake caliper mounting bolt
20- 31
2.0 - 3 . 1
14.5 - 22.5
Front brake pad mounting bolt
15 - 20
1.5 - 2.0
11.0 - 14.5
Brak e hose union bolt (Fron t & Rear)
20 - 25
2.0 - 2 .5
14.5 - 18.0
Air bleeder valve (Front & Rear)
6- 9
0 .6 - 0 .9
4 .5 - 6.5
Brake disc mounting bolt (Front & Rear)
18 - 28
1.8 - 2.8
13.0 - 20.0
Swingarm pivot nut
61 - 94
6 . 1 - 9.4
44.0 - 68.0
Front footrest bolt
44 - 66
4 .4 - 6 .6
32.0 - 47.5
Shock absorber mounting nut (Upper &
Lower)
48 - 72
4 .8 - 7. 2
34.5- 52.0
Rear cushion rod mounting nut
84 - 120
8.4 - 12.0
60.5-87.0
Rear cushion lever nut (Front)
60 - 96
6.0 - 9 .6
43.5 - 69.5
Rear cushion lever nut (Center)
84 - 120
8 .4 - 12.0
60.5 - 87.0
Rea r axle nut
85 - 115
8 .5 - 11.5
61.5-83.0
Rear brake pad mounting bolt
15 - 20
1.5 - 2.0
11.0- 14.5
Rea r brake ma ster cylinder mounting bolt
8 - 12
0 .8-1 .2
6.0 - 8.5
Rea r brake rod lock nut
15 - 20
1.5 - 2 .0
11 .0 - 14.5
2- 4
0 .2 - 0.4
1.5 - 3.0
Front axle sha ft
Front axle pinch nut
Spoke nipple
8·13 DR350S
PERIODIC MAINTENANCE SCHEDULE
IMPORTANT: The periodic maintenance intervals and service requirements have been established in
accordance with EPA regu lations. Following these instructions will ensu re that the motorcycle will
not exceed emission standards and it will also ensure t he reliability and performance of the motorcycle.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions
however, it is not necessary for ensuring emission level compliance.
The chart below lists the recommended intervals for all the required periodic sevice work necessary
to keep the motorcycle ope rating at peak performance and economy. Mileages are expressed in terms
of kilometers, miles and time for your convenience.
PERIODIC MAINTENANCE CHART
18000
24000
4000
12
12000
7500
24
11 000
36
15000
48
-
I
I
I
I
T
T
T
T
T
Valve clearance
I
I
I
I
I
Spark plug
-
I
R
I
R
C
C
C
C
km
1 000
6000
miles
600
2
Battery
Cylinder head bolts and nuts, cylinder nut s,
exhaust pipe bolts and muffler connections
INTERVAL:
THI S INTERVAL SHOULD BE JUDGED
BY ODOMETER READING OR
MONTHS WHICHEVER COMES FIRST
Spark arrester
months
Air cleaner
Clean every 3 000 km (2000 miles).
De-compression lever
I
I
I
I
1
Engine oil and oil filter
R
R
R
R
R
Engine oil hoses
I
I
I
I
I
Engine oil strainer
C
C
C
I
C
1
C
Carburetor
I
I
I
Fuel line
I
I
I
1
I
Replace every 4 years.
(Vapor hose ... California model only)
Clutch
Drive chain
Brakes
Brake hoses
I
I
I
1
I
I
I
I
I
I
Clean and lubricate every 1 000 km (600 miles).
I
I
I
I
I
I
I
I
I
I
Replace every 4 years.
I
Brake fluid
I
1
I
I
Replace every 2 years.
Tires
I
I
I
I
I
Spoke nipples
I
I
I
I
I
Steering
I
I
I
I
I
Front fork
I
I
I
I
I
Rear suspension
I
I
I
I
I
Chassis bolts and nuts
T
T
T
T
T
8·14
BATIERY
Inspect Every 6 000 km (4 000 miles, 12 months)
•
Remove the left frame cover.
• Check the battery voltage with a pocket tester.
09900· 25002 : Pocket tester
If the voltage reading is below 12.0 V. this battery need s
recharging.
Battery voltage: Above 12.0 V
• Disconect the battery
e and ® lead wires and remove
the battery.
WARNING :
When disconnecting the battery lead wires ,
e lead wire first.
CAUTION:
Read the " BATTERY SECTION" for the servicing battery.
(Refer to page 8 ~34 . )
DE-COMPRESSION LEVER
Inspect Inital 1 000 km (600 miles, 2 months) and
Every 6 000 km (4 000 miles. 12 months)
Incorrect adjustment of the lever clearance may result in start·
ing difficulties or engine damage. Check the lever clearance
and if necessary , adjust as follows :
• Adjust the valve clearance . (Refer to page 2-4 .)
• Remove the right fuel tank cover.
• Loosen both lock nuts <D on the cable adjuster ® .
• Locate the adjuster ® to provide the specified lever clearance ® as shown in potograph.
• Tighten the lock nuts CD.
De-compression lever clearance ®: 0 - 1 mm
(0 - 0 .04 in'
8·15 DR35DS
CARBURETOR
Inspect Initial 1 000 km 1600 miles , 2 months) and
Every 6 000 km (4 000 miles. 12 months)
THROTTLE CABLE PLAY
The throttle cable should be adjusted to have a play ®of
0 .5 - 1.0 mm 10.02- 0 .04 in).
If the adjustment is necessary, adjust the play in the follow·
ing way :
•
•
•
Loosen the lock nut CD and turn the adjuster ® fully in.
Remove the saat and fuel tank .
Loosen the lock nut @ and turn the adjuster @ to acquire
the specified play ® .
Throttle cable paly : 0 .5 - 1 .0 mm (0.02 - 0 .04 in)
•
After adjusting the play, tighten the lock nuts <CD and @ ).
NOTE:
Minor adjustment can be made by the adjuster ® after
loosening the lock nut
<D.
WARNING :
After the adjustment is completed. check that handlebar
movement does not raise the engine idle speed and that the
throttle grip retums smoothly and automatically.
IDLE R/MIN ADJUSTMENT
•
Adjust the throttle cable paly .
NOTE:
Make this adjustment when the engine is hot.
• Connect a tachometer.
•
Start up the engine and seat its speed at anywhere between 1 400 and 1 600 r/min by tu rning the throttle stop
screw @.
IDLE R/MIN
• 1 400-1 600 r/min
DR35DS 8·16
..-
TIRES
. r'-l
Inspect Initial 1 000 km (600 miles. 2 months) and
Every 6 000 km 14 000 miles. 12 months)
T1RE TREAD COND1T10N
Operating the motorcycle with excessively worn tires will
decrease riding stability and consequently invite a dangero us situation . It is highly recommended to replace tire when
the remaining depth of tire tread reches the following specification.
Tire tread depth limit
Front & Rear : 3 .0 mm (0 .12 in)
TIRE PRESSURE
If the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Threrefore . maintain the correct tire pressure for good roadability or shorter
tire lift will result .
Cold in flation tire pressure is as follows.
SOLO RIDING
COLO INFLATION
OUAL RIDING
TIRE PRESSURE
kP,
kg/em'
psi
kPa
I kg/em1 I
psi
FRONT
1 50
1. 50
22
150
1.50
22
REAR
150
1. 50
22
175
' . 75
25
I
CAUT10N :
The standard tire fitted on this motorcycle is 80/ 100-21 51 P
for front and 1 10/90-18 61 P for rear. The use of tires other
than the those specified may cuase instability. It is highly
recommended to use a SUZUKI Genuine Tire .
-
•
r...
8·17 DR350S
BREAK-IN PROCEDURES
During manufacture only the best possible materials are use and all machined parts are finished to
a very high standard but it is still necessary to allow the moving pans to " BR EAK -IN" before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends
on the ca re and restraint exercised during its early li fe. The gene ral rules are as follows .
•
Keep to these break-in engine speed limit s.
800 km (SOO miles ) : Below
5 000 r/min
Initial
Up to 1 600 km (1 000 miles) : Below 6 000 rl min
Ov er 1 600 km (1 000 miles) : Below 9 500 rl min
•
Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle
to full throttle operation .
However. do no t exceed 9 500 r/m in at any time.
ENGINE MOUNTING
L: 1
L: 11
,
.
't.,
•
Tightening t orque
ITEM
N'm
kg·m
Ib-ft
<D.®
37 - 45
3 .7 - 4 .5
27 .0 - 32.5
~.~
'.-
60 - 72
6 .0 - 7 .2
43.5 - 52.0
1R _? R
1 R_ ? R
l~() - ?()n
(f>
..
tJ. " ... 1" T I...H~ 1= tJ. n 1 nrk' <:1 1PI= R " 1 ':I.n ':I. ' ,
Iii)
DR35DS B·1B
KICK IDLE GEAR
CD Kick idle gear
@ Retainer
@ Bush ing
@) Spa cer
® Driveshaft
• Remove the kick idle gear CD by removing the retainer 00.
B·19DR350S
CARBURETOR
CONSTRUCTION
9•
I
®--J
,,
,
CD Top cap
® Spring
@ Jet needle
@ Diaphragm
® Piston valve
® Needle jet
o Main jet
® Pilot jet
® Starter plunger
@) Throttle valve
@ Pilot screw
@ Float
@ Throttle stop screw
@ Throttle valve shaft
@ Needle valve
UH35US 8·20
SPECIFIC AnON
ITEM
rei
type
Bore size
33 mm
--~
~~
~--r---~
1-7~ ~:in
~Ievel
I"FiC
M,
I
1.5 + 0 .5 mm
10.06+0.02 inl
14.6±1 .0mm
height
10.57±0.04 inl
iet
1M .
~
~N~,~~:Jt-iet=-==-=---'TN~
Throttle valve
~rn~~
I By-pass
ITI
Pilot outlet
\t". U .,
Valve seat
IV.
Istarter~~
iet
------';,
IPiiOt screw
~cablePlay
0 -6
--
# 115
~-- __________~
~ ---;
~ mm
-
~~~-------7~
Pilot air iet
# 135
0-
0-
I
---":"#~~-- - - _ - --1
.
IP.A
0 .8 mm
1.5 mm
f'RE:SET
1.3 mm
~
m~
m --10.02 - 0 .04 inl
1.0_ NO. LOCATION
Each carburetor has 1.0. Number CD printed on the carburetor body according to its specification .
B·11 DR350S
REMOVAL
•
•
•
Disconnect the fuel hose <D.
Remove the throttle cable <ID.
Loosen the clamp screws and remove the carburetor .
OISASSEMBL Y
•
Remove the top cap .
•
Remove the diaphragm with piston valve .
•
Remove the float chamber .
•
Remove the float w ith needle valve .
OR350S 8·22
•
Remove the main jet CD.
• Remove the starter plunger.
•
•
Remove the throttle valve by removing the screws ®.
Remove the throttle valve shaft and return spring by
removing the E-ring @.
INSPECTION AND ADJUSTMENT
Check foHowing items for any damage or clogging .
• Pilot jet
.. Starter jet
, Main jet
• Main air jet
.. Pilot air jet
.. Needle jet air bleeding hole
.. Gasket and O-ring
.. Throttle shaft oil seal
.. Diaph ragm
.. Pilot outlet and by-pass holes
~
Float
.. Needle valve
8·23 DR35DS
NEEDLE VALVE INSPECTION
If foreign matter is caught between the valve seat and the
needle, the gasoline will continue flowing and cause it to over·
flow . If the sea t and needle are worn beyond the permissi·
ble limits, similar trouble will occur. Conversely, if the needle
sticks. the gasoline will not flow into the float chamber. Clean
the float chamber and float parts with gasoline. If the needle is worn as shown in the illustration , replace it together
with a valve seat. Clean the fuel passage of the mixing chamber with compressed air .
CO RRECT
INCORRECT
FLOAT HEIGHT ADJUSTMENT
To c heck the float height, invert the caburetor body , wi th
the float arm kept free, measure the height @ while float arm
is just in contact with needle valve by using ca lipers.
Bend the tongue CD as necessary to bring the height ® to
this value .
Float height
119: 14.6 ± 1.0 mm (0 .57 ± 0 .04 in)
09900-20102 : Vernier calilpers
REASSEMBLY AND REMOUNTING
Reassemble and remount the carburetor assembly in the
reverse order of removal and disassembly.
•
After remounting the carburetor. the following adjustments are necessary .
• Engine idle r/min .. . . . . . . . . . . . . . . . . Page 8- 15
• Throttle cable play .........•.... _ . Page 8- 1 5
-+-®
DR350S 8·24
EMISSION CONTROL CARBURETOR COMPONENTS
DR350S motorcycles are equipped with precision , manufactured carburetors for emission level can·
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 (31 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 needle 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 possible for the best possible performance and durability _
Conventional Figures Used
on Standard Tolerance Jet
Components
1 2 3 4 5 6 7 8 9 0
Emission Type Figures
Used On Close Tolerance
Jet Components
I
2 :3 Lf 5 5 '7
a 9 0
The carburetor specification for the emission -controlled DR350S are as follows .
Carburetor
Main
Needle
Jet
Pilot
1.0. No .
,403
Jet
Jet
Needle
Jet
# 135
0 -5
SCD,6
# 3~. 5
(California model)
,402
(Other state models)
Pilot
Screw
PRE-SET
DO NOT
ADJUST
The pilot screw is pre-set by the factory utilizing specia lized testing and adjusting procedures. The
pilot screw is not adustable as the idle circuit is "sealed" after factory adjustment. Adjusting, interferring 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 carburetors the Suzuki dealer should restore the carbu retors to their original condition or if unable to effect repairs. contact the distributors representative for further technical information and assistance.
8·25 DR350S
IGNITION SYSTEM
Engine stop switch
1
L
-.
COl
Ignition coil
C
Neutral indicator sw
Magneto
Pick-up coil
Tachometer
DESCRIPTION
The DR350S engine is equipped with a new type ignition system . Thi s new sys tem further reduces
timing fluctuations . It has an " ignition timing control circuit" which accurately cont rols ignition tim -
ing depending on the e ngine r/min .
OPERATION
When the magneto rotor rot ates, an electric current is generated in the power sou rce coils . and this
current cha rges the capacitor " c" via diode " 0 ," . On the other hand . when the protrusion on the
rotor passes the pick-up coil, the cu rrents are generated, they flow to the ignition timi ng control circuit , and they are converted into one ignition signal. Thi s signal is sent t o "SC A". the "SC A" be·
comes ON, the c ircuit "C" - "Se A" - " Ig l" is formed , and as the electric ene rgy st ored in the
capacitor "C" is discharged instantly, a high voltage is induced in the ignition secondary coil " lg2" ,
and a spark .
This motorcycle is equipped with interlock switches for ignition ci rcuit . The engine can only be started
if :
The transmission is in neutral or
The transmission is in gear, the side stand is fully up.
INSPECTION
MAGNETO COIL
• Remove the seat.
• M easure the resistance between the lead wires in the fol lowing table wi th a pocket tester.
09900-25002 : Pocket tester
Magneto coil resistance
WIRE COLOR
BI
: Blue
Br
: Brown
: Green
G
W
: White
y
: Yellow
G- BI
Pick-up coil
180 -270 {) Ix 100 {) rangel
Power sou rce
coil
W-Br
250-370 {) Ix 100 {) rangel
y-y
Charging coil
0.1 - 1.30 (x 10 range)
IGNITION COIL
Refer to page 5-2.
COl UNIT
•
•
Remove the sea t .
Remove the CO l unit.
Measure the resistance between the lead wi res in the following table with the pocket tester.
09900-25002 : Pocket tester
Unit •· Approx • kO
® Probe of tester to :
G
G
·.
-•--••
-•
0
0
-
~
BI
7 - 14
(j)
W
W/BI
BIY
BIW
7 - 14
13-24
w
22 - 54
7 - 14
2- 5
w
6 - 18
0
J
BIIA
56 - 1501 4 - 10
w
400- 1000 17 - 42
160 -sooJ 12 - 35
7 - 20
BIY
w
w
w
w
BIW
7- 14
0
2- 5
~
6 - 18
B,
48- 110 32 - 72 64 - 180
w
2- 5
32 - 72
24-110
I
2- 5
2- 5
6 - 18
160- sooJ
w
w
w
w
~
1- 5
56 - 150
~
56-150 4 - 10
160- 500
~
160-500 56 - 120
BlIR
w
~
w
~
~
~
w
BIIB
~
w
w
w
w
w
w
2-5
GIA
~
~
~
~
w
~
w
w
32-18ot
~
80 - 180 16 - 33
w
2- 5
8 - 24
WIR
56-150
12-27
24 - 60
GIA
160 - 500 48 - 120 160 - 360 400- 1000
W
WIA
BlI.
w
WIBl
w
Br
12 - 24 BO- 180
64 - 180 40- 120
0
~
BI
172-3601 " - 2'
CAUTION:
As capacitors. zener diodes. etc. are used insid this unit. the
resistance values will defter when an ohmmeter other than
SUZUKI pocket tester is used.
I
22 - 601;20- 1000
~
~
I
w
w
w
w
w
w
w
~
320- 1000
WIRE COLOR
51
:8lue
8r :8rown
G :Green
W :White
BfW :Black with White tracer
B(Y :Black with Yellow tracer
BIIS :Blue with Black tracer
BUR :Blue with Red tracer
G /R :Green with Red tracer
W/BI :White with Blue tracer
W!A :White with Red tracer
8·27 OR350S
CHARGING SYSTEM
DESCRIPTION
The circuit of the charging system is indicated in figure . which is composed of an AC generator, regu·
lator/rectifier unit and battery.
The AC current generated from AC generator is rectified by rectifier and is turned into DC current,
then it cha rges the battery.
0 - -- -
------------
lighting switch
.-,
I
I
0
.••
0
I
"
c
I
0
u
I
I
I
I
I
I
I
I
I
19 switch
~
•
.ll
.
0
0
~
I
I
L _______________ _
Function of Regulator
While the engine rl min in low and the generated voltage o f AC generator is lower than the adjusted
voltage of regulator, the regulator does not function. However. the generated current charges the battery
directly at this time .
------------
Ughting switch
19 switch
,
.e
.e
0
"
c
0
u
I
I
I
I
I
I
I
I
I
L ________________ _
~
c•
.ll
.
0
0
~
OR3505 8-28
When the engine speed increases and the load decreases. the battery charge voltage will increase
due to the generated voltage by the generator. The battery will continue to be charged by the generated voltage until the battery voltage (voltage between @ and @ ) reaches the value set of the control
circuit in the regulator, then a signal from the circuit will flow to the SeR. When the SeR goes " ON ".
O and @will become conductive , hence the voltage does not cha rge the battery but returns to the
generator.
When the battery voltage falls . the signal to the seA will be out otf , causing the SeR to go " OFF" .
As a result, the generated voltage will start to charge the battery once again . Due to the repetition
of the above operation of the regulator. the battery voltage will be maintained constant, preventing
o vercharging of the battery_
------------ --,
,
-~
u
-5
-e
c
0
u
•
IL _______________ _
INSPECTION
CHARGING OUTPUT CHECK
• Remove the left frame cover _
• Start the engine and keep it running at 5 000 rl min with
the lighting swtich turned ON (High position).
• Using the pocket tester , measure the DC voltage between
terminal. If the tester reads
the battery ® terminal and
under 13.0V or over 15. 5V, check the AC generator noload performance and regulator/rectifier .
e
NOTE:
When making this test, be sure that the battery is in fullycharged condition.
STD charging output: 13.0 -15.5V (DC) at 5 000 r/min
09900-25002 : Pocket tester
I
I
I
I
I
I
I
I
,
Lighting switch
~
,, ••
~
,
'"
0
"
0
~
8·29 DR350S
AC GENERATOR NO· lOAD PERFORMANCE
• Remove the seat.
• Disconnect the AC generator lead wire coupler.
• Start the engine and keep it runn ing at 5 000 r/min.
• Measure the AC voltage between the three ye llow lead
wires with the pocket tester.
If the tester reads under 65 V. the AC generator is faulty.
STD No -load performance : More than 65V lAC) at 5 000
r/min
09900-25002 : Pocket tester
,,
(•
\
AC GENERATOR STATOR COil
Using the pocket tester, check the continuity between the
lead wires of the stator.
Also check that the stator core is insu lated.
STD resistance: 0.1 - 1 .3 n
09900-25002 : Pocket tester
NOTE:
When making this test, it is not necessary to remove the AC
generator.
REGULA TOR/RECTIFIER
• Remove the seat.
•
Disconnect the lead wires.
•
•
"
3
3
DR350S B·30
Using the pocket tester (x 1kG range); measure the resistance
bet ween the lead w ires in the follo wing table. If the reading
is incorrect. replace the regu lator/rectifier.
09900· 25002 : Pocket tester
Unit ·• Approx • kG
--• ~
-2
~
0
.!I0
.t
<D
@ Probe of tester to:
V,
V,
A
V,
.1
V,
~
y,
y,
A
8N1
0
~
1
~
~
1
1
~
~
~
~
I"
I
1- 5
1- 5
1- 5
~
1- 5
1- 5
1- 5
20- 60
20 - 60
20 - 60 40- 100
1
1
8N1
0
~
~
~
~
~
1
~
~
~
2- 8
4 - 10
15 - SO I
WIRE COLOR
o : Orange
Y : Yellow
A : Red
8IW : Blac k w ith White tracer
CAUTION:
As seA and diodes are used inside this regulator/rectifier unit.
the resistance values wm differ when an ohmmeter ot~ than
SUZUKI pocket tester is used.
LAMPS
HEADLIGHT
TAIL/ BRAKE LIGHT
""'" 1/:." ,
~
CAUTION : Do nOI overtighten the lens fitting screws
TURN SIGNAL LIGHT
CAUTION : Do not overtighten the ~ns fining screw.
8·3t OR3505
SPEEDOMETER AND TACHOMETER
G
'"
\')
SWITCHES
Inspect each switch for continuity with the pocket
tester referring to the chart. If any abnormality is
found . replace the respective swit ch assemblies
with new ones.
09900·25002 : Pocket tester
HORN SWITCH
IGNITION SWITCH
COLOR
f"'"
POSITION
BIY
BNI
OFF
0
-0
0
Gr
0
Br
COLOR
POSITION
BIBI
BNI
0
-0
G
BNI
ON (Push)
ON
p
R
0
C --0
0-
-0
0
-0
OFF
SIDE STAND SWITCH
r==:
LIGHTING SWITCH
COLOR
POSITION
(For Canada and U .S.A . models)
I"'"
~"'OR
POsrTtO
0
Gr
VNI
ON
0
-C
0
0
Gr
VNI
0
0
-0
ON
(Upright position)
OFF
(Down positionl
(For the other models)
;;;."''"'
'"'"
I
OFF
•
ON
-C
NOTE:
When inspecting side stand switch. connect the
Ef) probe of pocke t tester to 8IW lead wire and
probe to G lead wire.
e
-0
ENGINE STOP SWITCH
C"'-OR
DIMMER SWITCH
COLOR
POSITI~
POSITION
W
HI
LO
V
VNI
0
0
0
OFF
BIY
BNI
0
-0
RUN
-<J
NEUTRAL INDICATOR SWITCH
COlOR
TURN SIGNAL SWITCH
COLOR
POsmOti
B
POSITION
Lbl
ON
(Neutral position)
0
R
•
L
Lg
0
+
-0
0
OFF
Bl
Ground
FRONT BRAKE SWITCH
COLOR
POS ITION
Terminal
Terminal
ON
(Squeeze lever)
OFF
REAR BRAKE SWITCH
COLOR
POSITION
ON
IOepress pedal)
0
W /B
WIRE COLOR
B : Black
: Blue
B, : Brown
G : Green
G, ; Gray
Lbl : Light blue
L9 : Ugh. green
0
: Orange
R
: Red
"'
W
: White
y
: Yellow
BIBI : Black with Blue tracer
B/W : Blac k with White tracer
BN : Black w ith Yellow tracer
W/B : White with Black tracer
YIW : Yellow with White tracer
OFF
BATTERY
Up per 00""' ,~~
brea th; ;
SPECIFICATIONS
Type designation
YT4L - BS or FT4L - BS
Capacity
l 2V 10 .8ke (3 Ahl/ l0HR
Standard elec trolyte S.G.
1.320 at 20° C 168 0 Fl
INITIAL CHARGING
Filling electrolyte
•
Remove the aluminum t ape CD sea ling the battery electrolyte filler holes .
•
Rem ove th e caps @.
NOTE:
• After mling the elec tro l yte completely, use the removed
cap ® as the seald caps o{ battery-filler holes.
• Do not remove or p ierce the sealed areas @ of the elec·
erolyte con ts;ner.
I
Separat or
Ifibefglass
Anode
•
Insert the nozzles of the electrolyte container into the battery ' s electrolyte filler holes, holding the container firmly
so that it does not fall. Take precaution not to allow any
of the flu id to spill .
containers
Insert in
tinef holes
•
Make sure air bubbles are coming up each electrolyte container , and leave in this position for about more than 20
minutes.
Aif
NOTE:
If no air bubbles are coming up from a filler port, tap the bottom of the two or three times.
Never remove the container from the barcery.
•
•
Aher confirming that the electrolyte has entered the battery completely. remove the electrolyte co ntainers from
the battery. Wait for around 20 minutes.
Inse rt the ca ps into the filter holes, pressi ng in firmly so
that the top of the caps do not protrude above the upper
surface of the battery 's top cover .
Insert the caps
CAUTION :
• Never use anything except the specified battery.
• Once install the caps to the battery ; do not remove the
caps.
•
Using SUZUKI poc ket tester, measure the banery voltage.
The tester should indicate more than 12.5V (OCI as shown
in the Fig. If the battery voltages is lower than the specification, charge the battery with a battery cha rg er. (Aefer
to the recharging operation on page 8 -35.)
NOTE:
Initial charging for a new battery is recommended if two years
have p./eosed since the date of manufacture.
12
11
+-- -- --+-+----1
o
2
4
Time
10 IMinutesl
8·35 DR350S
SERVICING
Visually inspect the surface of the battery container. If any
signs of cracking or electrolyte leakage from the sides of the
battery have occurred. replace the battery with a new one.
If the battery terminals are found to be coated with rust or
an acidic white powdery substance. then this can be cleaned
away with sandpaper.
RECHARGING OPERATION
(V)
•
18
Using the pocket tester , check the battery voltage. If the
voltage reading is less than the 12.0V (DC), recharge the
battery with a battery charger.
CAUTION:
When recharging the battery. remove the battery from the
Charging period
-j
Stop c harging
"
16
15
14
~:
"
12
I
motorcycle.
o
10
10 30
TIme
"0
SO
60
(Minutesl
NOTE:
Do not remove the caps on the battery top while recharging.
Recharging time: 4A for half an hour or O.4A for 5 hours
CAUTION:
Be careful not to permit the charging current to exceed 4A
at any time.
(at o o'_ 40 oCI
(V)
"
13
12
I
"
•
After recharging , wait for more than 30 minutes and check
the battery voltage with a poc ket tester.
• If the battery voltage is less than the 12. 5V, recharge the
battery again .
• If battery voltage is still less than 12. 5V after recharging,
replace the battery with a new one.
• When a battery is left for a long term without using. it
is subject to discharge. When the motorcycle is not used
for more than 1 month (especially during the winter season), recharge the battery once a month at least.
"
I
100
75
50
25
o 1%1
Battery charged condition
DR350S 8·36
FRONT FORK
Fork spring
Service Limit : 602 mm 123 .7inl
STANDARD SUSPENSION SETTING
REAR
FRONT
Fork oil type : Fork oil # 10
Fork all capacity : 544 ml
(1 8.4 /1 9 .2 USl imp ozl
STO fork oil level : 170 mm 16.7 in)
-+
Spring pre- Damping force Spring sel
load adjus te r
adjust er
length
3
Max .- 7
272 .8 m m
00.74 in)
Damping fOfee
adjuster
Ma)(.- 1.5
TROUBLESHOOTING
ELECTRICAL
Symptom and po ssi ~e causes
Complaint
Generator does not
charge.
Generator charges,
but charging rate 1.
below the speeifieation
1. Open or short in lead wires, or loose tead connic t ions.
2. Shoned, grounded or open generator coils.
3. Shorted 01' punctured regulator/rectifier.
1. lead wi res lend to get shourted or open·circuited or
Remedy
Repair, replace or ret ighten .
Replace.
Replace.
Repair or ret ighten,
loosely connected at terminals.
2. Grounded or open-circui ted stator coils of generator .
3. Defective regulator/rectifier.
Replace.
4 . Def ective battery.
Replace
Genera tor
1. Internal short-circuit in the battery.
overc harges.
2. Resist or element in the regula t or/rect ifier damaged or
Replace the battery.
Raplalee.
Replace.
defective.
Unstable chargi ng .
J . Regulator/rectifier poorly grounded.
Clean and t ighten ground
connection.
1 . lead wire insulation fraved due t o vibration, resulting In
Repair or replace .
intermittent shorting.
2. GeneratOf Internallv shoned.
3. Defective regulator/rectifier,
Replace.
Replace.
BATTERY
Complaint
Battery run s down
quickly ,
Symptom and possible causes
1. The charging met hod Is not COfrect.
2. Cell plates have lost much of their act ive m aterial as a
result o f over·charging.
3 . A short-circuit condi t ion eKist s within t he banery due
to excessive accumulation of sediment s caused by the
incOfrect electrolyte.
4. Battery Is 100 old .
Rever.ed battery
polarity.
Battery dischargas
too rapidly
The battery has been connected the w rong way round
in the system. so that It Is being charged in the reverse
direction.
1. Dirty container top and sides. .
2. Battery is too old .
Rem ed y
Check t he generator, regula·
tor/rec tifier and circuit connec·
t ions, and make necessary
adjustments to obtain specified
charging operation.
Replace the battery, and
correct the charging system.
Replece the battery,
•
Replace Ihe battery .
Replace the battery and be
sure to connect the battery
properiy .
Clean .
Replace .
Il8ND! [ " ' . !
1"11111l1li- 3
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,
~'~
'Pt[og W[ J{B.rO~!
~
I
1
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•
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(")
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iii
lif
~
1~!1!I51~lnl'!£181
•
/
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Z
l>
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:::J
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rn
•
s:
l>
•
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=1=l=
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!!!I'I' -' U!!~, I ij"!>I. •It
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~
~
~
"BO'®:
LIW,.,r.IA ~ 1'
r~
,1
===t+
'!OMI . I LI1!I!, I Ci'fPl, ,L
IRE COLOR
Blick
... Blul
· .. Brown
...
... • Gree"
!£e,.cQ"~~r
MA.'T~'fflI
,L
I{
•
•
•
I. . •
Ught btu.
Ught orten
..· ... O'lngl
R.d
· ..
'
•
•
.. .. While
... • Yellow
w . • Slid! with Whit, uace,
.. Black with Yellow uac.,
W . Or•• n with Whit, IrlCI'
V•
L
!!ffjU£C
~
•
•
'"
B . ,.
G . •.
W .
V,llow w ith Blick ".cer
Yellow with G,nn !racer
Ya.now with White Iracer
~
"'"
Y . .. Gteln with Yellow Iraeer
.. Orlng. with Blick traee'
HI • . • Orange with Blul tlllCe!'"
G. .. Orange with OrHn Iracer
R. .. Orang. with Red traur
lB . • White with Black Iraelr
.. Whit. with Blul IF.CI'
-!I-
-
,
,fUi!!Ij...2t
HANllt £ · '•• l
~Jt
eSlicK'
ru,r-!QI
¢{ ~Q
,•
ill
•uc
I'a!iNf Ig
•
••
a
•
8·41 DR350S
"
I
,
'-
I
o
o
/
indicator switch
lead wire
DR35DS 8·41
CABLE ROUTING
mm
Throttle
brake
master cylinder
Clut ch ,cat.l.
De-comp. ca
clamp
F","! brake hose
rh".ttli' cable
Brake lever
Cluch lever
cable
'*
,
•
cable
I
8·43 DR35DS
HOSE ROUTING
Air v.,~, hose
Crankcase brea ther
posi tion
•
Clamp
Brake
10". clamp
cable
ca ble
Brake hose guide - /
Sr ake hose guide --~
14 "
After touching the brake hose union
to the caliper stopper, tigh ten the
union bolt.
OR350S 8·44
CANISTER HOSE ROUTING
(California model only)
cable
Clamp
Clamp
Wiring
5"'90 ho"o---1-hose
Surge hose
Purge hose
air hose
Wiri ng harness
Throt tie cable
B
A
Clamp
hose ' -.J..
hose
Purge
Clamp
VIEW A
Roll-over
valve _ _ _
~ ~ Purge hose
Surge hose
Clamp
Surge hose
Clamp
Wiring harness
harness
Clamp
Hose guide
Purge air hose
Clamp
hose
hose
Purge air hose
<-
VIEW B
Clamp
Purge air hose
Throttle c able
EVAPORATIVE EMISSION CONTROL SYSTEM
(California model only)
••
:• separator
••
Fuel tank
hose
Carburetor
valve
hose
FUEl/He VAPOR
<
I
FRESH A IR
Purge air hose
~------------------ CONTENTS -------------------.
SPECIFICA TlONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
70- 7
SERVICE OA TA . . . . . . . . . . . . . . . . . . . . . . _ . . . . . . . . ..
70- 2
ENGINE
MOUNTING .... . . .... _ . _ .. .. .... ... ....
70-70
WIRING
ROUTING .......... ___ . _ . . . . . . . . . . . . . . . 70-77
CANISTER HOSE ROUTING . . . . ..... _ . _ . ____ ..... _ 70-72
10·1 DR350SM ('91 ·MDDEL)
SPECIFICATIONS
DIMENSIONS AND DRY MASS
()Y. .U length • • • . • • . . • • • • • • • •
•
•
•
• • • • • • • • • • • • 2335 mm 191.9 inl ....• E IS. 17. IS. 22
2240 mm (8S2 in) •..•. E34
2235 mm (88.0 Inl ..• .• Others
Over.1I wlctth . _ . . . . . . .. . . • . • • . • . • . • • • • • • • • 886 mm (34B inl
Over,u hl lghl . . . . . . . . . . . . • . . ..
· . . . . . 1245 mm 149.0 In l
Whotl~ . . . . .
. ....
..
- .. 1440 ",m 156.7 inl
Ground eI.,rlnee _ ..
,
290 mm lilA In l
• • • • • ..
• • • • • • •
890 mm (35,0 In )
5'11 1'11111111 ••••. •.••• . •. , ••.••• • •• • ••••.
Drym.,. . . . , ... , ..•.••• • • . • • ••. • •• • • . . . .
118 kg 1260 lb.)
. .
. ·.. .
. ...
..
ENGINE
T vpe • • . • . . . • . • • • • • •
.
V,I". d-.nee , IN .•. • • • •
.
. . -.
EX •• • • • • • • • • • • • • • • • • • • • • •
· . . . . . . . . . . . . . . . . FOUf1trob, I lr<OOled wim SACS, OHC
· . . . . . . . . . . . . . . 0 .05 - 0 . 10 mm 10.002 - 0 ,004 Inl
.. . 0I .10 - 0 .15 mm (0.004 - 0 .006 Inl
Ii of evili'd... • •.••• · - - . . . . . . · . . . . ..
• •
Bore . . . . . . . . . • . .. . •
•
•
•
• · . . . . 79.omm13.110inl
Strob . . . • • . . . . . .
. · . . . . . . . . . . . . . . . •.•.. 71.2mmI2.8031" 1
Pinon dlaplaoement •.. •
• • • •
• • • • • • • • • ... .• 349cm l 12l-3eu . in)
ComprlJUlon flIllo .••. .. . • • • • • • • • • • • • •
9 .6 : 1
CMbuflltor . . . . . • .
.
•
• •
•
• •
• • • • • . • MIKUNI BSTlJ$S, sing"
Air d"ner . • • . . • . ...
• • • • ... • • .. . .• Pot",urell'l'll<I 'oam element
Slane, 'Yllem .. .
.. . ... . . . . . Prlml/'V kick
Lubrleallon 'YU.m .. . .. .
.. . • • .. . . . Dry ....mp
• •
•
Nu~
..
..
•
• •
•
• • • • •
• •
•
• • •
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
• •
•
•
•
•
•
•
•
TRANSMISSION
Clutch . . • . . . . . . . • . . • • • • • • • • • • • • •
TflIn&mlulon . . . . . . • . . • • • • • • • . .
..
G.anhlh pal1lUn . . . . • . . .
.
. .. ..
PrlmtrY r.ctuc:tion ,..tlo ..
· . .. .
,
,
,
F I ~ rlduc:tlon nl tlo . . • . ... • • • • • • • • • • •
·.. .
G.... ,etlol . Low •••••• • • • • • • • • • • • • • • • • • • • • •
2nd . . . . . . . • • • • • • • • • • • • • • •
.
.. . .. .
· ... ·
..
... ·.. .. . . . · . . . .. · . . .. ..
·... .
3nl . . . • . . • • • • • • • • • .. . .. . .. . • • • •
41h . . . . . . . . . . . . . . . . . . . . . . .. .
..
5th . . . ,
· , . . . . . , · , . . . . ... · , . ,
TOp ••.
• • • • • • • •
Orlv. ch"n . . . . . .
· . . •. •. .• .. . • ••• • • •
• • • • • • • •
•
CHASSIS
Front JUspeosio n
...
·....
•
...
..
or OAIOO OI05'20VC.5 .
TeteloCoplc. coil spri"1l. oil damped . tpr ln.g PfelCMd fullV adjustilble ,
comPfeulor'l d l mping force B-wev edjunable
A.., suspenslo n . . . .
, ,
. . link type , coil Jpri"ll. gal/oil ~mptd . 11)1'1"51 prlload fuliV adjunable.
compression dampi"51 forcelullv adjuulble
Fronl IlUspenlion I1rok• .. , • • • • • • • •
280 mm 11 1.0 in l
• • • • • • • • •
Ae., whei!1 ll'.....1 . • . . . • ' .• , •• •• ••••••..• , •.•.
280 mm 111.0 Inl
,
62°
30'
Caner , . . . . , . . • . • • . . • . .• .•. .. • . • . . . • • ' . '
T,./I ••..••.•••.• , • . • • . . . . • . . . . • . . " . , ..
115 mm (4.52 inl
St"ring angl • . . . . . . . .
45° (right & lel1 l
· . . .
·..
,
Turning radius . . . . . .
,
.
. 2 .3m l7 .5tll
..·
Front brab .• , . . . .. ." .• , •• ,.
OIK
,
Ae.,. brekt . • . . . • . .
OIK
• • • • • • • • • • • • • • • • • • • • •
FrOllt lir' .I~e .
. . , . • • • • . . • . • • .••• ,. • • • •. ,
80/ 100-21 S I P. lube
Ae., tI,.. Ilze . . . . . , •• , ••• " •. , • •.• , . . . . .•.
110190-18 6 1P. tube
... · . .
..
..
• • • •
· .
.. .
.
..
.·... .
· . . . . . . .. . · .
....
· . .. . . . . . . .
ELECTRICAL
I"nhlon tYPi •. • • • • • •
Ignit ion llml"ll ' • • • •
...
.. .
... .. .
• • • • • • · ..... SUZUKI " PE l"
.. . · . . . • • • • • • 6° B.T.D.C. below 2300 r /mln'Jld
•
30° B. T.O.C. aboYe 4300 rlm ln
Sperk plug . . •. . . . . • • ••. • •• • . ••• •. •• • • . • . . NGK OPR9EA·9 o r NIPPQNDENSO X27E PR·U9
httery . . . •. . • . • • • • • • • • • • • . • . • . , • • . • . . . • 12V lOB kC (3Ah l/l0HA
Gentrttor . . • • . . . . • . . • • • • . • , • • • • . • . • . , . . • . • Three1)hIM A.C. gIIIloIInilOt
FUM
• • • • • • • . . • • • • • . • . • • • • • • . • • • • • • • . • • • •
IS.
HtadI!ght , .• , . . • . • . . . • . . • . . • . . • . • • . • . . . . • . 12V 5SW
POIllkH!llght .. , . . . • . . • • . . • • • • . • • • • . • • • • •.•• 12V 3.4W .•..• e02. 24
12V4W .•.... E04. IS . 17 . 18 . 21 . 22. 2S, 34
Turn IIgllai light . . . . . . ·
..
12V 21W
, • • • • •
12V SnlW
Ten/S"ke IIghl . . . • . • • . • • • •
..
• •
licenM plete Ught .•••.
. · . . . 12V5W
..
Speedometer light . . . • . •
12V 1.7W hi 2 pesl
• • • • •
• • • • • • • • • • •
T echomltllt Ugh t . • . • • .
.
,
• • • • • • • ,
• ' 2V 3W
Neutral Indieator light •.•• ... • • • • •
12V 1.7W
,
High belm InOIeator li ght •. ... • • • • •
· . . 12V 1.7W
Tur n l ignal indlcetor light .. ..
, ,
•
12V UW
• • • • • • • • •
.
..
.
·. ..
.. . · . . . . .
.. . · .. · . .
.
·
...
...
. . .. . . . .
· . . . . . . · ..
. .
.·. .
...
CAPACITIES
Fuel tIIllk , InclU'di"ll rtWnl • . .
.
Rill''''!! . • . • • . • • • • • • • • •
· . . . . . . · . . , . . . . · .. 9 .0 L t2 .4f2 .0 US/ Imp. ga ll
· . . . . . . . . . . . · 1.5 L 10.410.3 US/ lmp. pi )
Engine 011. 011 change , ••• • • • • • • • · . . . . . . . . . . ,
1700 ml t 1 B /l.5 USl lmp, ql l
with fllllr ~nge , . . . . . . . . • • • • • • • • • • • •
1900 ml (2.011 ,7 US/Imp. ql )
overhiJUl • . • • • · . . . . . . . · . . . , . . . . . .
2 100 ml f2.2/ ,B US/ lmp. qll
Front lork oil II;odIlegJ .•. · . . . . , . . . · . . . . . . , . . . . 544 ml 118 .4 / 19.2 USJlmp. OIl
•
•
.
UH:t~U:SM n U -MUUt q l U·:t
SERVICE DATA
VAlVE +G UIDE
Uni t: m m (in)
ITEM
Valve diam .
IN.
EX.
Valve lift
IN.
EX.
Valve clearance (w hen cold )
IN .
EX.
Va lve guide to valve stem
clea rance
IN .
EX .
Valve guide LO .
Valve stem 0 .0 .
IN. 1\ EX .
IN.
EX.
Valve stem runout
Valve head thickness
Va lve stem end length
Va lve sea t wid th
Valve head radial runout
V al ve spring free length
liN . 1\ EX. I
STANDARD
30.6
11. 201
27 .0
11.061
8 .0
10.3 11
8 .0
10.3 11
0 .05 - 0 . 10
10.002 - 0 .0041
' 0 . 10 - 0 . 15
10.004 - 0 .0061
0.0 10 - 0 .0 37
10.0004 - 0 .00 151
0 .030 - 0 .057
10.00 12 - 0 .00221
5.000 - 5.0 12
10. 1969 - 0 . 19731
4 .975 - 4.990
10. 1959 - 0 .19651
4.955 - 4.970
10. 195 1 - 0 . 19571
IN. 1\ EX.
IN. 1\ EX.
0 .9 - 1. 1
10.03 5 - 0 .0431
0. 0 3
10 .00 11
3 5.0
11. 381
3 7.8
11.491
IN . 1\ EX.
INNER
OUTER
Valve spring tension (IN . & EX.)
INNER
5.3 - 6 .5 kg
11 1.7 - 14.3 Ibol
at length 2 8 .0 mm 11. 10 in)
OUTER
0.3 5
10.0 141
0 .35
10.0141
0 .0 5
10.0021
0. 5
10.021
1.8
10.0 71
IN. 1\ EX.
IN. 1\ EX.
LIMIT
13 . 1 - 15. 1 kg
128.9 - 33.3Ibol
at length 3 1. 5 mm ( 1. 24 in)
Asterisk mark ( - ) ind icates the new " M " model specification .
CAMSHAFT + CYLINDER HEAD
Uni t: mm (in)
ITEM
Cam height
STANDARD
IN .
EX .
Camshaft journal oil clearance
Right side
Le ft side
Camshaft journal holder 1.0.
Right side
Left side
Camshaft journal 0 .0 .
Right side
Left side
33.430 - 33.470
(1.3161-1.31771
33.460 - 33. 500
11.3173 - 1.31891
0 .032 - 0.066
(0.00 13 - 0 .00261
0 .028 - 0 .059
(0 .0011-0.00231
22.012 - 22 .025
(0.8666 - 0 .8671 I
17. 512 - 17 . 525
(0.6894 - 0 .69001
21.959 - 21.980
(0.8645 - 0.86541
17.466 - 17.484
10.6876 - 0 . 68831
0 . 10
(0.0041
128.9
(5 .071
Camshaft runout
Cam chain 20-pitch length
Rocker arm LD .
Rocker arm shaft 0 .0 .
IN . & EX .
IN . & EX .
12 .000 - 12 .018
(0.4 724 - 0.4 731 I
11.973 - 11. 984
10.4714 - 0.47181
0 .05
(0.0021
0 .05
(0.0021
Cylinder head distortion
Cylinder head cover distortion
·0- 2
(0 - 0 .081
De-compression lever play
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
Cylinder bore
Piston diam .
Unit : mm (in)
STANDARD
LIMIT
0 .055 - 0.065
(0 .0022-0.00261
79.000 - 79.0 15
(3 . 1102-3.1 1081
78.940 - 78.955
(3 . 1079 - 3 . 10851
0. 120
(0.00471
79.075
(3. 11321
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortio n
Piston ring free end gap
Piston ring end gap
LIMIT
33.13
( 1.30431
33. 16
( 1.30551
0 . 150
(0.00591
0 . 150
(0.00591
151
A
2nd
A
151
2nd
10.2
(0 .4 01
11 . 1
Approx . (0.441
0 . 15 - 0 .30
10.006 - 0 .0121
0 .35 - 0 . 50
10.014-0.0201
Approx .
78.880
(3 . 10551
0 .05
(0.0021
8 .2
10. 321
8 .9
(0.351
0 . 70
(0.0281
0.70
(0 .0281
ORJ!J05M nll-MUUtLJ 10-4
STANDARD
ITEM
Piston ring to groove clearance
1 sl
1s l
2nd
Oil
Piston ring thickness
1 Sl
2nd
Piston pin bore
Piston pin 0 .0 .
1.01 - 1.03
10.040- 0 .04 11
1.01 - 1.03
10.040 - 0 .0411
2.01 - 2.03
10.079 - 0 .0801
0 .97 -0.99
10.038 - 0 .0391
0 .97 - 0 .99
10.038 - 0 .039)
20.002 - 20.008
(0. 7875 - 0.7877)
19 .996 - 20.000
10. 7872 - 0 .7874)
CON ROD + CRANKSHAFT + BALANCER
ITEM
Corod small end I. D.
Conrad big end width
Crank web to web wid th
20.030
(0.7886)
19.980
10.78661
Unit: mm (in)
STANDARD
LIMIT
20.006 - 20.014
10. 7876 - 0 . 78801
20.040
10.7890)
3.0
10. 12)
1.0
(0.04)
Conrod deflection
Conrad big end side clea ran ce
LIMIT
0 . 180
(0.0071
0 . 150
(0 .0061
2nd
Piston ring groove wid th
I
0 . 10 - 0 .55
(0.004 - 0.022)
2 1.95 - 22 .00
(0. 864 - 0 .866)
60.0 + 0 . 1
(2.362 + 0 .004)
0 .05
(0.002)
10.3
(0.41 )
Crankshah run ou t
Balance r spring free leng th
OIL PUMP
ITEM
STANDARD
Oil pump reduction ratio
Oil pressure (at 60 oC, 140 0F)
1. 590135122 )
Above 40 kPa (0. 4 kg/ cm2, 5 . 7 psi)
Below 140 kPa ( 1 .4 kg /c m2, 19.9 psi)
at 3 000 r/min .
LIMIT
10·5 DRJ50SM ('91-MOOEL)
CLUTCH
Unit : mm (in)
ITEM
Clutch lever play
STANDARD
10~ 15
Drive plate thickness
2.72 ~ 2.88
LIMIT
(0.4 ~ 0 . 6)
2.42
10.095)
15 .2
(0 .60)
0 . 10
(0.004)
(0 . 107 ~ 0 . 113)
15.8 - 16.0
(0 .62 - 0 .63)
Drive plate claw width
Driven plate distortion
29.5
Clu tch spring fre e length
(1 . 16)
TRANSMISSION + DRIVE CHAIN
Unit: mm fin) Except ratio
STANDARD
2 .818 (62/22)
3.071 (43/1 4 1
2.416 (29/12)
1. 733 (26/15)
1.333 (24/18)
1. 111 (20/1S)
0.952 (20/2 1)
0 .S 26 (19/23)
0 . 1 ~ 0 .3
ITEM
Primary red ucti on ratio
Final redu ction ratio
Gea r ratios
Low
2nd
3,d
4th
5th
Top
Shift fork to groove ctearance
(0.004 ~ 0 . 012 )
Shih fork groove width
Shi ft f ork th ic kness
Drive chai n
(0. 19 7 ~ 0 . 200)
4. S ~ 4 . 9
(0. 189 ~ 0 . 193)
OAIOO: 0 .1.0. 520VC5
TAKASAGO: RK520S0
Links
lOS
319.4
(12.57)
20-pitch length
Drive chain slack
0.5
(0 .020)
5 . 0 ~ 5. 1
No. 1.No .2
& NO .3
No . 1.No.2
& No.3
Type
LIMIT
25 ~ 40
( 1 . 0 ~ 1.6)
un~ .....
,;jO'''' .. ' ..
nUU~"' 1
CARBURETOR
ITEM
Carburetor type
Bore size
1.0 . No
Idle r/min.
Fuel level
Float height
Main jet
Main air jet
Jet needle
Needleiet
Throttle valve
Pilot jet
By -pa ss
Pilot outlet
Valve seat
Starter jet
Pilot sc rew
Pilot air iet
Throttle cable play
SPECIFICATION
E-03
MIKUNI BST33SS
E-33
.--
33 mm
1402
1 500 ± 100 rlmin
1.5 + 0.5 mm
(0.06 ± 0 .02 inJ
14.6 + 1.0 mm
(0. 57 ± 0 .04 in)
IM .J .I
# /35
IM.A .J .I
0 .6 mm
IJ .N.I
SC016
IN .J .I
0 -5
ITh.V. 1
#115
IP.J .I
# 31.5
IB.P.I
0 .8 mm , 0 .8 mm , 0 .8 mm
IP.O.I
0 .8 mm
I
IV .S.I I
1.5 mm
IG .S.I
# 37 .5
IP.S. I
PRE-SET
IP.A. J .I
1.3 mm
0 .5 - ' .0 mm
10.02 - 0.04 ;nl
1403
-
.-
----.-.--
CARBURETOR
SPECIFICATION
ITEM
Carburetor type
Bore size
1.0. No
Idle r/min.
F-02.04. 16.
7.21.25.341
MIKUNI
BST33SS
E1S.2 2
E-24
E28
E- 18
-
----
-
-
"iOOf
-
33 mm
1401
1 500±
1404
rl min
Fuel level
Float height
1.5+0.5 rrrn
10.06±
0.02 in)
14.6+ 1.0
mm
Main iet
Main air jet
Jet needle
Needle jet
Throttle valve
PiloUet
By-pass
10.57+
0 .04 ;nl
# 135
-
--
IM .J .I
0.6 mm
IMAJ.I
IJ .N.I "SCOS6-3rd SC018 -4th
IN .J .I I " 0 -3
0 -6
ITh . V.I
# 115
• #42 . 5
IP.J .I
#40
IB.P.I 0.8,0 .8,0.8
mm
Asterisk mark ("J indicates the new " M " model specification.
1407
1406
-
---
-
140 5
1 SOO± 50
r/m;n
---
SC018-3rd 5C020-3rd
0 -7
#37 . 5
IU -O
10·7 DR350SM ('91-MODEL)
SPECIFICATION
ITEM
IP.O.I
IV.S.I
IG.S. I
IPS I
Pilot ou tlet
Va lve seat
Starter jet
Pilot screw
E·02.04.16.
E- 1 5.22
7.21.25.341
0.8 mm
1. 5 mm
*#45
PRE -SET
PRE -SET
(1 Va turn s
fl .0 turn
.-.-
ba ck)
Pilot air je t
Throttle cable play
IP.A.J .I
E-24
--
back)
1.3 mm
.5 - 1.0mm
10.02 0.04 in)
-
.-
E-28
E· 18
-
.PRE·SET
(2. 0 turns
back)
--
PRE-SET
(2 Va turn s
back )
-
1.4 mm
-
ELECTRICAL
Unit : mm (in )
ITEM
SPECIFI CA liON
5°B.T.D.C. below 2 300 rfm in and
30 o B. T .D.C. above 4 300 rfmin
Ignition timing
Spark plug
NO .: X27EPR ·U9
N.G.K. : OPR9EA-9
0 .8 - 0 .9
10.03 - 0.041
Type
Gap
Spa rk performance
Ignition coi l resistance
NOTE
Over 8 <0 .3) at 1 atm .
Magneto coil resistance
Primary
0.1-1.0n
Secondary
12 - 22 kfl
C ha~ng
0.1 - 1.3 fl
250 - 370 [)
180 - 270 [)
Power source
Pick-up
Lighting coil no -load voltage
(w hen engine is co ld )
Regulated voltage
Batt ery
Type des~ation
Capacity
Standard
electrolyte S. G,
Terminal Ground
Plug ca p Terminal
y- y
W - Br
G - BI
M ore than 65 V (AC) at 5 000 t/min .
13.0 - 15.5 V at 5000 r/min .
YT4L·BS 0' FT4L-BS
12V 10 .8 kC 13Ahl/ l 0HR
1.320 at 20 ° C 168° FI
15 A
Fuse size
WATTAGE
Unit: W
ITEM
Headl ight
--'-
Position light
Tail/Brake light
Turn signa l light
Tachometer light
Speedom eter light
Turn signal in dicator light
HI
LO
SPECIFICA TION
E-02.04 .15.16.17.18.
E-03.28 .33
21.22.24.25,34
60
55
3 .4
5/2 1
21
3
1.7
1. 7
----
--
OR35OSM ('91-MOOEL) 10·8
ITEM
1.7
BRAKE + WHEEL
ITEM
.Unit : mm (in 1
Brake lever play
Rear brake pedal heigh t
Brake disc thi ckness
Fron t
Rear
STANOARD
0 - 0 .3
(0 - 0 .0 11
5
(0.21
+ 0.2
3.5 (0 . I 38 + 0 ,0081
+ 0 .2
4 .0 + 0 .008)
(0 . 1 57 -
Brake disc runout
Master cylinder bore
Front
Rear
Master cylinder piston diam .
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper pi ston diam .
Fron t
Rea r
W heel rim (unout
Front
Tire tread depth
Front
Rea r
Front
Rear
3.0
(0. 1181
3.5
(0. 1381
0 .30
10.0 121
2.0
10.081
2.0
10 .081
0 .25
10.0 101
0 .25
(0.0 101
Axial
Rea r
Tire size
LIMIT
12.700 - 12.743
(0 .5000 - 0 .50171
12.700 - 12.743
10.5000 - 0 .50171
12.657 - 12.684
(0 .4983 - 0.49941
12.657 - 1 2.684
(0.4983 - 0.49941
27 .00 0 - 27 .050
11.0630 - 1.06501
30 .230 - 30 .280
11 . 1902 - 1. 192 11
26.900 - 26.9 50
(1. 059 1- 1.06 101
30, 160 - 30 . 18 0
11. 1874 - 1.1 8821
Rad ial
Wheel axle runout
18.
E·03.28 . 33
80/1 00-21 51P
110190- 186 1P
3.0
10. 121
3.0
(0. 121
10·9 DR350SM ('91-MODEl)
SUSPENSION
Unit: mm (in)
ITEM
LIMIT
STANDARD
280
111.01
Front fork stroke
Front fork spring free length
NOTE
602
123.71
Front fork oil level
170
16. 71
1 000 kPa
Rear shock absorber gas pressure
10 kg/em', 142 p~ 1
272.8
110.71
280
111.01
Rear shock absorber spring
pre-se t length
Rear wheel travel
0 .3
10.011
Swinga rm pivot shaft runout
TIRE PRESSURE
SOLO RIDING
COLD INFLATION I
TIRE PRESSURE
kPa ~cm2 psi
1. 50
FRONT
150
22
1. 50
REAR
150
22
DUAL RIDING
ps,•
150
1. 50
22
175
1.75
25
kPa !~cm2
I
FUEl+Oll
SPECIFICATION
Use only unleaded gasoline of at least 87
ITEM
Fuel type
pump octane (!!...:fM method ) or 91 octane or
higher rated by the resea rch method .
Gasoline conta ining MTBE (Methy l Terti ary
Butyl Ether). less than 10% ethanol, or
less than 5% met hanol with appropriate
coso lvents and co rrO SIon inhibitor 's
permissible .
Fuel tank incl uding rese rve
rese rve
Engine oil type
Engine oil ca pacity
Front fork oil type
Front fork oil capacity (each leg)
Use only unleaded gasoline of at least 87
pump octane (R ;M method) or 91 octane
or higher rated by the Research Method .
Gasoline used should be graded 85·95
oc tane or higher. An unlead ed gasoline is
recommended .
9.0 L
12.4/ 2.0 US/Imp gall
1.5 L
10.4/0 .3 US/Imp gall
SAE 10W/40, API SE or SF
1 700 ml
Change
(1 .8/1 . 5 U~'lmp qt)
1 900 ml
Filter change
12 .0 / 1. 7 US/Imp Qtl
2 100 ml
Overhaul
12. 211 .8 US/Imp QI)
Fork oil # 10
5 44 ml
118.4119 . 2 US/Imp ozl
Rr~k p
fll, irl t vnp
nnT 4
NOTE
E· 03
E· 28
For the others
DR350SM ('91-MDDEL) 10·10
ENGINE MOUNTING
l: 1 15
L:l00
Tightening torque
ITEM
N 'm
kg -m
Ib· ft
(j),®
37 - 45
3 .7 - 4.5
27 .0 - 32 .5
0,~
O,
5
60 - 72
6 .0 - 7 .2
43.5 - 52.0
®
18 - 28
1.8 - 2 .8
13.0 - 20.0
(J)
• Apply THREAD LOCK SUPER " 1 303"
199000· 3 2030)
10·11 DR350SM ('g1-MOOELI
WIRE ROUTING
Clamp
COl unit
DRJ50SM ('91-MODEL) 10·12
CANISTER HOSE ROUTING
(California model only)
harness
Clamp
Throttle
harness
harness
hose
hose
harness
harness
cable
ail hose
'--- Surge hose
r-\~- Purge hose
Surge hose
hose
Purge
ho,",
,
Surge hose
Purge air t'lose
Canister
DR350N/DR350SN ('92-MODELj
, - - - - - - - - - - - CONTENTS - - - - - - - - SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
71 - 1
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
71- 3
THROTTLE CABLE ADJUSTMENT (DR350SN) . ......
71-19
WIRING DIAGRAM (DR350SN) . . . . . . . . . . . . . . . . . ..
11-20
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
11-21
11·1
DR350NIDR350SN r92·MODELJ
SPECIFICATIONS (DR350N)
DIMENSIONS ANO ORV MASS
Overa ll length
Overall widlh
Overall hi!ighl
WheeJbiI~ ..
•
•
G.ound clearance .
• • • •
SU I 1'1&;111'11
• •
Dry man .. .. .
•
ENG INE
T yoe . . . . . . . . .
Va lve clearance. IN .
..
. ..
..
• •
• • •
· , . .. .
•
•
· Fout-li tro ke. " , .
• . 0 .05 - 0 ,10 mm
· ' 0 . 10 - 0.15 mm 1
•
1
•
• •
•
79.0 mm 13 . 1 10 in)
7 1.2mm (2.803 In)
349 em) 121.3 cu. in)
9 .5 : 1
MIKUNI TMJ3SS, single
Po lv ... re thane foam e lement
Prim ary kick
Dry sum p
•
..
4th .
5 th .
..
•
.. . .. . . . .
• •
..
. ..
•
..
...
·
.. • .
•
.
.,
• •
•
•
..•
•
•
•
•
•
...
O"v" Chain
•
•
•
..
•
..
..
.
•••
,
, ,
•
• • •
..
•
J,d
CHASS IS
Fronl s... spenslon
..
•• •
••
•
•
TRANSM ISS ION
Clutch
• • • •
Transmiuion . . . . .
•
Gearshi ft pattern . . .
Primary redu ct ion r~ lio
FInal reduction rat io
tiear ralio'. Lo.....
2'10 .
To,
•
• •
••• •
.
...
•
..
...
.
••
• • • •
• • ••
•
EX
Number 01 cvli nder
Bore • . . . .
SHo ke . . . . . . . .
P,ston d Isplacement
Compren ion rBtlo
Carburfto.
•
All clea ner . . . .
S taner system ..
LUbricat Ion syst&m .
..
•
2 165 mm IB2 .51nl
885 mm 134.8 inl
1250 mm 14 9 .2 inl
• 1440mmISS.7 inl
310 mm (12.2 in)
920 mm 136.2 in)
113 kg (249 Ibsl
•
DAIOO OIOS20VC ,S,
•
11 01ink!
•
R~af suspension
Front suspensiOn Itrok!
Aear ..... heel "lWei
Caster
... .
Trail
... .
•
Steering angle
T .... nlng radius
F ronl brilke
•
Reo, breke
Fron t li re siu .
•
Rear I;re si le
.. ...• •
.. . ...
• • •• •
...
•
•
•
•
•
•
•
•
•
ELE CTR ICAL
IgnlllO<\ type .
Ignition timing
Spark plug .
Gefl.era lor
Headl'ght
Taillight.
• •
.. .•
.....
· ..
•
•
•
•
••
•
••
· . ., .
•
..
•
•
..... .
•
•
• •
..
.
Tele5oCopic. coil 'prong, oll d~mped. spring preload fully adjuuable ,
compreniDn damp,ng force adj...stable
Lin k type, coif spring. gas/o il damped. Ipring pre fO&d f ... ll v adjunable ,
CDmpr~Siion and r~bound damping force adju,table
• 280 mm 111 .0inf
280 m m 111.0 inJ
62" JO'
118 mm (4 .65 in l
4 5" (right & le ft I
2.2 m 17.2 1tf
Oi$C
DI~
•
•
•
•
•
CAPAC ITIES
Fuel lank . incl ... d'ng reserve.
Reserve . . . . . .
Engine oil. 011 chang! . . . .
..... ' 11'1 fi lter changE!
oVl!Thau l . .
Front lork oil (each leg\ .
•
• • •
We t mulli-plate type
6·speed connan\ mesh
l..:l ow n. S "\Jp
2.8 18162(22)
3.357147 / 14 )
2 .416 (29/ 12)
1.733151
1.333 I
1. 11 I
I
I
•
•
Astensk mark (' J indiQlles the New " N" model specifica tion.
80/1oo·2151M.IUOO
11 0/ 100-18 64M, t... b e
SUZUKI "PE'"
5" S .T.O.C. below 2300 rlmin a Jld
30" B.T .O.C. above 4300 r /min
NGK OPR9EA·9 Of NO X27EPR-lJ9
Flvwheel magneto
12V SSW
12V SW
9.5 L (2.S/2 .1 US/lmp, gal)
1.8 L (0.5 /0 .4 US/Imp . gal l
1700 ml (1.8/1.5 US/Imp. q tf
1900mf {2.0/1.7 US/lmp. qt f
2100 ml {2.2/1..B US/Imp. q d
586 ml {19.8/20.6 US /Imp. oz f
un .Hlv ..l .. n .. " ...... \ .. ... ,..........,
I""
SPECIFICATIONS (DR350SN)
DIMENSIONS AND DRY MASS
0,..,. 11 ""IIth . . . . . • . . . . . . .
..... ............. 2335",m IQUI inl ..... E16, 16. 17. 18 . 22
2240 fTWTI 188.2 Inl ....• E34
..
.
· . ..
• • • ••
·....
· .. ..
· . . .. .. · . ..
• • • • •
• • • • • •
0....11 width .••. • • •
ev... 11 h'ivht . . . .
Wh .. l~ . . . . .
Q.ovnd et"'lnot ..
S..t hl l"ht .. ..
Dry ml" . . . . . .
2236",,,, t88.o Inl .. . •. Oth....
. " .
134.8 In l
. . .. ..
~
1049.0 Inl
mm 156.7 In)
. .
•• • • • •
'~: 111.04 inl
~~
135,o ln l
• • • • •
. .. .
.. . .
5:::::
· ..
...
·..... ••• • • •••••
· .• .• .• .• .• , . . , . . . .
• • • • •
kg
1260 Ibll
ENGINE
..
..
· · . . . . •. Four·t!rok" ,1.-cooIed wIth SACS. OHC
. . , . • O.OS - 0 .10",,,, IOJXl2 - 0 .0004 In)
·
.. .
EX
· . . . . . . , ..... . · .. · . . , . . 0 .10 - 0 .15 ",,,, 10 .0004 - 0.006 Inl
Nu~ of cy llndlt
1
• • • •
• • • • • • • • • • • • • • • • • • •
1ku'I • . • • . . • • · .. • • • • • • • • • • • • • • • • • • • • · 79.0 mrn 13.1'0 Inl
Slto ltt . . . . . . . . · . . ................... ,. • 7 1.2mm 12.803 In )
Pluon d lt.ptectm"' l
JA9c",J 121.3cu . in l
• • • · .. . . . , . .. . . • • • • • • • •
ComprHlIOf'l ''';0 • •
· . . . . . .. 9 .5 : .
• • • •
• • • • • •
C,rburllor . . .. .
· . . . .. . • • · . . . . . • . . • MIKUNI BSTlJ. I lngll
AI, etlln.,. . . . . . . .
.. . .. . • • • • • · • • • POlyurlth,,,, 'oem lle""nt
• • • •
S ilTI er "Vlllm .. .
•• • •
• • .. .
• • • • • · •.• Prlm.,.y k ic k
Lubrlc.t lon Iynlm .. .
, . . . • • • • • • • • • • • • • • • • • .• Dry lump
Type . • . . . . . . . · .
·..
•••••••
.
..
cln r l nee. IN . • • • • • • ••
.
.· .· .
V',.,.
•
•
•
•
•
TRANSMISSION
CI", ten . . . . . . . . • • • • • • • • • • • , . .
. , . .. . · . . · . . .
· .. .
. . . .. . . .
·. .. .. ...
.. . .
... .
· . . .. . . . .
.. . ....
.. ..
· . · ..
T09 . • • • .
. • • . • • .• • •.•• • • • • • •
0 ,1.,,1 en,ln . . . . . . . . . . . . . . . . . . • . • • · .. · .. • • • •
T'l nlmlulon . . . . . . . .•.
. .....•.••. ·
• • • •
Gllf1.h11t !)allirn . . . . • • .• • .••
,
. ..
Primary rtOuC1lon ,"10 ..
,
.. ·
·
.
FiJ'\ll rtdUC1IOf'1 "tio . . . . . • .
·...
. . • • • • • • •
Gelr " fial , Low • • • • •• ••
.. ••• •·. .
2nd . . . . •
• • • • • • • • • • •
• • • •
3rd • . . . • . • • • • • . • . • • • • • • • •
4th ., • . . . .
• • • • • •
·
·
5th
...•.
. ..
. .
• • • • • • •
m ....
K52OS0 or OAIOO DI0520VC.5 ,
CHASSIS
.. • • • • • • • • • · ..
Aur IUlJ)lnlion
· . . . . . .. • •
•
• •
Front IUsplnllo n n ro kl , , , •
· . . . . .. .
• · ..
Ru r whell
1 . . . . . •. . .. · . . . . . . .
•
C,UI.. . . . . . . . . . . . . . . •
Fro nt wJPen i lo n
• • • • •
•
•
• •
• • •
•
• • •
• • • •
· ..
ELECTRICAL
I"nllion tYpe • • • . •
IIInl110 n l iming ..
Pflload fully edjunlbl • .
•
• • • • • • • • • • • • • • • • • • •
Tr.lI . • . . . . . • . . . . . . . . • . • • • . • • • • . . • • .
St ... lng "'11"11 • . •• • • • • • • • . • • • • . • . • • • • • • • • •
Turn ing rld lu • . . • . • . • • • • . • • . . . • . . . . . , . . • . • • •
Fron t br,kl , •• . ••. , . • • • • • • . • . • . . . • . . . • •
R" .. b,..k, ..
...
. . . . . . . . . . . . • . . . . ..
Fro nt till sizi .
. ..
• •
• • • • • • •
• • • • •
•
AU r t l,. lill .
. • • •
•••••• • • • • • • • • • · .
.
... , .· .. .. ., .. ., • • • • • · .• .
•
•
• • •
•
•
115 mm 14.53 1n l
45" (rlght 6- I ~h l
2 .3m 17 5111
D l~
O lse
BO/ 100·21 SIP. lUbe
110190· IB 61P, t ube
•. SUZUKI " PEl "
•• S" B. T.O.C. below 2300 r fm ln end
30" B.T.D.C. ,bove 04300 rlm in
NGK OPR9EA·9 o r NO X27EPR·U9
•
. . '2V '0.8 kC 13Ah l/ IOHR
• • • • •
• • • • • • • • • • • • • • • • • • .. .
· , . . . . . . . . .., , .. ... . . . . . .
G.nelltor , . · . . . . · . . . , . • • • • • • • • • , . . . . · ..
ThrH1I'h_ A.C. lllne"tor
Fu.. . . . . . · . . · . .
· . . . . · . . . . . . . ......... 15.
HlMillgl'lt .. • • • • • • • ... , . . , . , . .
• • • • · . . . 12V 60155W
POi ldon IIghl · . . • • • • • • · .. · . . . . , . . • • • • • • .••. 12V3AW .. ... E02
·
Spark p luli •.
Ban.ry
...
•
j
• • •
1t.....
·
·.
II
• • •
•
•
•
' 12V04W .• . •. . EOo4, 15 , 16, 17. 18. 21 . 22 . 24. 25, JA , J9. 94
12V 21W
12V 5121W
12VSW
12V 1.7W he 2 pal
TKhoml'lrllght . . • . ..
. . , , . , , , .• , . •• ••. , , ,
12V'JoN
NlUtr,J Indieetor light . . . . . . , .. , . , • .. . .• •. . . . .
12V 1.7W
High ~m Indicato r livhl . . . . , •.. , , • , .. , . . • . . , , , • 12VI .7W
Turn l illNl IndiQIor light . . . • . . • • • • • . • • . • • . • • • , •. 12Vl .7W
Turn 1 11I~llIllhl . . • • . . , . , • • • . . . • , . . . •.. . . . .
TIlI / B,..k.llght . . . • . . . .
. • . • . . • . • . .• .. . . . .
Licen .. pl.tl light . . .
. • . • . . •.• • .• • . •• . .
Spud.:>mll.. light . . . . .
. • , • , • • • • • , •• " •• . ,
CAPACITIES
• • • • • • • • · . . . . . . . . . . 9 .0 L 12 .412 .0 US / Imp, gill
· . . . . . . . . . . . . . . . . . . . . . 15 l 10.41'0.3 US/ Imp. gall
Engl".. oil. oil chenge • . . . . . . • . . . . . . • . •• .. .. . • • • 1700 ml 11.8/ 1.5 US/Imp. qtl
FUll link . Including liMN.
•
RIMIIV' ••• , •
• • •
•
• • • • • •
• • • • • • • • • • • • 1900 ml 12 .011 .7 US/Imp. qtl
2 100",1 12.2/ 1.8 US/Imp. qtl
"569 "'I09.2no.0 USllmp. (),ll
11 ·3 DR350 NIDR350SN 1'92·MDDEll
SERVICE DATA (DR350N)
VAlVE + GUIDE
Unit: mm lin)
ITEM
I~Oi~1
IN .
Valve lift
Val ve clearance (when cold )
EX.
~
IN .
,,,8 ,g 1
EX .
~I
1006g~ -:g6g41
IN.
~61
0 .010 - 0 .037
EX .
Valve gl ;
to val ve stem
IN.
clearance
IN . & EX.
V alve stem 0 .0 .
IN .
EX.
~ stem runout
Igi},5_ ,
10 .0004 - 0 .00151
0 .030 - 0 .057
10 .0012 - 0 .00221
.
- 5.012
10 . 1969 - 0 . 19731
4 .975 - 4 .990
/0 . 1959 - 0 . 19651
EX.
~gl ;del.D.
10.0141
/0 . i 95 - 0 . 19571
IN . & EX.
Valve head thickne ss
10 .0021
0 .5
10.021
1.8
10.071
IN. & EX .
~ stem--;;;;(j lengt h
IN . & EX.
V alve sea t width
Val vj;ltl'e'ad
~
STAiiii5AiID
Valve diam .
0. 9 - 1.1
~- 0 . 043 1
IN. & EX.
runout
IN . & EX .
Valve spring free length
/I N. & EX.I
10.0011
35.0
11.381
37.8
11 .491
INNER
OUTER
Valve spring tension~
<.J
5.3=6.5 kg
111.7 - 14.3 Ibsl
INNER
1
all
j.
OUTER
all
-
~. 1- 33 . 3
Asterisk mark (., indicates the New "N " model specification .
•
1
•
1
I
OR350NjOR350SN 1'92-MOOELI
CAMSHAFT + CYLINDER HEAD
rc.
~
Unit : mm (in)
IN .
EX .
Camshaft journal oil clearance
Right side
Left si de
Camshaft journal holder 1.0 .
Right side
Lett sid e
Camsha ft journal 0.0 .
Right side
Left side
~
11.3 161 - 1.3 177)
11 .30431
I~3:ii~L 1 .:i~~~)
0.032 - 0 .066
10.0013 - 0 .0026)
1 1.3(}~5)
10.0011 - 0.00231
22.012 - 22.025
10.8666 - 0 .867 11
7
16768~~ 6 6900)
21.959 - 21.980
10.86 4 5 - 0 .8654)
7
16 6876 -- 0.
1 76ri~il
0 . 150
10.00591
1~659)
Camshaft runout
100641
128 .9
15 .07)
Cam cha in 20-pitch length
Rocker arm
Ac
arm
IN. & EX .
0:0:-
IN . & EX.
~~
164724
1 1.973 - 11 .984
10.4714 - 0.47 18)
Cylinder head distortion
0 .05
10.0021
0.05
iO.002)
~head coverdiStOo i >n
0- 2
10 - 0 .081
De -compression leve r play
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
Cylinder bore
Piston diam .
Unit : mm (i n)
STANDARD
LIMIT
0 .055 -0.065
10.0022 - 0 .00261
79.000 - 79.015
13. 1102 - 3. 11 081
78.940-78.955
13 . 1079 - 3.10851
0.120
10.00471
79.075
13. 11 321
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
Piston ri ng free end gap
Piston ring end gap
15t
R
2nd
R
15t
2nd
10.2
10.401
1 1.1
Approx .
10.441
0 . 15-0.30
10.006 - 0.0 121
0.35-0.50
10 .014 - 0.0201
Approx .
78.880
13.1055)
0 .05
10.0021
8.2
10.321
8 .9
10.351
0 .70
10.0281
0.70
10.0281
11 -4
11·5
DRJ5DN/DRJ50SN 1'92·MODEl)
STANDARD
ITEM
Piston ring to groove clearance
15t
2nd
Piston ring groove width
15t
2nd
Oil
Piston ring thickness
15t
2nd
Piston pin bore
Piston pin 0 .0 .
1.01 - 1.03
10.040 - 0.0411
1.01 - 1.03
10.040-0.041 )
2 .01 -2.03
10.079 - 0.0801
0.97 - 0 .99
10.038-0.0391
0 .97-0.99
10.038 - 0.039)
20.002 - 20.008
10.7875 - 0.78771
19.996 - 20.000
10.7872 - 0 .78741
CON ROD + CRANKSHAFT + BALANCER
ITEM
Corod small end 1.0.
Conrod big end width
Crank web to web width
20.030
10.78861
19.980
10.7866)
Unit : mm (in)
STANDARD
20.006-20.0 14
10.7876 - 0 .78801
Conrod deflection
Conrod big end side clearance
LIMIT
0 . 180
10.0071
0 . 150
10.0061
0 . 10- 0 .55
10.004 - 0.0221
21 .95 -22.00
10.864 - 0.8661
60.0 ± 0 . 1
12 .362 ± 0 .0041
LIMIT
20.040
10.78901
3 .0
10. 121
1.0
10.041
0.05
10.0021
10.3
10.4 1 I
Crankshaft runout
Balancer spring free length
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 oC,140 0 F)
STANDARD
1.590 135/221
Above 40 kPa (0.4 kg /cm2, 5.7 psi)
Below 140 kPa ( 1.4 kg /cm2, 19.9 ps i)
at 3 000 r/min .
LIMIT
I
DRJ50NIORJ50SN (,92·MODEl)
CLUTCH
11 ·6
Unit: mm (in)
ITEM
STANDARD
10 - 1 5
10.4 - 0 .61
2.72 - 2.88
10. 107 -0. 11 31
15.8 - 16 .0
10.62-0.631
Clu tch lever play
Drive plate thick ness
Drive plate claw width
LIMIT
2.42
10.0951
15. 2
10.601
0. 10
10.0041
29.5
11. 161
Driven plate dis tortion
Clutch spring free length
TRANSMISSION + DRIVE CHAIN
Unit: mm (in) Except ratio
to groove clearance
Shift fork groove width
Drive chain
No.l .No.
& No .3
_ _---'1..:.0_.1.,:.,97 - O. 2001
Type
10. 189 - 0 .1931
DAIDO, 0 .1.0 . 520VC5
~~~_ TAKASAGO' RK5E2~0~SO~====~==~;=~==
20-pitch leng th
25 - 4 0
11.0 - 1.61
112 .571
,
11·)
OR350NIOR350SN r 9Z·MOOELI
CARBURETOR
1
Throttle cable pia V
0 .5 - 1.0 mm 10.02 - 0.04 inl
I
ElECTRICAL
ITEM
Igni tion timing
Spark plug
Spark performance
Ignition coil resistance
Magneto coil resis tance
. Unit: mm (in)
SPECIFICATION
5°S.T .D.C. below 2 300 rlmin and
30 o B.T.O .C. above 4 300 rlmin
ND.: X27EPR·U9
Type
N.G .K .: DPR9EA-9
0 .8 - 0 .9
Gap
10.03 - 0 .041
Over 8 {Q,31 at 1 atm .
Prima ry
0 . 1 - 1.0 n
Terminal Ground
Secondary
12 - 22 kn
Plug cap -
Ug h ti ~
0 . 1 - 1.S0
2S0 - 370 0
180 - 2700
V- 8
W - Br
G- 81
[Power source
Pick -up
Lighting coil no-load vol tage
(when engine is cold)
Regulated voltage
NOTE
More than 75 V (AC) at 5 000 r/min .
12 - 14 V a t 5 000 r/min.
Term inal
U"J:JUN luroJIIU.u. \ .. ............. .. ,
WATTAGE
Un it : W
I
SPECIFICA nON
ITEM
55
5
Head~ht
Taillight
BRAKE + WHEEL
Unit: mm (in)
~
""iTEM
(g-~I
Brake lever play
jRe.;" b,ake
Brake disc thickness
5
(0. 21
+
Front
(0138 ±~
Rear
(0. 157 ~ 0 :0081
Front
16~331 = 6 .43481
Brake disc runout
~bO"
Rea r
Master cylinder piston diam .
I&a ;-Caiij ~ bo,.
Front
11 .0630 - 1.06501
27 .000 - 27.050
11 .0630 - 1.06501
26.900 - 26.950
11 .0591 - 1.06101
•
·
-
11 .059 1 - 1.06 101
2
(0 0<>81
Axial
•
10.081
0 .25
(0.0101
0 .25
(0.0101
Front
Rear
~
Tire tread depth
-+ F;
~
(0. 1381
30
(0.0121
-
Radial
Wheel axle runout
(~81
-
Front
Rear
Wheel rim runout
•
10.4983 - 0.49941
Front
•
16.5000 "': 6 .50 171
10.957-10.984
10.4314 - 0.43241
Rear
Rear
Brake caliper piston diam .
, , . ..
8OI1~
~
1 1 .Q!.1.29. ~
Front
(~7r,1
Rear
(04 .0
161
11·9
DRl5DNIDRl 5DSN f 92·MDDEU
SUSPENSION
Unit : mm (in)
ITEM
STANDARD
280
111.0)
Front fork stroke
LIMIT
Front fork spring free length
608
123.9)
145
(5.7)
Rear shock absorber gas pressure
1 000 kPa
(10 kg/cm2, 14 2 psi)
269.2
Rear shock absorber spring
pre-set length
11 O. 6)
Rear wheel travel
280
( 11.0)
Front fork oil level
Swingarm pivot sha ft runout
0 .3
(0.0 1)
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
•
kPa
kg/cm2
ps'
100
100
1.0
1.0
14
14
NOTE
I
DR150NIDR150SN ('92·MOOEl)
11 ·10
FUEL + Oil
ITEM
Fuel type
Fuel tank including reserve
reserve
Engine oil type
Engine oil capacity
SPECIFICATION
NOTE
I
I
Use only unleaded gasoline of at least 87
pump octane ( R ~ M method) or 9 1 octane or
higher rated by the research method.
Gasoline contain ing MTBE (Methyl T ertiary
E·03
Butyl Ether) , less th an 10% ethanol, or
less than 5% methanol with approp riate
coso lvents and co rros ion inhibitor I• S
permissible .
Use on ly unleaded gasoline of at least B7
pump oc tane (6 ! M method) or 91 octane
E· 28
or higher rated by the Research M ethod .
Gasoline used should be graded 85· 95
octane or higher . An unleaded gasoline is For the others
recommended .
9.5 l
12 .5/ 2. 1 US/Imp gal)
1.8 L
10.5/0.4 USll mp ga l)
SAE 10W/4 0 . API SE or SF
1 700 ml
Change
11.811 . 5 US/Imp qt)
1 900 ml
12 .011 . 7 US/Imp qt)
2 100 ml
Overhau l
12 . 2/ 1.8 US/Imp qt)
Fo rk oil # 10
586 ml
119 .8/ 20.6 US/Imp oz)
DDT 4
Fil ter change
Front fork oil type
Front fork oil capacity (each leg)
Brak e fluid type
11 ·11
SERVICE DATA (DR350SN)
VALVE+GUIDE
Unit: mm lin)
ITEM
I
Valve diam .
IN .
EX .
Valve lift
IN .
EX .
Valve clearance (when cold)
IN .
EX.
Valve guide to valve stem
clearance
IN.
EX .
Valve guide 1.0.
Valve stem 0.0.
IN. & EX.
IN .
EX .
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
liN . & EX .I
STANDARD
30.6
11 .201
27 .0
11 .061
B.O
10.31)
B.O
10.311
0 .05-0. 10
10.002 - 0 .0041
0 . 10 -0. 15
10.004-0.0061
0.010-0.037
10.0004-0.00151
0 .030-0.057
10.0012 - 0 .00221
5.000 - 5.012
10. 1969 - 0 . 19731
4.975- 4.990
10.1959 - 0.19651
4.955 - 4.970
10.1951-0.19571
IN . & EX .
IN. & EX .
0 .9 - 1.1
10.035-0.0431
0.03
10.001)
35.0
11 .3BI
37 .B
11.491
IN . & EX .
INNER
OUTER
Valve t spring tension (IN . & EX .)
INNER
5.3 - 6.5 kg
111 .7 - 14.3Ibsl
at len th 28 .0 mm (1 . 10 in)
OUTER
0.35
10.0141
0 .35
10.0141
0.05
10.0021
0 .5
10.021
1.B
10.071
IN . & EX .
IN. & EX .
LIMIT
13. 1 - 15. 1 kg
128.9 - 33.3Ibsl
at length 31 .5 mm (1 . 24 in)
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
------.-----~~
arm
Rocker arm shaft 0 .0 .
IN. & EX .
IN . & EX .
10.4724 - 0 .47311
11.973 - 11 .984
10.4714 - 0.47 181
\-;:--,,---,--;---,------.,___-c-- _ _ _ _ _ _ _ _ _ _ __ _--I-_-'-'
10.002C'1-----j
head cover distortion
10.0021
De· compression lever play
10 - 0 .081
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
Cylinder bore
,
Piston diam .
Unit : mm (in)
STANDARD
LIMIT
0 .055 - 0 .065
10.0022 - 0 .00261
79.000 - 79.015
13. 1102 - 3 . 11081
78.940 - 78.955
(3. 1079 - 3. 10851
Measure at , 5 mm (0.6 in) from the skirt end.
0 . 120
10.00471
79.075
13. 11321
Cylinder distortion
Piston ring free end gap
Piston ring end gap
1s1
R
2nd
R
1sl
2nd
10.2
(0.401
11.1
Approx . (0.441
0 . 15 - 0 .30
(0.006 -0.01 21
0.35 - 0 .50
(0.014-0.0201
Approx .
78.880
(3.10551
0.05
(0.0021
8 .2
10.321
8 .9
10.351
0 .70
(0.0281
0 .70
(0.0281
11·13 DRJ50NIDRJ50SN r92·MODElI
ring to groove clearance
1
s.
2nd
groove
(0.0061
s.
1.01 - 1.03
2nd
(0.040 - 0 .0411
1
1
Oil
1-_'S_'_+-__.:..:.,
(0.038 - 0 .0",39",1_ _ _ - - - - - - 1
2nd
(0.038 - 0 .0391
Piston pin bore
•
(0.7872 - 0 .78741
CON ROD + CRANKSHAFT + BALANCER
(0.78661
Unit : mm Hnl
•
(0.7876 - 0 .78801
(0.78901
(0.004 - 0 .0221
(0.041
deflection
Conrod big end w idth
(2.362 ± 0 .0041
runout
(0.411
OIL PUMP ,
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140 ° F)
STANDARD
1.590 (35 /221
Above 40 kPa (0 .4 kg/cm 2 , 5 .7 psi)
Below 140 kPa ( 1.4 kg /cm2, 19.9 psi)
at 3 000 rIm in.
LIMIT
UHJ:'U"I UH,, :'U:ao,. I ~"''''UUtL'
.. . ...
Unit: mm (in)
CLUTCH
~
LIMIT
STANDARD
10 - 15
10.4 - 0 .61
2.72 - 2.88
10. 107 -0. 1131
15.8 - 16.0
10.62 - 0 .631
I
ITEM
Clutch lever pla y
Drive plate thickness
Drive plate claw width
2.42
10.0951
15.2
10.601
0. 10
(0.0041
29.5
11 . 161
Driven plate distortion
Clutch spring free length
TRANSMISSION + DRIVE CHAIN
Unit: mm (in) Except ratio
LIMIT
Gear ratios
4th
to groove
110.004-0.01
I
Shift fork groove width
•
10.0201
5.0 - 5. 1
~ c:-.-.;: ~.,-,----_ _ -;;'=- ~ +-_-",,-,1 97 •
Drive chai n
Type
10. 189 - 0 . 1931
DAIDO: 0 .1.0 . 520VC5
TAKASAGO: RK5=.20"'S"'O
= --_ _ =:::;~:=;==~
20-pitch leng th
chain slack
(12 . 57)
25 - 40
.0 - 1.61
CARBURETOR
ITEM
Carburetor type
Bore size
1.0. No
Idle r/min .
Fuel level
33 mm
I
I
·14E2
1 500 ± 100 rl min
1.5 ± 0 .5 mm
10.06 ± 0 .02 inl
14 .6 ± 1.0 mm
Float height
MainJ!!t
Main air jet
Jet needle
SPECIFICATION
E-33
E-03
MIKUNI BST33SS
10.57 ± 0 .04 inl
IM.J .I
IM.A.J .I
IJ.N .I
# 135
0 .6 mm
5CD16
-
E-28
-
--
·14E3
I
--
·14E7
-
# 135
-
5C018-3rd
11·15 DR350N/DR350SN 1'92·MODEl)
ITEM
Needle~ t
Thronle valve
Pilot jet
By-pass
Pilot outlet
I Valve seat
Staner~t
Pilot screw
Pilot a i r~ t
Throttle cable play
(pulling cable)
ITEM
SPECIFICATION
E-33
E-03
0 -5
# 115
IN .J .I
ITh.V .1
#3ry.5
IP.J .I
IB.P.I 0 .8 mm , 0 .8 mm ,
0 .8 mm
0 .8 mm
IP.O.I
IV .S.I
1.5 mm
I
IG .S.I
#37.5
IP.S.I
PRE-SET
IP.A .J .)
1.3 mm
0 .5 - 1.0 mm
10.02 - 0 .04 in l
~:02.04.
16.
E- 15. 22
17.21 .25.
I
E-2B
0 -6
~
~
~
~
#37 .5
~
~
~
~
~
I
~
#45
PRE-SET
~
~
·(2 Y. turns back)
~
~
~
~
SPECIFICATION
I
E-18
E- 24
E-39
34.94
Carburetor type
MIKUNI
BST33SS
Bore size
33 mm
1.0. No
"14EO
·14E6
"14El
"14E4
1407
Idle r/min .
1 500 ±
"1400± 50 1 500 ± ·14oo± 50
100 rlmin
rlmin
100 rlm in
rlmin
Fuel level
1.5+0.5 mil
10.06±
0 .02 inl
Float height
14.6+1 .0
mm 10 .57
:t 0 .04 in)
Main jet
IM .J .I
# 135 I
"# 130 I #135
# 130
Ma in air jet
IM.A.J .I
0 .6 mm
Jet needle
IJ .N.I 5C056-3rd 5C018-4th 5C020-3rd 5C018-4th 5C020-3rd
Need f e~t _
IN.J .I
0 -3
0 -6
0-7
0 -6
0 -7
Throttle valve
# 115
ITh.V .1
Pilot jet
IP.J.I
#42 .5
#40
#37 .5
#37.5
#40
By-pass
IB.P.) 0 .8.0.8.0.8
mm
0 .8 mm
Pilot outlet
IP.O.I
I
Valve seat
1.5 mm
2.0 mm
1.5 mm
IV.S.I
Staner~t
IG .S.I
"#45
"Pilot screw
PRE-SET
PRE-SET
PRE-SET
PRE-SET
PRE-SET
IP.S.I
(lYe turns .( 1 Y4 turns *(2 .0 turns (1 V. turns (2 .0 turns
back)
back)
back)
backl
backl
Pilot air jet
IP.A .J .)
1.35 mm
1.3 mm
"Throttle cable play
10.5-1 .0 11m
(pulling cable)
10.02 0.04 inl
.
•
•
•
Astensk
mark (* ) •tndlca tes the New N model specifications
.
~
~
-
-
~
--
-
-
-
~
~
~
~
~
~
~
-
-
~
~
~
~
-
~
~
•
~
-
~
~
.. ..
-
-
~
~
-
~
~
·Hb
ELECTRICAL
Unit: mm (in)
5°B .T.o .C. below 2 300 r/min and
30 o B.T.D .C. above 4 300 t/min
Igni tion timing
Type
N .G. K.: DPR9EA -9
Gap
10.03-0.041
Primary
0 . 1 - 1.00
Secondary
12-22 kO
capTerminal
Magneto coil resistance
voltage
More than 65 V (AC) at 5 000 r/min .
Standard
I
S.G. ___~1.::.3~2~0~at 20· C 168· FI
__:-::-:c :c:--.J---"-~~~~~-I-
WATTAGE
Unit: W
ITEM
E-02
Headlight
1.7
Asterisk mark (-) indicates the New "N"specifica tion.
------
T he others
•
----
11·17 DR350NIDR350SN r 92·MODEl)
BRAKE + WHEEL
Unit: mm (in)
ITEM
STANDARD
Brake lever play
Rear brake pedal height
Brake disc thi ckness
Front
Rear
0 - 0 .3
10 - 0 .0 11
5
10.21
+ 0 .2
3.5 10. 138 +
- 0 .0081
4 .0 + 0 .2
10. 157 + 0 .0081
Brake disc runout
Ma ster cylinder bore
Front
Rear
Master cy linder pi ston dia m.
Front
Rear
Brake caliper cylinder bore
Front
Rea r
Brake ca liper piston diam .
Front
Rear
Wheel rim runou t
2.0
10.081
2.0
10.081
0 .25
10.0101
0 .25
10.0101
Axial
Front
Rear
Tire size
Tire tread depth
Front
Rear
Front
Rear
3 .0
10. 11 81
3 .5
10. 1381
0 .30
10.0 121
12 .700- 1 2.743
10.5000 - 0.50171
12 .700 - 12 .743
10.5000 - 0 .50 171
12.657 - 12 .684
10. 4983 - 0.49941
12.657 - 12.684
10.4983 - 0 .49941
27 .000 - 27 .050
11.0630 - 1.06501
30.230-30.280
11. 1902 - 1. 19211
26.900 - 26.950
11.059 1 - 1.06 101
30. 160 - 30. 180
11 . 18 74 - 1.18821
Radial
Wheel axle runout
LIMIT
80/ 100-21 51P
110190-1861P
3 .0
10. 121
3 .0
10. 121
U"JOU" ,,-,n,,au,),, 10 .. · ............ ,
SUSPENSION
Unit: mm (in)
STANDARD
280
( 11 .01
ITEM
Front fork stroke
LIMIT
NOTE
602
(23 . 71
Front fork spring free length
'152
(6.01
Rear shock absorber gas pressure
1 000 kPa
(10 kg/em', 142 psi)
Rear shock absorber spring
'268 .2
pre-set length
(10 .61
Rear wheel travel
280
111.01
Swingarm pivot shaft runout
Front fork oil level
0 .3
(0.011
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FUEL+ OIL
I
ITEM
SPECIFICATiON
Use only unleaded gasoline of at least 87
pump octane 18..:fM method) or 91 octane or
higher rated by the research method.
Gasoline con taining MTBE (Methyl Tertiary
Butyl Etherl. less than 10% ethanol , or
less than 5% methanol with appropriate
•
cosolvents and corrosion inhibitor .s
permissible .
Fuel type
NOTE
E·03
Use only unleaded gasoline of at least 87
pump octane I
method) or 91 octane
or higher rated by the Research Method .
Gasoline used should be graded 85-95
octane or higher . An unleaded gasoline is
recommended .
9 .0 L
(2 .4 / 2.0 US/Imp gal)
B;M
Fuel tank including reserve
reserve
E-28
For the others
1.5L
(0.4/0 .3 USnmp gal)
E~ne oil"!ype
Eng ine oil capacity
SAE 10W/40, API SE or SF
1 700 ml
Change
(1.8/ 1.5 USnmp qtl
1 900 ml
Filler change
(2 .0 / 1. 7 US/Imp qtl
2 100 ml
Overhaul
(2.2/1 .8 US/I mp qtl
Fork oil # 10
Front fork oil type
Front fori< oil capacity (each legl
'569 ml
(19 .2/ 20.0 US/Imp oz)
D~ o """
fl. ,in tvn",
DOT 4
I
.. ..
11·19 OR350NIOR350SN 1'92·MOOELI
THROTTlE CABLE ADJUSTMENT (DR350SN)
(Except for Australia)
A twin t hrottle cable system is used in this motorcycle. Cable
ill is for pulling and cable @ is for returning . To adjust the cable
play . adjust the returning cable first and then adjust the
pull ing cable.
Return ing Cable Play
The returning cable adjuster ® should have 2 - 3 mm (0.08 0 .12 in ) of clearance as shown in the illustration. If the adjust-
ment is necessary, carry out the procedure below :
• Loosen the lock nut @.
• Move the adjuster @ toobta in the clearance (6. of 2 - 3 mm
10.08 - 0.12 ;nl.
• Tighten the lock nut @ securely.
Pulling Cable Play
The pulling cable play @ should be 0 .5 - 1.0 mm (0.02 0.04 in) , If the adjustment is necessary, carry out the procedure
below:
• Turn the handlebar all the way to the left.
• Loosen lock nuts (®, @l.
• Turn adjuster ill or move the adjuster @ to obtai n a cable
play of 0 .5 - i .O mm (0 .02 - 0 .04 in) .
• Tighten lock nuts (®, ® ) securely.
WARNING :
After the adjustment is completed, check that handlebar
movement does not raise the engine idle speed and that the
throttle grip returns smoothly and automatically .
STANDARD SUSPENSION SETTING
REAR
FRONT
Spring pre· load adjuster
Damping force adjuster
Spri ng set length
Damping force adjuster
3
Max. - 8
268.2 mm (10. 56 ;nl
Max . - 3/4
nnt," , B
Ir"IIIQ!!·B
II> ."
1<;"1 11I1f1-£0I L
"Q. 0~
'IOf . ,,? Q,'\ I
!itp" CM _Ito '1
,IIII' .LIIII',"
<
<
-
c J> :IJ
. cv. Zu>
.i>;-_. G)
,rrrflC!!( ! EII · CQ",
»
C'l
" :IJ
»
II>
•
1
C
n
II>
II>
Q.
II>
3:
-:cc
I
to)
(J1
tfllB _ IIII!'" lIie .1
0
!!lie
-z
L IUIIY oL
" . , . . , . , ., , , , .
en
,L
COLOR
81Kk
8u
• Blown
• GrNn
Ught blue
,. Ught grNn
0,_
•
Rod
Whltl
Yellow
INack with Whit, u.c...
BlKk wllh Y"ow trKII'
GrHn with Whit, trlcer
Gr ...... with Yillow IrICI'\'
Or.ng. with 81Kk trKII'
Orlng. with 8tue UK.,.
'0 Orlngl with GrNn IrlClr
o
Orangl with Rid IrllCll'
, WhIte wlm 8!Kk UK.,
WhIte with 8101 f r _
0'
YlIIow with INKk uac.,
., Yellow whh arlin UIC"
, YlIIow with WhIt. ule"
o
!(~I!!rc
o
,!!I Uln
00
o
0
0
o
"'!ffJ! [ . S! , L
""I+1 I Q
-
11 ·21 DR350NIDR350SN 1'92·MODEl)
CABLE ROUTING
De-comp.
'S·
5-10 mm
harness
I cable. / __- _ ,
Throttle
cable
harness
cable
cable
Right __
0-
+ leh
FOREWORD
This chapter describes service data and servicing procedures which differ 'rom those
of the DR350N/ SN ('92 -MODELJ.
Please refer to the sections 1 through 11 for details wMch are not given in this section.
NOTE:
Any differences between DR350NISN and DR350P/ SP in specificBtions and service
data are clearly indica ted w i th the asterisk marks (.).
r - - - - - - - - - - CONTENTS - - - - - - - - - SPEC/FICA TIONS , .......... , ................................................. ........ . 12- 1
DR350P ............................... ...•.... ... .... ...•............. ................... 12- 1
DR350SP ..... .. ..........................•................ .............. ................ 12- 2
SERVICE DATA ..... ................. .... ..............•••....... ............... ........ 12- 3
DR350P ... .... ........... .. ........... .... .............................................. . 12- 3
DR350SP ... ............................................................................ . 12- 11
OIL CHECK BALL ............ ................. ...... ....... ............................ . 12-19
EMISSION CONTROL CARBURETOR COMPONENTS ............... . 12-20
MAGNETO ........................ .. ............. ..... ... ................................. . 12-21
COl UNIT .... ... ....... ... .............. .. .. ... ............ .. .............................. . 12-22
REAR SHOCK ABSORBER (DR350PJ .......... .............•................. 12-23
WIRING DIAGRAM ................................................... ................. 12-24
OR350P .................. ....... .................................. .... ........ ... ........ 12-24
DR350SP ........ ........................................................................ 12-25
WIRE ROUTING ...... ....... ....... .... ............ ..... ........... .... .... ........... .. 72-26
12·1 DR35DP/SP 1'93·MDDElI
SPECIFICATIONS
DR350P
DIMENSIONS AND DRY MASS
OVlmllt lungth
OVlll811 widlh
•
O\l61all he.ght
Whcelba!sel
.
. ...
.. ... · .......- ......
.. . ..
.
• • •
GIOtmd cloluance
SaOI height
0.'0' mass
..
•
..
•
•
••
•••••
•
2 165 mm 182 .5 In)
885 mm 134.8 in!
1 250 mll'l (49.2 In)
1 440 mm (56.7 In)
3 10 mm 112. 2 In)
920 mm (36. 2 in)
1 13lc.g t2491bsJ
ENGINE
TVpe
.
..
....
EX .
_.
•
•
• • ••
...
Nurnbt!1 01 cylinder
Slfoke
- ..
••
••
•
•
•
•
•• •
Piston dIsplacement
..
Ai, cleane.
.. . .. . ..
·
..
..
•
...
.. ... ... . . ...
•
. . .. ..
•
SUHlcr system •..••
•
•
•
•
•
T RAN SMISSION
Clulch
T'ansmlss,on
.
Goal',.,." gaHen>
• • • • • • • •
•
•
•
.... . . .
lId ..
51h •
Top •..
Fmal redU Ction IlIlio •
•
•
•
•
•
•
..
·
- .. .
· , ..., . ... . ..
.
•
..
...
CHASSIS
FlOnl luspens.(ltl .
•
..
•
Rear suspenSIOn
..
.. .
•
Front suspension stroke
Rcal wheul !rlvel
Castel .
· ..
T r811 . •.
Stflflring angle
ELECTRICA L
Ignillon IVpe
Ign.llon tMTIlog
~alk plug
GenerDto.
Headlight
Ta,llight
•
•
.'"""
Fl on t brake
Real brake , .
Front tire size
Real III' sile
•
•
· .
.. .
..
PumalY redUCllon ,all()
Geel lallOS, Low
Turning ra.dlus
• • • • •
•
•
•• • •
lubnclIl;on svstem ...
Olive c hain
•
•
•••
. ...,....... .
ComprCISIon ' 8ltO .
Cu.bureI O'
. ... ..
.. .. . ...
•
Valve clearance, IN .
•
•
•
•
•
• • • ••
••
·
•
•
•
• •
•
• • • •
••
. . •
• •
•
. ". . .
•••
..
.. . ...
· . . .. ..
·.. .. ..
•
••
••
...
· .. . . . .
•
• •
• • • • • • •
.
.".....
..
"
•••••••••
•
• •• •
CAPACITIES
Fuel tank Including raserv. ,
.•..• , .• .••. • . ..
ReSO lve . . . . . . .
. . • • ••.••. " • , .•.
Engine 011. oil change . .
. . , , .• ,
.•.......
with lille. chan.ge ...... .. . ... .. ... .
ovelhaul
. .. .• •
Front fork oil leach leg!
. .
••
. .
FOUI ' SHoke, air-cooled with SACS, OHC
0 .05 - 0 . 10 mm 10.002 - 0 .004 11"1'
0 . 10- 0 , 15 mm 10.004-0.006 Inl
1
79.0 mm 13. 110 inl
71.2 mm 12. 803 inl
349 cm ' 121.3 cu. inl
9. 5 : 1
MIKUNI TM 33SS, singl e
Polyurethane foam element
Prlmaly kick
Dry sump
Wet multi·plate type
a ' speed constant mesh
I ·down. 5·up
2.818 162/22)
2.416129/ 121
1 733 126115)
1.333 (2 4118)
1. II I (20118!
0 .962120/ 211
0 .826 (19 / 23)
3 .357 (47114)
TAKA5AGO RK 520S0 01 DAIDO DI0520VC . S,
110 links
link
mm
mm
30'
Coil spring, oil damped, ,pIing preload lully adJuuablo,
damping lorce adjustable
cod spring, gas /oil damped. Iprlng p.eload fully adjusnlblo.
damping force adjus table
.Olnl
.0 inl
1
mm f4 .65 Inl
45" fligh t & leltl
2. 211'117. 2 It)
Olsc blake, hydraulically opl;t18ted
Disc brak,e , hydraulically oporated
80/ 100·21 5 1M , tubl;t
110(1OQ.18 64M. lube
SUZUKI " PEl"
- 30" H .D.C. above 4 300 r(min
NGK DPR9EA·9 01 NO X27EPR· U9
Flywheel magneto
12V SSW
12V SW
9 . 5 L 12.512. 1 USfimp. gall
1.8 L (0. 5/0.4 US /lmp. gall
1700 ml 11 .811.5 USfimp. QtJ
1900 11'11 12 .011 . 7 USfimp. qll
2 100 mI12 .21 1.8 USfimp. QtJ
58611'11119. 8 /20.6 U5f1 mp. ozl
Allellik malk 1" 1 Indicates tile New " P" model speCifICation.
OR350PISP ('93·MOOElJ 12·2
DR350SP
DIMENSIONS AND DRV MASS
Q V(!fuU
length
Overall width
OV&fall height
Wheelbase
Ground clearance
Seal he'g ht
Dry mass _ .
· ..
••
· .•..• . .....
.
•
• • •
•
- ....
•
- .. . ..
....
•
•
ENG INE
. ... . . - .. •
..
Type
• • • ___ _
Valve clearance, IN
EX •
""'-
•
5 1roke
.
Piston dIsplacement .
• •
•
Comp!'euion ,allo
C.r burOlor .. .
Ail cleaner •.
S tllrlel system
• •
.
-.•• ...... .
•••
•
• • • • • • •
•
- .. ...
•
• ••••
••• •
•••
••
•
•
·.
•
.
l ubricel'on svslem
TRANSMISSION
Ckm;:h
.
·..
Number 01 c ylind e r
• • • ••
•••••
•
•••••
• • ••
..
••
••
- . ...
· .. . .
·. -.. .
·
TI81'1sm ;55'011 •
Geursh i lt p ettern ..
. .....
. . ..... .
• • • • · . - .. .. ... .
.. .....
·.
. . . ..
·. . . . .
..
..
......
.
•
· . .... . .
PrImary reduction raho
Gear 18tros. low ..
·
•
''''' .
3.,
"h
5th .
Top
FInal reGuChon ratio
Drive cha,n .. .
·
· ._. ...
CHASSIS
Fro nl suspension
· . .. ..
· ...
Rear suspenSIOn _
Front suspenSion s to oke
Real wheel u ave! .
Cas tel
TraIl
Sleellng angle . _ _
Turning rad,us
• • ••
Fron t brake , ..
•
•
Rear blake , .
, .
F,onl Ille size .
Rear lIIe sile!
.. .
•
· . . .. .
.. · . . .
•
•
..
•
••
.. .....
..
.
......
- .. . , .... · . . , . . .
...
.. ...
• • • ••
•
•
•••
ELECTRICAL
IgnItion type ... .
•
•
Ignilion timIng
•
•
•
• •
•
Spa" plug
•
•
Sanery
.
·..
• •
Generator . _ .. . . . ,
...
·
Fuse . . .......
•
Headlight . . .
........ , . . .• .., .•...•..
Position light _..... ..•.••..•.•..•. • •••. , .
.
..
......... .
.....
Turn signal lighl . .
_. . • • . . . . . . .. . .•. , ..
T.,I/8raka Irghl •.• .••.• . . • . • .
.•.... , , .. .
, .• , ..... , ....... .
License plaIa light . .
Speedometer light _
.. .
. .. . .. • .. . .
_ .. .•.. . .
TlK;homet8f light. ...
Neutral Ind,ca tor light " , •. " .••.• • .••• . .••.. .
• ..... .
HIgh beam indica tor ligh t .
Turn IIIgnal Ifld,caux ligh t . .
•
. .. . ..
R'"Ullve ..
. ...
. For Fmland. Gellnany and Sweden
. For Italy
Others
Four ·stroke. a;l -(:ool ed with SACS, OHC
0 .05 - 0 . 10 mm 10002 - 0004 in)
0 . 10- 0 . 15 mOl 10.004 - 0 006 in)
1
79.0 mm 13. 110 in,
7 1.2 mm 12. 803 in)
349 em' 121 . 3 cu. In)
9.5 : I
MIKUNI 85T33. SIngle
Polyurathane l oam element
Primary kick
Dry somp
Wet multi·plate tv pe
6·speed cons tant mesh
l ·down. 5·up
2.8 18162/ 221
2.4 16 12911 21
1.7331 26/15)
1.333 124/1S)
1.111 (20118)
0 .952 120/ 211
0 .826 119/231
3 .071 14311 4 1
TAKA5AGO RK520S0 or DAtoO OI0520VC5.
IDS Unks
Telescopic , coil Spllng. 01 . damped . spring preload lully odluStabto.
compression damping lorca ad;ustable
LlIlk type. coil spring. gas/oil damped. spring preload fuliV adiu, l lIbllt,
compre ssion damp'"g force IKIjoslllble
2S0 mm (11 .011'11
280 mm 111 .0 In)
620 30'
115 mm (4 .53 Inl
45 0 I'ighl & lefl l
2 .3 m 17 .5 h i
Disc brake. hvdraullcaliV operated
Di sc br ake. hvdraulicall v ope.aled
801100· 21 SIP
110/90· 186IP
SUZUKI " Pfl"
30 S.T.O.C. above 4300 I lm in
....... . NGK
OPR9EA· 9 or NIPPONOENSO X27EPR·U9
..
..........
CAPA CITIES
Fual tank, inch,~lng raserve!
2335 mm 19 1.9 ,nl
2 240 mm 188 .2 inl .
2 235 mm 18S.0 in.
S85 mOl 13 4 .8 In)
1 24 5 mm 149 .0 in,
I 440 mm 156. 7 inl
290mm 111.4 in,
900 mm 135.0 in,
118k9 1260lbs,
· . ..
... .... ..
·. , . , , .. ... . .. .
0
12V 10 .S kC (3Ahll1 OHR
Three·phase A .C. generalor
15A
12V 60/55W
12V 3.4W .•.. , For U.K.
12V 4W . . . . . . Olhers
12V 21W
12V5I2 1W
12V 5W
12V I. 7W (x 2 pes )
12V 3W
12V 1. 7W
12V 1. 7W
12V 1.7W
9 ,0 L 12. 412 .0 USllmp gat). , . Olher5
8 .0 L 12. 1fl .S USJlmp gall ,. Fa. Calolorl'll& (U. S.A .I
' 2.0 L 10. 510.4 USllmp gal)
12·3 DR350PISP 1'93·MODELI
SERVICE DATA
DR350P
VALVE + GUIDE
Unit: mm lin)
ITEM
Valve diam .
IN.
EX.
Valve lift
IN.
EX .
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
cleara nce
IN .
EX.
Valve guide 1.0 .
Valve stem 0 .0 .
IN . & EX .
IN .
EX .
Valve stem runout
Va lve head thickness
Va lve stem end length
Va lve seat width
Va lve head radial runout
Valve spring free length
liN . & EX .I
STANDARD
30.6
11.201
27.0
11.061
8.0
10,311
8.0
10.311
0 .05 - 0 . 10
10.002 - 0.0041
0 . 10 - 0.15
10.004 - 0.0061
0.010 - 0.037
10.0004 - 0.00151
0.030 - 0.057
10.0012 - 0 .00221
5.000 - 5.012
10. 1969- 0 . 19731
4 .975 - 4 .990
10.1959 - 0 . 19651
4 .955 - 4 .970
10. 1951 - 0 . 19 571
IN . & EX.
IN . & EX.
0 .9 - 1. 1
10.035 - 0.0431
0 .03
10.00 11
35.0
11 .381
37.8
11 .491
IN. & EX.
INNER
OUTER
Valve spring tension (IN . & EX .)
INNER
OUTER
0.35
10.0141
0.35
10.0141
0 .05
10.0021
0 .5
10.021
1.8
10.071
IN . & EX .
IN . & EX .
LIMIT
5.3-6.5 kg
111.7 - 14.3Ibsl
at len th 28.0 mm (1.10 in)
13. 1 - 15. 1 kg
128.9 - 33.3Ibsl
at length 31 .5 mm (1.24 in)
OR350PISP 1'93·MOOELI 12·4
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
Unit: mm (in)
1
STANDARD
IN .
EX.
Camshaft journal oil clearance
Right side
Left side
Camshaft journal holder 1.0 .
Right side
Left side
Camshaft journal 0.0.
Right side
Left side
33.430 - 33 .470
11.3161 - 1.31771
33.460 - 33. 500
11.3173 - 1.31891
0.032 - 0 .066
10.0013 - 0.00261
0.028 - 0.059
10.00 11 - 0 .00231
22.012 - 22.025
10.8666 - 0.86711
17 .512 - 17.525
10.6894 - 0 .69001
21.959 - 21.980
10.8645 - 0 .86541
17.466 - 17.484
10.6876 - 0. 68831
Camshaft runout
0.10
10.0041
128.9
15.071
Cam chain 20~pitch length
Rocker arm 1.0.
Rocker arm shaft 0 .0 .
LIMIT
33. 13
11 . 30431
33. 16
11 . 30551
0.150
10.00591
0.150
10.00591
IN. & EX .
IN . & EX .
12.000 - 12 .018
10.4 724 - 0.47311
11 .973 - 11.984
10.4714 - 0.47181
Cylinder head distortion
0.05
10.0021
0 .05
(0.0021
Cylinder head cover distortion
De ~co mpressjon lever play
0- 2
(0 - 0.081
CYLINDER + PISTON + PISTON RING
Unit: mm Hn)
ITEM
STANDARD
LIMIT
Piston to cylinder clearance
0.055 - 0.065
(0.0022 - 0.00261
79.000 - 79.015
(3.1102 - 3.11081
78.940 - 78 . 955
(3.1079 - 3.10851
0.120
(0.00471
79.075
(3.11321
Cylinder bore
Piston diam.
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
151
R
2nd
R
151
-
,
10.2
10.401
11 . 1
Approx . (0.441
0.15 - 0.30
(0 .006 - 0.0121
0.35 - 0,50
Approx .
78.880
(3.10551
0 .05
10.0021
8.2
(0.321
8.9
10.351
0 .70
(0.0281
0.70
12·5 oR350PISP ('93·MooELI
ITEM
STANDARD
Piston ring to groove clearance
1st
2nd
Piston ri ng groove w idth
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O. D.
..J.
1.01 - 1.03
10.04 0 - 0 .0 4 11
1.0 1 - 1.03
10.040-0.0411
2 .0 1 - 2.03
10.079 - 0 .0801
0.97 - 0.99
10.038 - 0 .0391
0.97 - 0.99
10.038 - 0.0391
20.002 - 20.008
10.7875 - 0 .78771
19.996 - 20.000
10.7872 - 0.78741
CONROO + CRANKSHAFT + BALANCER
ITEM
Cored small end I.D .
Conrad big end width
Crank web to web width
20.030
10.78861
19.980
10.78661
Unit: mm (inl
STANDARD
LIMIT
20.006 - 20.014
10.7876 - 0.78801
20.040
10.78901
3 .0
10 . 121
1.0
10.041
Conrad deflection
Conrad big end side clearance
LIMIT
0.180
10.0071
0 . 150
10.0061
0 .1 0 - 0 .55
10.004 - 0 .0221
21 .95 -2 2.00
10.864 - 0 .8661
60.0 ± 0 .1
12.362 ± 0 .004)
0.05
10.002)
10.3
10.4 1)
Crankshaft runcut
Balancer spring free length
Oil PUMP
ITEM
STANDARD
Oil pump reduction ratio
Oi l pressure (at GOoe , 140 0 F)
Above 40 kPa 10.4 kg /cm2, 5.7 psi}
1.590135/22)
Below 14 0 kPa 11 .4 kg/em', 19.9 psil
a t 3 000 rI m in.
LIMIT
DR35DPISP ('93·MDDEl) 12·6
CLUTCH
Unit: mm (in)
10 - 15
Clutch lever play
cc:-:: -..,-,-.,------ _ _ _ _ _~:;_4-0. 6) - - - - - l - 10. 107 - 0 . 113)
10.095:-')_ -1
plate claw
1 .
Driven plate distortion
10.60)
0 . 10
11 . 16)
TRANSMISSION + ORIVE CHAIN
Unit: mm (in) Except ratio
li=c
to groove clearan~c:eel-----=Oo~.
Shift fork groove width
- 0 .012)
5 .0 - 5. 1
No . 1
10.020)
~~~hidkrWs,;---~~&~NG°N,·t321--_1~0_.1~97 -0 . 2~0~0)~--4------1
No . . No. 2
nl
& No .3
Drive chain
0 .1.0.
. 189 - 0 . 193)
or RK520S0
20-pitch length
i slack
25
1.0 - 1.
12·) DR350PISP 1'93·MODELI
CARBURETOR
mm
.
Throttle cable
mm
0 .5 - 1.0 mm 10.02-0.04 inl
ca ble)
ELECTRICAL
Unit: mm (in)
ITEM
SPECIFICATION
*30 B.T .D.C. above 4 300 rl min
NO .: X27EPR·U9
Type
N.G.K .: OPR9EA· 9
0 .8 - 0 .9
Gap
10.03 - 0 .041
Ove r 8 (0. 3) at 1 atm.
Ignition timing
Spark plug
I Spark performance
Ign ition coil resistance
Magneto coil resistance
Primary
0 . 1 - 1.0n
Secondary
12 - 22 kO
Lighti'.!a.
0 . 1 - 1.50
·350 - 6500
·350 - 7000
·350 - 7000
Power source
Pick -up No . 1
Pick -up No. 2
Magneto no-load voltage
(when engine is cold)
.
More than 40 V lAC) at 5 000 r/min .
12 - 14 V a t 5000 r/min .
Regulated voltage
•
NOTE
D
.
Asterisk mark (.) indicates the New "P" model specifications .
I
I
Terminal Ground
Plug cap Terminal
V- B
W - Br
G - BI
Y - Gr
V- B
DR35DPISP ('93·MDDEl) 12·8
WATTAGE
Unit'• W
SPECIFICATION
ITEM
Headlight
Taillight
55
5
BRAKE + WHEEL
Un it: mm (in)
ITEM
STANDARD
Brake leve r play
Rear brake pedal height
Brake di sc thickness
Front
Rea r
0 - 0 .3
10 - 0.0 11
5
10.21
3.5 -+ 0.2
+ 0 .0081
10.138 4 .0 +
- 0.2
+ 0.0081
10. 157 -
Brake dis c runout
Master cylinder bore
Front
Rea r
Master cylinder piston diam .
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam .
Front
Rear
W heel rim runout
2.0
10.081
2.0
10.081
0 .25
10.0101
0.25
10.0101
Axial
Front
Rear
Tire size
Front
Rear
Tire tread depth
Front
Rear
3.0
10.1 181
3.5
10. 1381
0.30
10.0 121
1 1.000- 11.0 4 3
10.433 1 - 0 .43481
12.700 - 12.743
10.5000 - 0 .50171
10.957 - 10.984
10.431 4 -0. 43241
12 .657 - 12.684
10.4983 - 0.49941
27.000 - 2 7.050
11.0630 - 1.06501
27.000 - 27.050
11.0630 - 1.06501
26.900 - 26.950
11 .0591 - 1.06 101
26.900 - 26.950
11.059 1 - 1.061 01
Radial
Wheel axle runout
LIMIT
80/100-21 51M
110/1 00-1864M
4 .0
10. 161
4 .0
10. 161
12·9 DR350P/SP (, 93·MODEl)
SUSPENSION
Unit: mm (in)
ITEM
I
Front fork stroke
STANDARD
280
111 .01
LIMIT
I
Front fork spring free length
608
123.91
145
15.71
Rear shock absorber gas pressure
1 000 kPa
(10 kg /cm 2, 142 psi )
Front fork oil leve l
Rea r shock absorber spring
pre· se t length
Rea r w heel travel
-268 .2
11 0 .6 1
280
111 .0 1
0.3
10.011
Swing arm pi vot shaft runout
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
kg /cm 2
p SI
100
100
1 .0
1.0
14
14
A steri sk mark ( - ) indica tes th e New " P" mod el spe cif ic ation .
I
NOTE
I
OR350PISP !'93·MOO Ell 12·10
FUEL + OIL
type
at
pump octane (
or 91 octane or
higher fated by
research method.
Gasoline con taining MTBE (Methyl Tertiary
Buty l Ether). less than 10% ethanol, or
less th an 5% methanol with appropriate
cosotve nt s and corro sio n inh ibitor is
For U.S.A .
I
Use only
octane
For Canada
rated
gasoline is
reserve
12 . 512 . 1 USlimp
1,
reserve
L
10.510.4
Change
Filter change
Overhaul
Front
Front fork oil capacity (each leg)
10
For the others
12·11 DR35DPISP {'93·MDDELI
DR350SP
VALVE + GUIDE
Unit : mm (in)
ITEM
Valve diam .
IN.
EX .
Valve lift
IN .
EX .
Valve clearance (when cold)
IN.
EX .
Valve guide to valve stem
clearance
IN .
EX .
Valve guide LD .
Valve stem 0 .0 .
IN. & EX .
IN .
EX .
Valve stem runout
Valve head thickness
Valve stem end leng th
Valve seat width
Valve head radi al runout
Va lve spring free length
(IN . & EX .I
STANDARD
30.6
11.201
27.0
11.061
8.0
10.311
8.0
10.311
0.05 - 0 . 10
10.002 - 0 .0041
0.10 - 0 . 15
10.0(14 - 0 .0061
0.010 - 0 .037
10.0004 -0.00 151
0 .030 - 0 .057
10.0012 - 0.00221
5.000 - 5.012
10. 1969 - 0.19731
4.975 - 4 .990
10.1959 -0. 1 9651
4.955 - 4 .970
10. 1951 - 0 . 19571
IN. & EX.
IN . & EX.
0 .03
10.0011
35.0
11.381
37 .8
11 .491
INNER
OUTER
INNER
OUTER
0 .35
10.0141
0.35
10.0141
0.9 - 1. 1
10.035 - 0 .0431
IN . & EX .
Valve spring tension (IN . & EX.)
LIMIT
0 .05
10.0021
0 .5
10.021
1.8
10.071
IN . & EX.
IN . & EX .
I
5.3 - 6.5 kg
111.7-14.3Ibsl
at length 28.0 mm (1 . 10 in)
13. 1 - 15. 1 kg
128.9-33.3 Ibsl
at length 31 .5 mm (1.24 in)
DR350PISP ('93·MOOELJ 12·12
CAMSHAFT + CYLINDER HEAD
I
ITEM
Cam height
Unit: mm (in)
I
STANDARD
IN .
EX.
Cam shaft jou rnal oil clearance
Right side
Left side
Camshaft journal holder 1.0 .
Right side
Left side
Cam sh aft journal 0 .0 .
Right side
Left side
LIMIT
33.430 - 33.470
11 .3161 - 1.3177)
33.460 - 33.500
11 .3173 - 1.3189)
0 .032 - 0 .066
10.0013 - 0 .0026)
0 .028 - 0 .059
10.0011 - 0 .00231
22.012 - 22.025
10.8666 - 0 .86711
17.512 - 17 .525
10.6894 - 0 .69001
21 .959 - 21 .980
10.8645 - 0 .86541
17.466 - 17.484
10.6876 - 0 .68831
0 . 10
10.004)
128.9
15.07)
Ca msh aft runout
Cam chain 20 -pitc h length
Rocke r arm 1.0.
Rocker arm shaft 0 .0 .
IN . & EX.
IN . & EX .
12.000 - 12 .018
10.4 724 - 0.4 731 1
11 .973 - 11 .984
10.4714 - 0 .47181
0.05
10.0021
0 .05
10.0021
Cy lind er head distortion
Cylind er head cover di stortion
0- 2
10 - 0 .08 )
De-co mpression lever play
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
Cy lind er bore
Pist on diam .
Unit: mrn (i n)
STANDARD
LIMIT
0 .055 - 0 .065
10.0022 - 0 .00261
79.000 - 79.015
13. 1102 - 3 . 1108)
78.940 - 78.955
13. 1079 - 3 . 10851
0 . 120
10 .00471
79.075
13. 11321
Measure at 15 mm (0.6 inJ from the skirt end.
Cylind e r dis to rtion
Piston ring free end gap
Pist on ring end gap
33. 13
11.30431
33. 16
11 .30551
0 . 150
10.00591
0 . 150
10.00591
1st
R
2nd
R
1s t
? nrl
10.2
10.401
11.1
Appro x . 10.44)
0 . 15 - 0 .30
10.006 - 0 .012 )
0 .35 - 0.... .50
... ... ,
Approx .
....... ..
~
78.880
13. 1055)
0 .05
10.002)
8 .2
10.32)
8 .9
10 .35)
0 .70
10.028)
0 .70
, ... ... . . . . ,
1Z·13 DR350PISP 1'93·MODEl)
to groove
lst
10.0071
2nd
groove
1st
(0.040 - 0 .0411
2nd
Oit
thi ckness
10.079 - 0 .0801
1st
2nd
•
Piston pin 0 .0 .
10.7875 - 0 .78771
19.996 - 20.000
10 .7872 - 0 . 78741
CONROO + CRANKSHAFT + BALANCER
10.78861
19.980
10.78661
Unit: mm (in)
10.7876 - 0 .78801
10.78901
3 .0
10. 12:::'_ _
10.004 - 0 .0221
10.041
Co nrad deflection
1
big end width
12 .362 ± 0 .0041
Crank shaft runout
-
10.3
10.4 1 I
STANDARD
LIMIT
OIL PUMP
ITEM
Oil pUl12E....reduction ratio
Oil pressure (at 60 a C, 140 D F)
1.590135122)
Above 40 kPa (0 .4 kg/cm2, 5 .7 psi)
Below 140 kPa ( 1.4 kg /cm 2 , 19.9 psi)
at 3 000 r/min .
DR350PISP ('93·MODELI 12·14
CLUTCH
Unit: mm (in )
STANDARD
10 - 15
IOA - 0 .61
2 .72 - 2.88
10.107 - 0 . 1 131
15.8 - 16.0
10.62 - 0 .631
ITEM
Clutch lever play
Drive plate thickness
Drive plate claw w idth
LIMIT
2A2
10.0951
15. 2
10 .60)
0 . 10
10.0041
29.5
11. 161
Driven plate distortion
Clutch spring free length
TRANSMISSION + DRIVE CHAIN
Unit: mm (in) Ex cept ratio
,.
ratio
i
Gea r ratios
to groo ve
Shift fork groove width
No. 1,No. 2
& No. 3
•
& No .3
--"
Orive chain
10 .004 - 0 .0121
5 .0 - 5. 1
10. 197 - 0.:.0'20-=0,-=
0,1__
4.8
.
10.189- 0 .193)
0 .1.
10.020)
+ ____--j
20 -pitch leng th
112.57)
- 40
11 .0 - 1.61
CARBURETOR
ITEM
Carburetor type
Bore size
1.0 . No
Idle r/min .
Floa t height
M ainJ!!t
M ain air jet
Jet needle
E·03
BST33SS
33 mm
"14E9
1 500 ± 100 r/m in
, 4 .6 ± 1.0 mm
10.57 ± 0 .04 inl
IM .J .)
"# 12'7.5
0 . 6 mm
IM.A.J .I
IJ .N.I
5CD16
SPECIFICATION
E-33
E·28
· 14EC
·14EF
'-
*#1 27.5
--
--
Asterisk mark (.J indicates the New " P" model specifications.
--
'5CD56-4th
12·15 oR350PISP ('93·MooELI
ITEM
E· 28
,Pilo t '~-------------c~~-+~~-"~~~----r-------~
---------+----~#~~c----(B ,P.) 0 .8 mm , 0 .8 mm ,
By-pass
0 .8 mm
mm
PRE·SET
mm
0 .5 - 1.0 mrn
- 0 .04 in)
SPECIFICATION
I
E-02 ,04 ,
17, 21 ,25,
34, 94
BST33SS
ITEM
Ca rburetor type
Bore size
33 mm
LD . No
Idle r/min .
14EO
1 500+
100 rlmin
14.6± 1.0
mm (0.57
+ 0 .04 in )
# 135
Float height
M ain jet
Main air jet
Jet need le
Needle jet
Throttle valve
Pilot jet
By -pass
(M .J .)
(MAJ.)
(J.N. )
(N .J.)
(Th .V .)
(P .J.)
(B .P.)
0 .6 mm
5CD56-3rd
0 -3
# 115
#42 . 5
0.8,0. 8 ,0 .8
mm
Pilot outlet
Va lve seat
Starter jet
Pilot screw
(P.O .)
(V .S. )
(G.S.)
(P.S.)
0 .8 mm
1. 5 mm
E· 15,22
E-2 4
E-3 9
~
~
~
~
~
~
·14EA
'14EE
~
~
~
~
*#127 . 5
~
'5CD56-4th
-r
·0-5
~
<1#37 . 5
~
Thro ttl e cable play
(pulling cable )
(P .A .J .)
rlmin
-
, ~
, ~
. ~
,-
-
,
~
-
~
"0-6
~
-
'-
~
~
'-
*0.9 mm
-
#45
PRE-SET
*#35
, ~
,~
(1 Va turns
, ~
'-
*(2 Ve turns
back)
1.3 mm
*1 .2 mm
,~
0.5 - 1.0 mm
(0 .02 0.04 in)
~
PRE-SET
bac k)
Pilot air jet
·,4ED
1400+50
1.35 mm
-
Asteri sk mark (. ) indi ca te s the New " P" model specifica tions.
E-02: U .K. E-04: France E- 15 : Finl and E- 17 : Sweden E- 21 : Belgium E- 2 2: Germ any
E- 24 : Au stralia E- 25 : Netherlands E-34 : Italy E-39:Au stria E-94: Barbados
~
DR350PISP 1'93·MDDEl) 12·16
ELECTRICAL
Unit: rnm (in)
:;------,----,
Type
_ _ _ _-j-_-'.N::.G
" '.K.: DPA:'SE
-'-A_,-'S_--t_ _ _ __
Gap
(0.03 - 0 .041
( Ground
0 . 1 - 1.011
Primary
Plug cap ...,-,,--_ _-,,----,_ _ _ _ _ - s,"'e,-CO
_"_d" a_rv
_ +-_ _ _"".,2,--2
..,2--=-k..,I1,--____--,Tc:ermina",I__
Magneto coil resistance
Magneto no-load voltage
(when
.
More than-60 V lAC) at 5 000 r/min.
:-:'-'-'---'-'---
•
I
Battery
v- v
.
Type designation f - - - - - - -
1.320 at 20 ° C (68°F)
S.G.
WATTAGE
Unit: W
ITEM
5
---
-
Asterisk mark (.) indicates the New lOp" model speci fications.
---,-
12·11 DR350P/SP ('93·MODELI
BRAKE + WHEEL
ITEM
Unit: mm (in)
STANDARD
Brake lever play
Rear brake pedal heigh t
Brake disc thickness
Front
Rear
LIMIT
0 - 0.3
10 - 0.0 11
5
10.21
3.5 + 0.2
10. 138 + 0.0081
4.0 +
- 0.2
10. 157 + 0 .0081
3 .0
10. 11 81
3.5
10. 1381
0.30
10.012 I
Brake disc runou t
Maste r cylinder bore
Fro nt
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Front
Rea r
Brake caliper piston diam .
Fron t
Rear
Wheel rim runout
12.700 - 12.743
10.5000 - 0.50 171
12.700 - 1 2.743
10.5000 - 0.50 171
12.657 - 1 2.68 4
10.4 983 - 0 .49941
12.657 - 12.684
10.4983- 0 .49941
27.000 - 27.050
11.0630- 1.06501
30.230 - 30.280
11. 1902 - 1. 192 11
26.900 - 26. 9 50
11.059 1 - 1.06 101
30. 160 - 30. 180
11. 1874 - 1. 18821
2.0
10.081
2.0
10.081
0 .25
10.0101
0.25
(0.0101
Ax ial
Radial
Wheel axle runout
Fro nt
Rear
T ire size
Tire tread depth
Front
Rear
Front
Rea r
+
80/ 100-2 1 5 1P
1 10 /90-186 1P
3.0
10. 1 21
3.0
10. 121
DRJ5DP/SP 1'9J·MODELI 12·"
SUSPENSION
Unit: mm lin)
+
ITEM
Front fork stroke
STANDARD
LIMIT
280
111.01
J
NOTE
602
123.71
Front fork spring free length
152
16.01
Rear shock absorber gas pressure
1 000 kPa
110 kg/em', 142 psil
Rear shock abso rber spring
268. 2
pre-se t length
110.61
Rear wheel travel
280
111.01
Front fork oil level
0 .3
10.011
Swing arm pivot shaft funout
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
L
SOLO RIDING
kPa ~cm2 pSI•
DUAL RIDING
kPa ~cm2 pSI
150
150
150
175
1.50
1.50
22
22
1.50
1.75
22
25
FUEL+OIL
NOTE
SPECIFICATION
I
I
Use only unleaded gasoline of at least 87
pump octane
method) or 91 octane or
higher rated by th e resea rch method.
Gasoline con tain ing MTBE (Methyl Tert iary
For U .S. A .
Butyl Ether). less th an 10 % ethanol. or
less than 5% methanol wi th appropriate
•
coso lve nts and co rrosion inhibitor IS
permissible .
Use only unleaded gasoline of at feast 87
pump octane (~ method) or 9 1 octane
For Canada
or hi her rated by the Research Method.
Gasoline used should be graded 85-95
octane or higher. An unl eaded gasoline is For the oth ers
recommended.
For Ca lifornia
Fuel tank including reserve
8 .0 L
12. 1/ 1.8 US/ Imp gall
IU .S.A.)
9 .0 L
For the others
12 .4/2.0 US/Imp gall
·2.0 L
reserve
10. 5/0.4 US~mp gal)
SAE 10W/40, API SE or SF
E~ne oil type
1 700 ml
Eng ine oil capaci ty
Change
11 .8 / 1.5 US/Imp QtI
1 900 ml
Filter change
12.0 / 1. 7 US/Imp QtI
2100 ml
Overhaul
12.2/ 1.8 US/Imp QtI
Fork oit # 10
Front fork oil type
Front fork oil capacity leach leg)
569 ml
ITEM
Fuel type
IBfM
1 1n "11"1"" I I CIt _ _ _ _ I
12·19 DR35DPISP ('93·MDDELI
OIL CHECK BALL
REMOVAL
•
•
•
•
•
•
Drain engine oil.
Remove the rear brake m aster c ylind er bolt s.
Remove the clutch cable bra cket bolts.
Remov e the oil pipe b olt on the c lutc h cove r.
Remove the kic k starter lever.
Remove the clutch cover .
• Rem ove the oil check ball
the bushing ®.
<D and spring ® by rem oving
REASSEMBLY
Reassemble the spring @. oil c heck ball CD and bu shing @
to the clutch cover @) as sho wn in the illu strat ion .
CAUTION :
When fitting the bushing ® to the clutch cover. face the
rubber part of bushing to the outside.
DR35DPISP ('93·MDDEl) 12·20
EMISSION CONTROL CARBURETOR COMPONENTS
DR350S motorcycles are equipped with precision , manufactured carbu retors for emission level control. 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 repl aced by standard 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 needle 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 possible for the best possible performance and durability.
Conventional Figures Used
on Standard Tolerance Jet
Components
1 2 3 4 5 6 7 8 9 0
Emission Type Figures
Used On Close Tolerance
Jet Components
I
2 :3 if 5 5
'7 B :3 0
The carburetor specification for the emission-controlled DR350S are as follows .
Carburetor
1.0 . No.
14EC
(California model)
14E9
(Other state models)
Main
Jet
Needle
Jet
Jet
Needle
Pilot
Jet
Pilot
Screw
# Jc~.5
D· G
5CD16
#3 ~.5
PRE-SET
DO NOT
ADJUST
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 , interferring 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 carburetors the Suzuki dealer should restore the carburetors to their original condition or if unable to effect repairs , contact the distributors representative for further technical information and assistance.
12·21 DR350P/SP /,93·MDDEl)
MAGNETO
MAGNETO COIL
• Remove the frame cove rs and sea t.
• Disconnect the magne to lead wires .
Measure the resistance between the lead wires with a pocket
tester as shown in the illustration .
09900-25002 : Pocket te s ter
M agneto coil resistan ce (OR350PI
lighting coil : 0 . 1 -1 . 5 n (Y - B)
Power source coil : 350 - 650 n (W - BrI
Pick -up coil No .1 : 350 - 700 n (G - 81)
Pic k-up coil No .2 : 350 - 100 0 IY - Grl
DA3S0P
Magnet o coil re sistan ce (DR350SP)
Charging c oil : 0 . ' - 1.5 n IV - VI
Power s ource coil : 350 - 650 {} (W - Brl
Pi ck -up coil No.1 : 350 - 700 n (G - 811
Pi ck -up coil No.2: 350 - 700 {} (Y - Grl
WIRE COLOR
B : Blac k
Gr : Gray
BI : Blue
W : White
Br : Bro wn
Y •• Yellow
G : Green
OR350SP
k·u,. coil No. 1
Pick-up coli
wire
Magneto
wire
ne,o S t8tOl
DR350PISP ('93·MDDElI 12·22
COl UNIT
• Remove the frame covers and seat.
• Disconnect the COl unit lead wires .
Check the continuity and measure the resistance values wi th
a pocket tester.
09900· 25002: Pocket tes ter
Unit: kfl
DR350P
WIRE COLOR
81
• Blue
Br
G
Gr
W
Y
eM
B/Y
BUB
BI/R
GIR
WIBJ
W/A
DR350SP
; B,own
: Green
: Gray
. White
: Yello w
: Black with While tfacef
: Black with Yellow IrBcer
: Blue with Black uace,
: Blue with Red HeeD'
: Green with Red tr&eel
: White with Blue 'facel
: White with Red If,cer
kO
•
•
NOTE:
As capacitors. diodes, etc. are used inside this COl unit, the resistance values will detfer when an
ohmmeter other than SUZUKI pocket tes ter is used.
NOTE:
Remove the spark plug and place the spark plug on the cylinder head cover kick the engine and check
the sparks 01 the spark plug. If no sparking a t spark plug gap, replace the COl unit or inspect the
magneto coils, ignition coils and spark plug. If the magneto coils, ignition coils and spark plug checked
are correct, the COl unit may be faulty. replace the COl unit with 8 new one.
12·23 OR350P/SP 1'93·MOOEU
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)
09910·6061' : Universal clamp wrench
CAUTION :
Ahar adjusting the pre-load. tighte n the spring adjuster lock
ring securely .
SETTING TABLE
Spring length
STO : 268. 2 mm 110 .6 in)
Softer : 273.2 mm 110 .8 in)
Stiffer : 260 .2 mm 110 .2 in)
Damping force adjuster (STO)
Compression : Fully turned ·out position
Rebound
: 2'h turned-out position from the fully
turned-in pos ition .
NOTE:
Fully turned-in position provides stiffes t damping force.
DR350PISP 1'93·MDDElI 12·26
WIRE ROUTING
-
Io.t .....
.....""
-
FOREWORD
This section describes service data and servicing procedures which differ from those
of 'he OR350P/SP 1'93-MOOELI.
NOTE:
• Any differences between DR350PI SP and DR350RI SER in specifications and service datB are clearly indica ted with the asterisk marks (") .
• Please refer to the sections 1 through 12 for decaHs which are not given in this section.
- - - - - - - - - - - - - - - - - - - CONTENTS - - - - - - - - - - - - - - - - - - ,
SPEC/FICA TIONS ....... ...................... ...... .......... -................ ,' ....... 13- 1
SERVICE DA TA ..... ........ ........ ... ........ ......................................... 13- 3
TIGHTENING TORQUE (DR350SERI .. ....... .... .............................. 13-19
PERIODIC MAINTENANCE SCHEOULE (DR350SERI ................... 13-20
CAMSHAFT/AUTOMA TIC DE-COMP. ASSEMBLy ·· ············· ·· ····· 13-21
STARTER CLUTCH (DR350SERI ................................................ 13-24
TRANSMISSION ASSEMBL Y .... .. ............................. .. ...... •_......... 13-27
EMISSION CONTROL CARBURETOR
COMPONENTS (DR350SERI ...................................... .... .••.. ....... 13-2B
IGNITION AND STARTER SYSTEM (DR350SERI ............. •• •.. ..... . 13-29
GENERA TOR (DR350SERI ......... ..... .............. ......... ..... ... .... ........ 13-30
COl UNIT (DR350SERI .. ... ..... ............. .. ................. ..... .... ....... ..... 13-31
STARTER MOTOR (OR350SERI ............................. .. ......... .. ....... 13-32
STARTER RELA Y AND SIDE-STAND/IGNITION
INTER LOCK RELA Y (DR350SERI ...... ..... ........ ... ..... ........ ..• ... ..... 13-35
BA TTERY (DR350SERI ..... ..... .......... .............. .. ... .... .... .. ...•• .... .... 13-36
FRONT FORK (DR350RI ......... ............ .... .... ... ... .. .... .... .. .. ..• -... .... 13-37
REAR SHOCK ABSORBER ................................................ -......... 13·44
WIRING DIAGRAM (DR350SERI .. .... .•. .............. ••. ............•••....... 1346
WIRE ROUTING ... ......... .. .... .... .......................... ................... ...... 1347
CABLE ROUTING ······· ·· .. ......... ... .. ...................... ................•..... " 1349
CARBURETOR HOSE ROUTING ... ................. .... _•• .............••....... 13-50
CANISTER HOSE ROUTING (DR350SERI ..........•. ..... ........••• -... ... 13-51
13
13·1 DR350RISER 1'94·MDDEL)
SPECIFICA nONS
DR350R
DIMENSIONS AND DRY MASS
Ovorall length ............................ . .
2 165 mm 182.51"1
885 mm 134 .8 10)
Overall helght. ..... .• . _ ., .. _ .. _ .... __ .. _ 1 250 mm 14 9 . 2 In)
Wheelb... . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . .. · 1 450 mm (57. 1 Inl
GIOUnd ciHf1Ince...... . ....... .. .... .. .. . ...
3 10 mrn 112.21nJ
Selt he~II ., ........••.•...•...•..••..... _
920 mm 136.2 InJ
Ov er.1I width .... _ . . . . • . . • . . • . . . . . • . . . . • . . . .
Dry m • ••. • _.................. . ............
113 kg
1249 1bl '
ENG INE
Type ..•..... , .. , . . • . . . . . . . • . . . . . • . . . . • . . .
Valve c!eaflll1Clt, IN... . ........ . .............
EX ... ..••.•.. ••.••. . • •.....
Number of cyli nder . • . . . . . . • . • • . . • • . • . • . . • . . • .
Sore . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . • • . • . .
Stroke .... , •• , •.• . , •...••.•..... • ... ,.....
Piston dlsplacement. ... ,., •.... , .• ,.. ... ... ..
Compre. slon retio ........... . ........... . ...
Carburetor , •. ,." .... , ,.,., , • • , . , .••.• ,....
A ir e leanor , , •• , ••••. , •.•• , • • • • • • • • . • • . • . . . .
Starler .yllom . , ........• ' , •• , •• , ••.••..•. , .
Lubrlce tlon sys tem .. , . , , , •. , , , , .. , , . . . . . . . . . .
Four-strOke, air-cooled w il h SACS, OHC
0 .05 - 0 . 10 mm (0.002 - 0 .004 Inl
· 0 . 17 - 0 .22 mm 10.007 - 0 .009101
1
79.0 mm 13. 11 0 In )
71. 2 mm 12.803 In)
34 8 c m' 12 1. 2 cu, In)
9 .5 : 1
TM33SS, single
Polyure thaM foam element
Prim ory kick
Dry sump
TRANSMISSION
Clutc h , ...• " " , . " . " , .••. . ..•.• . .. . .• , .•
Transm laslon •. , . , , ••• . •..••••.•••• , .•• , • .. .
Gearshift patl om ...... , ..•. . •.•• , ••..•.....•
Primary reduction rallo , .. , .....••.•...........
Glla r lado" low ..•••• , .• . •. , .. , .. ,., .. , ..• ,
2nd ........... " ......... . .... .
3rd . . ......•....•......... ... .
4th , , .. . .. ,., • • , .• , ••. .• .••. ,.
5th •..•••••••• , •.••.•• . ••••• . ..
Top . , . , .. , . , •..• , .• , • • . • .. •• ...
Flnal red uction rado ...••.•.....•..••....•....
Drive chain .• , .• , .•.• " ... , , .. , ..•..•.... ,.
We t multl·plate type
e ·speed const ant mesh
1-down, SoUp
"3 .200 16 4/ 20)
2.41 6 (29112)
1.733 (26/ 15)
1.333 (2 4/ 18 )
1. 11 1 (20/ 18 1
0.952120/211
0,826 ( 19/ 23 )
" 2.933 (44/ 15)
RK520s0 or OID52OVC,5. 1 10 link.
CHASSIS
Front suspeoalon •..•.••.••.••.••. .• .• • , .• ..•
Reat su,pen..;on ••••.••..•.•..•.•....•....•••
FIo nl suspen,ion auoke . , .•..•.....•..........
Rear wheel travel . , ••• ,. • ••••.• • •••..•......
Caster .....•..•... " . , . , .•••. , ••• . .• . .•...
Tlllil .......•................•... •. • •. .. . .
Sloering angle •.• , •••••. , .. , ........... ,., ..
Turning radius .....• " . . .....••.•....••... .
Front brake .....................•.....•....
Re ar brake ,."., ...•. .• . .• . . •....•..•......
Front tire .Ile .•. ,., •.••. .•.• • •• . • •..•.•.. ..
Rellr tire ' lIe ....•.... . .............. . . . ....
ELECTRICAL
Ignition type ..•. , ....•.............•... . ...
Ignition timing ..•••.•••••••.••• . ••• •• • , •. ..•
Sperk plug .. , .• , .. ,., • ..... . .•••.•. , • .• . ...
Generator ................••.• , . . ......... .
Headlight ••••••••..•.•••••••....•......•. , •
Tailligh t ....•........ , . , •. , ••.•• ' •••.•.• , ..
CAPACITIES
Fuel tank including reserve •.•....• • .• . . •• ..•.. ,
Reserve •••••••• , •.••. • ••• . • .• •.. ..
EngiM oil, oil chango ..•.•••••. , ••••.••.• • .. , ,
with litter change •..•. ,.,., •. , .••.. ,
overhaul .•...•....•.....•... . .....
Front fork oil (each legl , , , . , , .• , .•.•.... , , . . ..
"Telescopic. C()jj S9fing. 011 damped. coml)feuion damping force , 2·way
adjus table ..... For Canada and U.S.A.
Talescoplc. coil spring. 011 damped. eprlog preload lully edjus table. damp·
ing lorce adjus t ebio ..... For Barbados
Unit.
• coil spring. gas/oil damped. spring preload full y adjuSlebio.
damping force fuily adjus t&ble
.0 Inl
mm
.O lnl
30'
1 18 mm 14 .6511'11
45 0 (lIgh t & leh )
' 2.3mi7.5 h )
Disc brake, hyd raulic all y operated
Disc brak e , hydraulic all y operated
80/100-2 1 51 M . tubo
1 10 11 ()()" 18 64M, tuba
Electronic Igni tion (COil
JO" B.T.O.C. above 4 300 r/min
"NGK CRSEK or NI PPQNOE NSO U27ET· R
Ayw heel magnet o
1211 6SW
1211 5W
9.5 L 12.6/ 2 . 1 USllmp. gal)
(0 ,5fO.4 US(lmp. gal)
ml ll . 8/ l,S USllmp, qt )
mlI2,01l ,7 USllmp. qt )
mI 12.21 1.8 USllmp. q t l
"
ml 08,3/ 19,0 US/mp. 01) ..... For Canada and U,S.A,
ml 119 .8/ 20.6 US,,",p. 011 ... " For BarblKlos
ASioriak mark I " 1 Indicates the Naw " R" model speclli~ tions.
DR350RISER ('94·MDDEL) 13·2
DR350SER
DIMENSIONS AND DRY MASS
Overall leogth . . . . . . . . . . . . . . . . . . . . . • . . . . . . . .
Overall width .••.... ,. . . . . . . ..•..••.•.••.
Overall height ......... . •. " ........ .• • . ...
Whttefba58 . . . . . . . . . .. .. _ .. _ ....•..•.••..•.
Ground cleorance . • . . . .. . ............. .. ... .
Sea! height .. . . . . . . • . . • . . . . . . . . . . . . • . . • . . . .
. ..•.......•• . .. . ••..
Dry moss . . . . . . . . . . ..
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....
lIal\l8 efoafance, IN .
_.......
. ........•.....
EX .•••••••••.•••••••••••••
Number of cylinder . . .. ... • • • •.•............
Bore ••••••••••••••••••••••••••• • • • • • •••.•
Suotte . • • • . . . . . . . . .. . •.• • ..•.••..•.••....
Piston dlsplacefT11!lnt ••••.•.• , •••••• , ••• • •.••••
COffIpression ratio ........••• • ..•.....• _ .• _ .•
CarboretOf .... _ . _ ..... _ ........•...•.......
Air cleaner . . . . . • . . . . . ..
. .......•........ _ .
Startor sys tem ............•...•...•..•.. _ ...
Lubrication system ....•.•• , •.. _ . • _ • . .. • ......
2335 mm 191.9 in). .... Germany and Switzerland
• 2235 mm 188.0 inl ..... 01OOs
885 mm (34 .8 inl
1 245 mm 149.0 inl
'1
mm 156. 7 inl
mm 11' .4 Inl
•
mm 135.0 in)
•
kg 12861bsl
Four· auoka, air-cooled with SACS. OHC
0 .05 - 0 . 10 mm (0.002 - 0 .004 In)
0 . 17 - 0 . 22 mm (0.001 - 0.oo9Inl
1
19.0 mm (3. 11 0 Inl
11.2 mm (2.803 In)
348 em' 121.2 cu. In)
9.5 : 1
BST33. Iingia
Polyurethane loam element
" Eleculc
Ory sump
TRANSMISSION
Clutch .•. _ •••..•..••.•.••.•...............
Transmission .• _ . . . . . . . . . . . . . . . .. . ........ .
Geershift pattern ...... _ . . . . . . . . . . . . . . . . . . . . .
Primary redllCtlon ratio ......•. __ .• _ ... _ ...... .
Gear ratios . low ....... .. . •..•••• _ ••.•••. _
2nd . . . . . .
. .
Jrd ...
4th ......... . .
5th ..... . .. .
,~:~::,:,;ype
~
mesh
. . . . . .. . . . - - - . . .......... - .. - ... ..
- ........... ..
....... -- ....... -
Top ......••.••.•.....•••••.•.
Final reduction rotio .......... • •.•..••.•...•..
Drive c hain .........•..••••••.••.••. • •.....
CHASSIS
Front suspension ........•
Aear wspensi.on . _ . . . ..
"
............... .
. ................... .
Front .uspension stroke . • . • .. ••.•• . •. . •.....
Rear wheel travet ••.•........••.••.••.••.....
CastOI' •. .. . _ •
Trail _ . _ .. _. _. _ .. _ ... _ . . . • . . . . . . . . . . . . . .
Steering a'"!Pie . . . . . . . . . . . . . . . . . . . . . . . . . . . . • .
Turning radIUS •••.••.•••••••••.•..•..•.•.•••
Front brake . _ . .. . • • .• • .•••.•.•..••..•.....
Aear brake ......... • .•.. . •.••.••.• • .••. _ ...
Front ura slle ........•..... • .. • ...... • .•...
Rear tire sile ...............•...............
. ..
. ............. .
ELECTAICAL
Ignition type _ ..•...•.•..••. • •..•.••.••.•...
Ignition l iming ..•.....••.••.••.••.•••••.•...
Spark plug .. • .. .. .. .. •
.. . . ..
.. ....
Battery __ . _ .... _ .. _.
•
...•........•....
GenerllOf •..•..•••.•..•.....•.•. _ ..•.. _ ...
Fun . . . .. ... . ..•.••.•••••.••• _ .••..•..
Headlight ..• . .....•.•••••.••••••.•.•• . ••.
PoSItion Itght .... .•...• . •.••..•.••.••.••• ,
Turn .Ignallight . _ .. _ .......•............•...
raillBrake light •••.•.••.•...................
Ucen~ plato light ........•.•..•.•.... . ....•.
Speedometer light .. _ ........•..... . .........
TachOfTletor light ........... . ••..•. ••. •• . •...
Neutral Indicator light ...••.....•.••.••.••. • ...
High beam indicator light •..•..•...•.• • .. • . • ...
Turn .Ignal Indicator light . . . • .. ..•. . ....•..•.
CAPACITIES
Fuel tank. including reserve ... , •..•.•.•........
Re50fVe ................ . ...... ..
Engine 011. oil change .•. _ .. _ .. _ ..•.....•..•...
with filler change . , , •...............
overhaul . . . . . . . . . . . . . . . . . . . . . . . . .
Front fork oil leach legl . _ . _ .. _ .•.........•...
108 links
Telescopic. coil spring. 011 damped . spring preload l uUy adjustable,
comp re.slan damping lorce B· wsy ,dju.table
link type. coli spring . gas(oll damped. spring preload luRy adjullabla,
compressloo damping force fully adjustable
280mmlll .01n)
" 255 mm (10.0 Inl
620 30'
115 mm (4. 53 In)
45 0 (right & lefll
2. 3 m 17. 5 III
Disc brake, hyd rautlcaUy operated
Disc brake, hyd raulically operated
80( 100-21 51P
11 0 190- 1861P
Electronic Ignition
30 0 B.T. O.C. above 4 300 rl m ln
NGK CA9EK or NIPf>ONDENSO U27ETA
' 12V 21.6 kC 16Ahlll OHR
Three·pha.. A .C. generator
15A
12Veo/55W
12V 4W
12V2 1W
12V 5/21W
12V 6W
12V 1.7W Ix 2 pcI)
12V 3W
12V l .1W
12V 1.7W
12V 1.7W
9 .0 L .2.4 /2 .0 US/lmp gal) ... Other.
8 .0 LI2. 1I1.8 USllmp gall ..• Califomla only tU.S.A .)
2 .0 L 10. 5/0.4 USIImp gal)
1 700 ml 11.811. 5 U S/Imp qtl
1 900 mI12.0/1 . 7 US/lmp ql)
2 100 mI12. 2/1.8 US/Imp qt)
569 ml 119.2/ 20.0 USfimp oz)
I J.J DRJ50RISER ('94-MODEL)
SERVICE DATA
DR350R
VAlVE+ GUIDE
Unit: mm !in)
ITEM
Valve diam .
IN.
EX.
Valve clea rance (w hen cold )
IN .
EX .
Valve gu id e to valve stem
clearance
IN.
EX.
Valve stem deflection
Valve guide 1.0.
Va lve stem 0. 0 .
IN . & EX .
IN .
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
liN . & EX.)
5.000 - 5 .012
(0. 1969 -0. 1973)
4 .975 - 4.990
to. 1959 -0. 1965)
4 .955 - 4 .970
10. 1951 - 0.1957)
0 .05
10.002)
0.5
10.02)
1.8
10.07)
IN . & EX.
IN . & EX.
IN . & EX.
IN. & EX .
0 .9 - 1.1
10.035 - 0.043)
0.03
10.001)
35.0
11. 38)
37.8
11.49)
IN . & EX.
INNER
OUTER
Valve spring tension (IN . & EX.)
INNER
5.3-6.5 kg
11'.7 - 14.3 Ibs)
at len th 28.0 mm ( 1.10 in)
OUTER
LIMIT
0.35
10.014)
IN. & EX.
EX .
Valve stem runout
STANDARD
30.6
(1.20)
27.0
( 1.06)
0.05-0.10
(0.002-0.004)
·0. 17 - 0 .22
10.007 - 0.009)
0.010 - 0 .037
10.0004-0.0015)
0.030 - 0.057
(0.00 12 -0.0022)
13.1- 15. 1 kg
128.9-33.3Ibs)
at length 31 . 5 mm (1.24 in)
Asterisk mark (*1 indicates the New " A" mod el specification.
-I
DR350RISER 1'94-MODELJ 13-4
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
ITEM
Cam height
IN .
EX .
Cam shaft journal oil clearanc e
Right side
Left side
Camshaft journal holder 1.0 .
Right side
Left side
Camshaft journal 0 .0 .
LIMIT
STANDARD
Right side
Left side
'33.450 - 33.490
11.3169 - 1.31851
'33 .520 - 33.560
11.3197 - 1.32131
0 .032 - 0 .066
10.0013 - 0 .0026)
0 .028 - 0 .059
10.0011 - 0 .00231
22.012 - 22 .025
(0.8666 - 0 .8671 )
17.512 - 17.525
(0 .6894- 0 .69001
21 .959 - 21.980
10.8645 - 0 .8654)
17.466 - 17.484
10.6876 - 0 .68831
0 . 10
10.004)
Camshaft runout
Rocker arm 1.0 .
Ro cker arm shaft 0 .0.
IN. & EX.
IN. & EX.
12.000 - 12.018
10.4724- 0.47311
11 .973 - 11 .984
10.4714 - 0.47181
0 .05
10.002)
0 .05
10.0021
Cylinder head distortion
Cylinder head cover distortion
0- 2
10- 0 .08)
De·c ompression lever play
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
Cylinder bore
Piston di am.
Unit: mm (in)
STANDARD
LIMIT
0 .055 - 0.065
10.0022 - 0 .0026)
79.000 - 79 .015
(3. 1102 - 3.1108)
78 .940 - 78.955
(3. 1079 - 3. 1085)
0 . 120
10.0047)
79.075
(3. 1132)
lMeasure at 15 mm 10.6 in) from the skirt encl.
Cy linder distortion
Piston ring free end gap
Pis ton ring end gap
I
'33. 150
11 .30511
'33.220
(1 .30791
0 . 150
10.0059)
0 . 150
10.00591
1st
R
2nd
R
1st
2nd
10.2
Approx . 10.40)
11 . 1
(0.44)
0 . ' 5 - 0 .30
10 .006 - 0 .012)
0 .35 - 0 .50
(0.014 - 0 .020)
Approx.
A st erisk mark (.) indicates the New " RIO model specific ations .
78.880
(3. 10551
0 .05
10.0021
8 .2
(0.32)
8 .9
(0.35)
0 .70
(0.0281
0 .70
(0.028)
13·5 DR350RISER 1'94- MODEl/
ITEM
Piston ring to groove
clearance
STANDARD
0.180
(0.007)
0 . 150
(0.006)
1st
2nd
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin 0.0 .
1.01 - 1.03
(0 .040 - 0 .041 )
1.01 - 1.03
(0.040 - 0 .041 )
2.01 - 2 .03
(0.079 - 0 .080)
0.97 - 0 .99
(0.038 - 0 .039)
0.97 - 0 .99
(0.038-0.039)
20.002 - 20.008
(0.7875-0.7877)
19.996 - 20 .000
(0.7872-0.7874)
CON ROD + CRANKSHAFT + BALANCER
ITEM
Conrad sma ll end 1.0.
Conrad big end width
Crank web to web width
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
STANDARD
LIMIT
20.006 - 20.014
10.7876 - 0 . 7880)
20.040
(0.7890)
3 .0
(0.12)
1.0
(0 .04)
Conrad deflection
Conrad big end side clearance
LIMIT
0. 10 - 0.55
(0 .004 - 0.022)
21.95 - 22.00
(0.864 - 0.866)
60.0 + 0.1
(2 .362 ± 0.004)
0.05
(0 .002)
10.3
(0.41)
Crankshaft runout
Balancer spring free length
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 ° C. 140°F)
STANDARD
1.590 (35/22)
Above 40 kPa (0.4 kg/cm2 , 5. 7 psi)
Below 140 kPa f 1.4 kg/ cm2, 19.9 psi)
at 3 000 r/min.
LIMIT
DR350RISER 1'94-MDDEl) 13·6
CLUTCH
Unit: mm (in)
,-------.-10.4 - 0 .6)
Drive plate thickness
10.62 - 0 .63)
10.60)
plate
Clutch spring free length
I 1 . I 6)
TRANSMISSION + DRIVE CHAIN
Unit: mm (in) Except ratio
,---~----
ratios
Shift fork to groove clearance
I
°
10.004 - 0 . I 2)~_ _ _ _---'1"0;..:.0"'2"'0:...)_ - j
groove
10. I 97 - 0 .200)
-S~h-i~h~fo-r-k-t-h-ic-k-n-e-s-s--------~N~o~.~1~,N~o=.~2 ------~~~~~==~-------------------~
iri;;;;-cl;;;;;;-- - - - - - --r& No. 3
20·pitch length
Drive chain slack
25 - 40
1.0 - 1
Asterisk mark (.) indica tes the New " A" model specificati ons .
112 . 57)
13-7 DR35DRISER 1'94-MODEl)
CARBURETOR
ITEM
SPECIFICATION
TM33 SS
Carburetor type
Bore size
J.D. No
Idle r/min .
Float height
Main iet
Main air jet
Jet needle
Needle jet
Cut-away
Pilo ~et
By-pass
Pilot outlet
Valve seat
Starter jet
Pilot screw
Pilot air jet
Throttle cable play
33mm
14DO
1 400 + 100 r/min
14. 2 + 1.0 mm 10.56 + 0.04 in)
# 127.5
0 .7 mm
5FP96· 3rd
P· 8
1.5
#37.5
0 .8 mm
0 .6 mm
1 .8 mm
#50
1 1IB turn back
' .1 mm
-
IM.J .I
IM.A.J.I
{J.N.I
IN.J.I
IC.A.I
IP.J .I
IB.P.I
IP.O.I
IV.S.I
IG.S.I
IP.S.I
IP.A.J.I
0 .5- 1.0 mm 10.02 - 0.04 inl
(pull ing cable)
ELECTRICAL
ITEM
Ignition timing
Spark plug
Spark performance
Ignition coil resista nce
Magneto coil resis tan ce
Unit: mm (in l
SPECIFICATION
0
30 8.T .D.C. above 4 300 rl min
ND :'U27ETR
Type
NGK :'CR9EK
'0.6 -0.7
Gap
10.024 - 0.0281
Over 8 (0.3) at 1 atm.
Prima ry
0 . 1 - 1.011
Secondary
12 - 22 kll
~ting
0. 1 - 1.511
350 - 65011
350 - 70011
350 - 70011
Power source
Pick-up No . 1
Pick-up No .2
Magneto no-load voltage
(when engine is co ld )
Aegulated voltage
More than 40 V lAC) at 5 000 r/m in.
12 - 14 V at 5 000 r/min .
Asterisk ma rk I·) indicates the New " A" model specifications.
NOTE
Term inal Ground
Plug cap Terminal
Y- B
W - Br
G - BI
Y - Gr
Y- B
DR350RISER 1'94-MDDElI 13·8
WATTAGE
Unit: W
BRAKE + WHEEL
Unit: mm (in)
10.gci! = g~1 0)
Brake lever play
~
Brake di sc th ickness
BI
UMiT
STANDARD
ITEM
10.2)
3~5
±
Front
10. 138 ± 0 .008)
Rear
10. 157 +
4 . 0+~
di sc run ou t
M aster cylinder bore
•
10.012)
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake ca liper cylinder bore
Brake caliper piston dia m.
Wheel axle run out
T ire size
jn;e tread d epth
11 .000 - 11.
•
•
10.5000-0.5017)
~-6°
·
•
10.4983 - 0.4994)
Front
/7 . 000 - ~
1.0630 - 1
Rear
(1.0630 - 1.0650)
Front
Ji6ci~~~ _ I .~~~0
Rear
Wheel rim runout
10~118)
3 .5
10. 138)
•
='-:~~ci~10)
Axia l
(O.OB)
Radial
10~
Front
(~)
Rear
0 .25
(0.0 10)
~
~/ l00- 21
51M
~
Front
4 .0
(0. ~)
Rear
(0.16)
13·9 DR 350RISER ('94·MOOEL)
SUSPENSION
Unit: mm (in)
ITEM
STANDARD
280
(11.01
Front fork stroke
LIMIT
Front fork spring free length
"551
121.71
608
(23 .9)
·144
(5 .67)
145
15 .71)
Rear shock absorber gas pmssure
1 000 kPa
(10 kg/em'. 142 psi)
Front fork oil level
Rear shock absorber spring
pre-set length
Rear wheel travel
"267.3
(10.5)
268.2
(10.6)
280
(11 .0)
E·03.28
E·94
0 .3
(0.0 1)
kPa
kg/cm2
psi
100
100
1.0
1.0
14
14
Asterisk mark (.) indicates the New " R" model specifications.
E-28 ..... Canada
E-94 ..... Barbados
E-94
E-94
TIRE PRESSURE
E·03 .. .. . U.S.A .
E-03. 28
E-03.28
Swingarm pivot shaft (unout
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
NOTE
I
DR350RISER 1'94-MODELI 13·10
FUEL + OIL
Fuel type
Use only unleaded gasoline of at least 87
pump octane ( Ri M
method) or 91 octane or
higher rated by the research method.
Gasoline coma ining MTBE (Methyl Tertiary
Butyl Ether) , less than 10 % ethanol , or
less than 5 % methanol with appropriate
coso lven t s and corros ion inhibitor is
I
E-03
E-28
graded
oct ane or higher . An unleaded gasoline is
E·94
recommended.
Fuel tank including reserve
reserve
t-='-' I
I
Engine oil capacity
Change
Filter change
Overhaul
type
Front fork oil capacity (each leg)
*541 ml
E-03 , 28
18.3/ 19.0
586 ml
19.8 /20.6 u~~~~______~____:E-:9:4____~
=
Asterisk mark (*) indic ates the New " A" model specifications.
E-03 .... . U.S.A .
E-28 _... . Canada
E-94 ... .. Barbados
13·11 oR350RISER 1'901- Moo El)
DR350SER
VALVE + GUIDE
Unit·• mm (in)
ITEM
Valve diam .
STANDARD
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX .
Valve stem deflection
Valve guide 1.0.
Valve stem 0 .0.
IN.
EX .
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
liN. & EX .)
0.35
(0.014)
IN. & EX .
IN. & EX.
5 .000 - 5.012
(0. 1969 - 0 .1973)
4 .975 - 4.990
(0.1959 - 0.1965)
4 .955 - 4 .970
(0. 195 1 - 0 .1957)
0 .05
(0.002)
0 .5
(0.02)
1.8
(0.07)
IN. & EX .
IN. & EX.
IN . & EX .
IN . & EX .
0 .9 - 1 . 1
(0.035 - 0 .043)
0 .03
(0.001)
35.0
(1.38)
37.8
(1.49)
IN . & EX.
INNER
OUTER
Valve spring tension (IN. & EX.)
INNER
OUTER
LIMIT
30.6
( 1.20)
27.0
( 1.06)
0 .05-0. 10
(0.002 - 0.004)
0 . 17 - 0.22
(0.007 - 0 .009)
0 .010 - 0.037
(0.0004 - 0 .0015)
0 .030 - 0 .057
(0.0012 - 0 .0022)
5.3 -6.5 kg
(11. 7 - 14.3 Ibs)
at length 28.0 mm (1 .10 in)
13. 1 - 15 .1 kg
(28.9 - 33.3 Ibs)
at length 31.5 mm (1.24 in)
DR350RISER ('S4-MODEU 13-12
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
STANDARD
ITEM
Cam height
IN .
EX .
Camshaft journal oil clearance
Right side
Leh side
Camshaft journal holder 1.0 .
Right side
Left side
Camshaft journal 0.0 .
Right side
left side
LIMIT
33.450 - 33.490
(1.3169 - 1.31851
33.520 - 33.560
(1.3197 - 1.32 131
0.032 - 0.066
(0.0013 - 0 .00261
0.028-0.059
(0.0011 - 0.00231
22.012 - 22 .025
(0.8666 - 0 .86711
17 .5 12 - 17 .525
(0.6894 - 0 .69001
21.959 - 21.980
(0.8645 - 0.86541
17.466 - 17.484
(0.6876 - 0 .68831
0 . 10
10.0041
Camshaft runout
Rocker arm 1.0 .
Rocker arm shaft 0 .0 .
IN. & EX.
IN . & EX .
12 .000-12 .018
(0.4724- 0 .47311
11 .973 - 11 .984
10.4714 - 0.47181
0 .05
10.0021
0 .05
(0.0021
Cylinder head distortion
Cylinder head cover distortion
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder c learance
Cylinder bore
Piston diam.
Unit: mm (in)
STANDARD
LIMIT
0 .055 - 0 .065
(0.0022 - 0 .00261
79.000- 79 .015
(3. 1102 - 3 . 11081
78.940- 78 .955
(3. 1079- 3 . 10851
0 . 120
(0.00471
79.075
(3. 11321
Measure at 15 mm (0.6 in) from the skirt encl.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
33. 150
(1.30511
33.220
(1.30791
0 . 150
(0.00591
0 . 150
10.00591
10.2
151
R
Approx . (0.401
2nd
R
Approx. (0.441
151
2nd
11 . 1
0 .15-0.30
(0.006 - 0 .0121
0 .35 - 0 .50
(0.014 - 0.0201
78.880
(3. 10551
0 .05
(0.0021
8 .2
(0.321
8.9
(0.351
0.70
(0.0281
0 .70
(0.0281
13·13 OR350RISER 1'94-MOOELI
ITEM
Pi ston ring to groove
cleara nce
STANDARD
1sl
2nd
Pi ston ring groove width
1s l
2nd
Oil
Piston rin g thickness
1sl
2nd
Pi st on pin bore
Pi ston pin 0.0 .
1.01 - 1.03
(0.040 - 0.04 11
1.01 - 1.03
(0.040 - 0 .041)
2 .01 - 2 .03
10.079 - 0 .0801
0 .97 - 0 .99
10.038 - 0 .0391
0 .97 - 0.99
10.038 - 0 .0391
20.002 - 20.008
(0.7875 - 0 .78771
19 .996 - 20.000
10.7872 - 0 .78741
CON ROD + CRANKSHAFT + BALANCER
ITEM
Conrad small end l. D.
Conrad big end wid th
Crank web to web width
Crankshaft ru nout
Balance r spring free length
OIL PUMP
I
20.030
10.78861
19 .980
(0.78661
Unit: mm (in)
STANDARD
LIMIT
20.006 - 20.014
10.7876 - 0 .78801
20.040
10.78901
3 .0
10. 121
1.0
10.041
Conrad deflec tion
Conrad big end side clearance
LIMIT
0 . 180
10.0071
0 . 150
(0.0061
0 . 10 - 0 .55
10.004 - 0 .0221
21 .95 -22.00
10.864 - 0 .8661
60.0 ± 0 . 1
12 .362 ± 0 .0041
0 .05
(0.0021
10.3
(0.4 11
DR35DRISER !'94·MDDELI 13·14
CLUTCH
Unit: mm (in)
ITEM
Clutch leve r play
STANDARD
10 - 15
(0.4 - 0.61
2.72 - 2.88
(0. 107 - 0. 11 31
15.8 - 16.0
(0.62 - 0 .631
Drive plate thickness
Drive plate claw width
LIMIT
2.42
(0 .0951
15.2
(0.601
0. 10
10.0041
29.5
( 1.161
Driven plate distortion
Clutch sp ring free length
TRANSMISSION + DRIVE CHAIN
ITEM
Pri maiY.. reduction ratio
Final reduction ratio
Gear ratios
l ow
2nd
3rd
4th
5th
T op
Sh ift fork to groove clearance
Shift fork groove width
Sh ift fork thickness
Drive chain
No. l ,No .2
& No .3
No . l ,No .2
& No.3
Type
links
Unit: mm (in) Except ratio
STANDARD
3.200 (64 /20)
2.733 (4 1/ 15)
2.416 (29 / 12)
1.733 (26 / 15)
1.333 (24118)
1.1 11 (20118)
0.952 (20/21)
0.826 (19 /23)
0 . 1 - 0 .3
(0.004 - 0.0121
5.0 - 5. 1
(0.197 - 0 .200)
4.8 - 4 .9
(0. 189 - 0 . 193)
0.1.0. 520VC5 or RK520S0
108
25 - 40
(1.0 - 1.6)
Specifications marked w ith asterisk (*) are exclusive to DR35QSER .
E-03 ... U.S.A. (other than California) E-04 ... Fran ce
E-2 1 ... Be lg ium E-22 ... Germany E-28 ... Canada
E-33 ... California E-34 ... Italy E-94 ,., Barbados
0.5
(0.0201
3 19.4
112.57)
20-pitch length
Drive chain slack
LIMIT
E- 18 ... Switzerland
13-15 DR350RISER 1'94-MODELI
CARBURETOR
SPECIFICATION
ITEM
"14EP
"
14.6 ± 1.0mm
Floa t heig ht
#
mm
-----
-
--
Pilot screw
turns
I . mm
Pilot
--
PRE·SET
-
1.0 mm
play
- 0 .04
ITEM
"1 4 ER
-----
Pilot sc rew
IP.S.I
PRE· SET
-
PRE· SET
#
---
mm
PRE· SET
OH3!:1UHISt:H nt4·MUUt:Lj lJ· l b
ELECTRICAL
Unit : mm (in)
Spark plug
U27ETR
Type
Igni tion coil resistance
-+________-1
e R 9~E~
K____
•
Gap
10.024 - 0 .028)
Primary
0 . 1 - 1.0 {}
Terminal Ground
Secondary
12-22 kll
cap Terminal
Magneto coil resistance
no-load voltage
•
I
y -y
More than 60 V (AC) at 5 000 r/min .
•
I
Battery
i
Standard
S.G.
1 .3 20 at 20 0 e 168°F)
WATTAGE
Unit: W
ITEM
others
--- ------1
Headlight
1 .7 x 2
•
I
License
5
Specifications marked with asterisk (.) are exclusive to DR350SER.
--
---
13·17 OR350R/SER 1'94·MDDELI
BRAKE + WHEEl
Unit: mm (in)
ITEM
Brake lever play
Rear brake pedal height
Brake disc thickness
Front
Rear
STANDARD
0 . 1 - 0 .3
10.004 - 0 .0101
5
10.21
3 .5 ± 0 .2
10. 138 ± 0 .0081
4 .0 ± 0.2
10.157 ± 0 .0081
Brake disc runout
Master cylinder bore
Front
Rear
Master cylinder piston diam .
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam .
Front
Rear
Wheel rim run out
2 .0
(0.081
2 .0
(0.081
0 .25
(0.0101
0 .25
(0.0101
Axial
Front
Rear
Tire size & type
Front
3 .0
10. 1181
3 .5
(0 . 1381
0 .30
(0.0121
12.700 - 12 .743
(0.5000 - 0 .50171
12.700 - 12.743
(0.5000- 0 .50171
12 .657 - 12.684
(0.4983 - 0.49941
12 .657 - 12.684
(0.4983 - 0.49941
27 .000 - 27.050
( 1.0630- 1.06501
30.230 - 30. 280
(1. 1902 - 1. 19211
26.900- 26.950
(1.0591 - 1.06101
30. 160 - 30. 180
(1.1874 - 1 . 18821
Radial
Wheel axle runout
LIMIT
80/ 100-21 51P
·Dunlop D601J (E-03,28,331
Dunlop K560J (others)
110/90-1861P
Rear
·Dunlop D601 (E-03,28,331
Dunl~ K560J
Tire tread depth
(others)
Front
Rear
Specification s marked with asterisk (-) are exclusive to DR350SER .
3 .0
(0 .121
3.0
(0. 121
UKJ'UK I ~tK r '''MOOElI 13·18
SUSPENSION
Unit: mm (in)
ITEM
STANDARD
280
111.01
Front fork stroke
LIMIT
NOTE
602
123. 71
Front fork spring free length
Front fork oil level
152
16.01
Rear shock absorber gas pressure
1 000 kP.
110 kg/em', 142 psi I
·253.4
Rear shock absorber spring
(10 ,01
pre*set length
• 255
Rear wheel travel
(10.01
0 .3
10.011
Swingarm pivot shaft runout
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FUEL + OIL
SPECIFICATION
ITEM
Fuel type
Use only unleaded gasoline of at least 87
pump octane (R 2M) or 91 octane or higher
rated by the research method .
Gasoline conta ining MTSE (Methyl Tertiary
Butyl Ether) , less th an 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 ( R ;- M method) or 91 octane or
hi her rated by the Research Method.
Gasoline used should be graded 85-95
octane or higher . An unleaded gasoline is
recommended.
Fuel tank including
reserve
Engine oil ~e
Engine oil capacity
Front fork oil type
Front fork oil capacity leach legl
Rr::.lrp fll lirl h /np
8.0 L
12.1/1.8 US/Imp gall
9 .0 L
12.4/2 .0 usnmp gall
2.0 L
10.5/0.4 USlimp gall
SAE 10W/40, API SE or SF
1 700 ml
Change
11.8/1 . 5 usnmp qt)
1 900 ml
Filter change
12 .0/1 . 7 usnmp qt)
2 100 ml
Overhaul
12. 2/ 1.8 US/Imp qtl
Fork oil # 10
569 ml
119.2120.0 USlimp ozl
nOT 4
NOTE
E-03,33
E-28
For the others
E33
For the others
13·1. DRJ5DRISER 1'94-MOD ELI
TIGHTENING TORQUE (DR350SER)
ENGINE
N 'm
kg ~m
Ib-It
Cylinder head cover bolt
10
1.0
7.0
Camshaft sprocket bolt
15
1.5
11.0
Cylinder head bolt
38
3.8
27.5
Cylinder head nut
25
2.5
18.0
Cylinder base nut
25
2.5
18.0
Rocker arm shaft bolt
28
2.8
20.0
Balancer shaft bolt
50
5.0
36.0
Primary drive gear nut
70
7.0
50.5
Magneto rotor nut
130
13.0
94.0
Starter clutch bolt
'26
"2.6
' 19 .0
Clutch sleeve hub nut
50
5.0
36.0
Gearshift arm stopper
19
1.9
13.5
Gearsh ift cam driven gear boh
10
1.0
7.0
Cam chain tensioner spring holder bolt
10
11
8
1.0
1. 1
0.8
7.0
8.0
6 .0
Engine oil drain plug (on the crankcase)
21
2.1
15.0
Engine oil drain bolt (on the frame I
18
1.8
13.0
Crankcase bolt
11
1.1
8 .0
Oil pipe union bolt
21
2.1
15.0
Oil gallery plug
23
2.3
16.5
28
2.8
20.0
Oil hose union bolt
28
2 .8
20.0
Oil check bolt
10
1.0
7.0
Oil hose bolt (on the crankcase)
10
1.0
7.0
Oil hose bolt (on the cylinder head)
23
2.3
16.5
Oil hose clamp screw
1.8
0 .18
13.0
T.D.C. plug
23
2 .3
16.5
66
41
23
6.6
48
Engine mounting bolt and nut
4 .1
2 .3
29.5
16.5
Exhaust pipe bolt
23
2.3
16.5
Muffl er connection bolt
23
2 .3
16.5
Muffler mounting bolt
26
2 .6
19.0
ITEM
Cam chain tensioner mounting bolt
Oil strainer
-
Right hand
Left hand
13·20
PERIODIC MAINTENANCE SCHEDULE (DR350SER)
IMPORTANT: The periodic m aintenance intervals and service requirem ents have been established in
accordance with EPA regulations . Following these instruc tions w ill ensure that the m otorcycle w ill
not exceed emission standards and it will also ensure the reliability and performance of the motorcycle.
NOTE:
M ore f requent servicing ma y be performed on m o torc ycles that are used under severe condi ,;ons
however_ it is not necessary for ensuring emission level compliance.
The chart below lists the recommended intervals for all the required periodic service work necessary
to keep the motorcyc le operating at pea k performa nce and econom y . Mileages are expressed in terms
o f kil ometers. miles and t im e for y our convenien ce .
PERIODIC MAINTENANCE CHART
km
1 000
6 000
12000
18 000
2 4 000
miles
600
4 000
7 500
11 000
15000
2
12
24
36
48
Cylinder head bolt s and nuts, cylinder nuts,
exhaust pipe bolts and muff ler connec tions
T
T
T
T
T
Valve clearance
I
I
I
I
I
Spark plug
-
I
R
I
R
C
C
C
C
INTERV AL:
THI S INTERV AL SHOULD BE JUDGED
BY ODOMETER READING DR
MONTHS WHICHEV ER COMES FIRST
months I
Spark arrester (Only for U.S.A . and Canada)
Air cleaner
I
I
Clean every 3000 km (2 000 miles) .
Engi ne oil and oil fil t er
R
R
R
R
R
Engine oil hoses
I
I
I
I
I
Engine oil strainer
C
C
C
R
Carburetor
I
I
C
1
I
I
Fuel line
(Vapor hose ... California model only)
I
I
I
I
I
Clutch
I
I
I
I
I
I
I
I
I
I
Orive chain
Brakes
Brake hoses
Replace every 4 years.
Clean and lubricat e every 1 000 km (600 miles).
I
I
I
I
I
I
I
I
I
I
Replace every 4 years.
I
Brake fluid
I
I
I
I
Replace every 2 years.
lires
I
I
1
I
I
Steering
I
I
I
I
I
Front forks
I
-
I
I
Rear suspension
1
-
-
I
-
I
Chassis bolts and nuts
T
T
T
T
T
I : Inspect and adjust , clean, lubricat e or replace as nec essary
R : Replace
T : Tighten
C : Clean
13·21 DR35DRISER ('94-MDDEL)
CAMSHAFT/AUTOMATIC DE-COMP. ASSEMBLY
o
Th1 303
SG:
SG
ApplV SUZUKI MOLY PASTE
199000-251 4 0 )
Th 1303: Apply THREAD LOCK SUPER
" 1303" (99000·32030)
Tightening torque
ITEM
(i)
N' m
15
kg-m
1. 5
REMOVAL
• Rem ove the frame covers, seat and fuel tank .
• Drain engine oil.
• Rem ove the T.O.C. inspection plug and magneto cover cap .
• Turn the crankshaft co unter clockwise to set the posit ion
at T.D.C. on the compress ion stroke .
•
•
•
•
•
Rem ove th e chain tensioner.
Remove the intake and ex hau st v alve inspection ca ps.
Remove th e c ylind er head cover.
Rem ove the ca mshaft end ca p.
Flatten the lock w ashers and remove the camshaft sproc ket bol ts.
• Rem ove the sprocket and ca mshaft/auto-d ecompression
assembly _
CAUTION :
Do not attempt to disassemble the camshaft/automatic de·
compo assembly . It is not serviceable .
•
DR350RISER 1'94-MDDEl! 13-22
INSPECTION
CAMSHAFT
The camshaft should be checked for runout and also for wear
o f cams and journals if the engine has been noted to produce
abnormal noise or vibration or to lack ou tput power. Any of
these malconditions CQuid be caused by a worn cam shaft.
CAMSHAFT CAM WEAR
Worn-down cams are often the cause of mislimed valve oper·
ation resulting in reduced output power . The limit of cam wear
is specified for both intake and exhaust cams in terms of cam
height <J}. which is to be measured with a micrometer.
Replace the camshaft if found it worn down to the limit.
Cam height
Height QlI
Service Limit
Intake cam
33. 150 mm 11.3051 in)
Exhaust cam
33.220 mm 11 .3079 in!
Inle t open
(B.T.D.CI
T. D.C
Inlet clos.
IA. B.D.C.I
d'aglam
B.D.C.
ExkaUli dose
(A.T. D.C.I
hhs us t open
18.8 .0 C.I
o
09900·20202: Micrometer 125 - 50 mm)
CAMSHAFT JOURNAL WEAR
Determine whethe r eac h journal is worn down to the limit
or not by measuring camshaft journal oil clearance w ith th e
camshaft installed . Use plastigauge to read the c learance.
which is specified as follows.
Camshaft journal oil clearance
Service limit: 0 .150 mm 10 .0059 in)
• TIghten the cylinder head cover bolts evenly and diagonally
to the spec ified torque .
Tightening torque : 10 N'm (1 .0 kg -ml
09900-22301 : Plastigauga
If the camshah journal oil clearance measured exceeds the
limit. measure the outside di ameter o f cam shaft . Replace
either th e cylinder head set or the camshaft if the clearance
is incorrect .
Camshaft journal 0 .0 .
Standard
Right side
21.959 - 21.980 mm 10.8645 - 0 .8654 in!
I left sid. I 17.466 - 17.484 mm 10.6876 - 0 .6883 inl I
NOTE:
To properly measure the oil clearance
with plastigauge, all gaske t material
must be removed from fitting surfaces
of cylinder head and cover. Do not apply SUZUKI 80ND No. 12078/ 1215
until after the oil clearanc e has been
determined.
13·23 DR350RISER 1'94-MODElI
CAMSHAFT RUNOUT
Measure the runout with a dial gauge. Replace the camshaft
if the runout exceeds the limit.
Service Limit : 0.10 mm 10.004 in)
09900·20701 : Magnetic stand
09900· 20606: Oial gauge 11 /100 mml
AUTOMATIC OE· COMP. ASSEMBLY
Move the automatic de*comp . weight by hand to inspect if
operating smoothly.
If it does not smoothly must be replaced with a new camshaft/automatic de-comp, assembly.
REMOUNTING
Remount the camshaft/automatic de-comp oassembly in the
reverse order of removal.
DR350RISER 1'94-MDDEU 13·14
STARTER CLUCH (DR350SER)
REMOVAL
• Drain engine oil.
• Remove the frame covers .
• Remove the seat.
• Disconnect the magneto lead wires after moving the COl
unit.
• Remove the gearshift lever.
• Remove the magneto cover .
• Remove the starter idle gears with shaft.
CD: Starter idle gear No.1
@: Starter idle gear No.2
@: Starter idle gear No.3
• Remove the magneto rotor nut with a 27 mm box-end
wrench .
• Remove the magneto rotor assembly with the special tool.
09930-349 12: Rotor remover
CAUTION :
Do no t hit t he rotor with a ha mmer.
13·25 DR35DR/SER ('94·MDDEl)
• Remove the starter gear and bearing .
• Remove the three bolts with 6 mm hexagon wrench and
27 mm box· end wrench .
• Remove the starter clutch holder CD and starter c lutch ®.
REASSEMBLY AND REMOUNTING
Reassemble and remounting the starter clutch in the reverse
order of removal and disassembly, and also carry out the fol-
lowing steps.
• When installing the starter clutch to the rotor, face the cut
@ of the cage to the rotor as shown in photo.
• Apply THREAD LOCK SUPER " 1 303" to the bolts and
tighten them to the specified torque .
99000·32030: THREAD LOCK SUPER " 1303"
Tightening torque: 26 N' m (2. 6 kg -m . 19.0 Ib-ft)
DR350RISER ('94-MODEL) 13·26
• Install the starter gea r CD to the stater clutch.
• Check that the rotor @ turns in the direction of the arrow
mark @ on the starter clutch holder while holding the start-
CD.
®
er gear
and that the rotor
never turns in the opposite direction of the arrow mark @ .
• Degrease the tapered portion of the magneto rotor and also
crankshaft.
• Fit the key ® and washer ®.
• Install the magneto rotor assembly.
• Apply THREAD LOCK SUPER " 1303" to the threaded part
of the nut and tighten it to the specified torque with a 27
mm box-end wrench.
99000·32030; THREAD LOCK SUPER ··1303"
Tightening torque: 130 N -m 113.0 kg-m . 94 .0 Ib-ft)
13-27 DR35DRISER ,'94·MDDELI
TRANSMISSION ASSEMBLY
0 ,32
mm
0 :28 mm
I Spacer
Retainer
:2
3 Spacer
Driveshaft
Countershah
Note: "0" means the outer diameter of washers .
• Install the spacer CD to the driveshaft @) before installing
the retainer @ .
OR350R/SER ('94-MOOEL) 13-28
EMISSION CONTROL CARBURETOR COMPONENTS (DR350SER)
DR350SER motorcycles are equipped with precision. manufactured carburetors for emission level control. These ca rburetors require special mixture control components and other percision adjustments
t o function properly .
There are several carburetor mixture control components in each carburetor assembly. Three (3) of
these components afe mac hined to much c loser toleran ces than standard mac hined carburetor jets.
These three {31 particular jets - MAIN JET, NEEDLE JET. PILOT JET - must not be replaced by standard jets. To aid in identifying these three (3) jets a different de sign 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 needle is also of special m anufacture. Only one clip position is provided on the jet needle.
If repl acem ent becom es necessary the jet needle may only be replaced with an equivalent performing
replacement component. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best possible pe rformance and durability.
Conventional Figures Used
on St andard Tolerance Jet
Components
1 2 3 4 5 6 7 8 9 0
Emission Type Figures
Used On Close Toleranc e
Jet Components
I
2 3 Lf 5 5 '7 B 9 0
The carburetor specification for the emission-con trolled DR350SER are as foHows.
Carburetor
1.0. No.
14ES
(California model)
14EP
(Other state models)
Main
Jet
Needle
J et
J et
Needle
Pilot
J et
Pilot
Screw
#12'1.5
0-6
5CD16
#:1'1.5
PRE-SET
DO NOT
ADJUST
The pilot screw is pre-set by the fac tory utilizing specialized testing and adjusting proced ures. The
pilot screw is not adjustable as the idle c ircuit is "sealed " after fac tory adjustment. Adjusting, interferring 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 ca rburetor servicing requirements tamper w ith the carburetors the Suzuki dealer should rest ore the carburetors to their original condition or if unable to effect repai rs. contact the di stributors representative for further technical information and assistance.
13·29 DR35DR/SER ('94.MDDELI
IGNITION AND STARTER SYSTEM (DR350SER)
DESCRIPTION
The capacitor discharged ignition system consists of a signal generator, COl unit. ignition coil and
spark plug. The electrical energy generated by the signal generator charges the capacitor. This energy
is released in a single surge at the specified ignition timing point. and current flows through the primary
side of the ignition coil. A high voltage current is induced in the secondary windings of the ignition
coil resulting in strong spark between the spark plug gap. Ignition cut-off circuit is incorporated in
the COl unit . If the crankshaft turns in the reverse direction and reverse current is produced . this circuit works on the capacitor to cut off the primary current of the ignition coil . It causes no sparking
between spark plug gap.
The staner system consists of a side-stand switch, neutral switch . clutch switch and side-stand relay. This function is to supply the current from the battery to the side-stand relay and starter relay
only when the transmission gear is at the neutral position or when the side·stand is at the upright
position .
Neutl al indic ator light
COl unit
Ignllion
s witc h
Sta rte r bu tton
Fuse
'::-;:~:"" VI
T
,,: Battelv
Signal
generator
Ignition coil
Slde· s tand
switch
Tachomet er
Starter
m otor
Note: Clutch switch is installed only for U.S.A. and Canada.
r
~
1
DHJ5UR/SEH fS4-MODELI 13·30
GENERATOR (DR350SER)
GENERATOR STATOR COIL
• Remove the frame covers and seat .
• Disconnect the generator lead wires.
Measure the resistance between the lead wires with a pocket
tester as shown in the illustration .
09900-25002: Pocket tester
Generator stator coil resistance (OR350SERI
Charging coil : 0 .1 - 1 .5 0 IV-VI
Power source coil : 350-650 0 IW-Bri
Pick-up coil No.1: 350 - 700 {l IG - BII
Pick-up coil No.2: 350- 700 {} IY -Grl
WIRE COLOR
B : Black
BI : Blue
Br : Brown
G : Green
Gr : Gray
W : White
Y : Vellow
GENERATOR STATOR INSTALLATION
c oil N o. 2
,k-up coil No. 1
Magneto
lead wire
DA350SEA
13·31 DR35DRISER ('94-MDDElI
COl UNIT (DR350SER)
• Remove the frame covers and seat .
• Disconnect the COl unit lead wires.
Check the continuity and measure the resistance values with
a pocket tester .
09900-25002: Pocket tester
WIRE COLOR
81
; Blue
8r
: Brown
G
Gr
W
Y
BIW
aN
81 /8
BIIR
GJR
W/BI
W!R
DR350SER
: Graf!fl
: Grav
: White
: Yollow
: Black with White tracer
: Black with Yellow tllcar
; Blue with Black u acer
: Blue w ith Rod trSCG!"
: Green with Red tracer
: White with Blue tr lCet
: While with Red tracer
Unit: kO
NO TE:
As capacitors, diodes, etc. are used i nside this COl unit, the resistance values will defter 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 COl unit or inspect the magneto
coils, ignition coils and spark plug. If the magneto coils, ignition coils and spark plug checked are cor·
rect, the COl unit may be faulty, replace the COl unit with a new one.
DR350RISER ('94-MDDElJ 13-32
STARTER MOTOR (DR350SER)
STARTER MOTOR REMOVAL AND
DISASSEMBLY
• Remove the exhaust muffler .
• Remove the engine oil pipe
cable holder bolts.
CD aher loosening the clutch
13·33 DR35DR1SER 1'94-MDDEl)
• Remove the cam chain tensioner adjuster.
• Discon nect the starter motor lead wire CD.
• Remove the s tarte r motor .
• Remove the bolts .
• Disassemble the sta rter motor.
o
,
STARTER MOTOR INSPECTION
CARBON BRUSH
When the brushes are worn, the motor will be unable to
produce sufficient torque, and the engine will be difficult to
turn over. To prevent this, period ically, in spect the length of
the brushes. replacing them when they are too short or
c hipping.
DR350RISER 1'94-MDDElI 13-34
COMMUTATOR
If the commutator surface is dirty. starting performance decreases. Polish the commutator with # 400 or similar fine
emery paper when it is dirty .
After polishing it. wipe the commutator with a clean dry cloth.
Measure the commutator under-cut CD.
Service Umit: 0 .2 mm (0 .008 in)
ARMATURE COIL
Using a pocket tester, check the coil for open and ground
by placing probe pins on each commutator segment and rotor core Ito test for ground) and on any two segments at various places (to test for open). with the brushes lifted off the
commutator surface .
If the coil is found to be open-circuited or grounded. replace
the armature . Continuous use of a defective armature will
cause the starter motor to suddenly fai l.
09900-25002: Pocket t ester
STARTER MOTOR REASSEMBLY
O-RING
CAUTION :
Replace the O·ring with new ones to prev ent oil leakage and
moisture.
ARMATURE
• Apply a small quantity of moly paste to the armature end .
99000-25140: SUZUKI Moly Paste
• When Installing the motor housing and housing end, align
the marks .
I'
•
13·35 DR35DRISER ('94-MDDElI
STARTER RELAY AND SIDE-ST AND/IGNITION INTERLOCK RELAY
(DR350SER)
STARTER RELAY INSPECTION
• Disconnect the lead wire of starter motor at starter relay .
• Turn on the ignition switch, inspect the continuity between
the terminals. positive and negative. when squeezing the
clutch lever and pushing the starter button .
If the starter relay is in sound condition. continuity if found .
09900-25002: Pocket tester
• Disconnect the lead wires from the starter relay .
• Check the coil for "open". "ground " and ohmic resistance .
The coil is in good condition if the resistance is as follows .
Starter relay resistance: 3 - 7 n
09 900·2 5002 : Pocket test'a r
SIDE-STAND SWITCH INSPECTION
BlacklWhite
Green
ON
(Up-right position)
0-
I
-0
OFF
(Down position)
SIDE-STAND/IGNITION INTERLOCK RELAY
INSPECTION
Disconnect the side-standlignition interlock relay .
First, check the insulation between CD and ® terminals w ith
pocket tester. Then apply 12 volts to @ and @ terminals .
@ to @ and
to @, and check the continuity between CD
e
and @.
If there is no continuity. replace it with a new one .
09900· 25002: Pocket tester
NOTE:
When inspecting side-stand switch.
connect the <±) probe of pocket tester
to Black./White lead wire and
probe
to Green lead wire.
e
OR3S0R/SER r94·MOOEL/ 13·3 6
BATTERY (DR350SER)
SPECIFICATIONS
Type designation
YTX7L· BS
Capacity
1 2V 21.6 kC (6 Ah)/10HR
Standard electrolyte S .G.
1.320 at 20 ° C (68°F)
I
RECHARGING OPERATION
• Using the pocket tester, check the battery voltage. If the
voltage reading is less than the 12.0V (DC). rec harge the
battery with a battery charger.
CAUTION :
When recharging the battery. remove the battery from the
motorcycle.
Charging period
17
16
,."
13
"
o
NOTE:
10
20
30
40
50
60
Time
fMinUle l'
Do not remove the caps on the battery top while recharging.
,.
Recharging time : O.7A for 5 hours or 3A for one hour
(VI
CAUTION :
13
Be careful not to permit the charging current to exceed 3A
12
(at 0° - 40° C)
at any time.
"
10
• After recharg ing, wait for m ore than 30 minutes and check
the batte ry voltage wi th a pocket tes ter.
• If the battery vo ltage is less than the 12. 5V , rec harge the
battery again.
• If battery voltage is still less than 1 2 .5V after recharging,
repl ace the battery with a new one .
• When a battery is left for a long term without using, it is
subject to discharge. When the motorcyc1e is not used for
more than 1 m onth (especially during the winter season),
check th e battery voltage once a month at least .
100
75
50
25
Of""
Battery charged cond it ion
13·3) DR350RISER ,'94·MDDELI
FRONT FORK (DR350R)
Tightening torque
I
REMOVAL AND DISASSEMBLY
• Remove the front wheel.
• Remove the front brake caliper mounting bolts.
• Remove the front brake hose holder and meter cable guide.
ITEM
N' m
kg-m
CD
@
35
20
35
3.5
2.0
3.5
0
7
0 .7
®
I
OR35DRISER ('94-MOOEU 13,38
• Remove the front fork by loosening the upper and lower
c lamp bolts .
NOTE:
Slightly loosen the front fork cap facilitate later disassembly, before loosening the lower clamp bolts.
• Remove the front fork cap CD by loosening the lock nut @.
• Remove the washer @ and spring @.
•
• Invert the fork and stroke the inner tube and inner rod
several times to drain fork oil. Hold the fork inverted for
a few minutes to drain oil.
• Remove the damper rod bolt.
•
13·39 DR35DRISER ('94·MDDELI
-
• Remove the inner rod.
CAUTION :
Do not attempt to disassemble the inner rod . It is not serv-
iceable.
• Remove the boot by loosening the clamp screws.
• Remove the dust seal <D.
• Remove the oil seal stopper ring ®.
• Separate the in ner tube from the outer tube .
CAUTION :
• When separating the inner tube from the outer tube . both
antifriction metals may be damaged and must be replaced
with new ones.
* The removed oil seal should be replaced with a new one .
•
-
DR350RISER ('94-MDDEl( 13-40
INSPECTION
DAMPER ROD RING
Inspect the damper rod ring for wear or damage.
DAMPER ROD BOlTJQAMPING FORCE ADJUSTER
Inspec t the damper rod bolt/damping force adjuster f or wear
or damage.
DAMPER ROD
Move the inner rod by hand to inspect it jf operating smoothly.
INNER AND OUTER TUBE
Inspect the inner tube and outer tube sliding surfaces for any
scuffing or flaws.
FORK SPRING
Measure the fork spring free length. If it is shorter than the
service limit. replace it with a new one .
Service limit: 551 mm (21.7 inl
13·41 DR35DRISER ('94-MDDEl)
REASSEMBLY AND REMOUNTING
Reassemble and remount the front fork in the reverse order
of removal and disassembly. and also carry out the follow-
ing steps:
INNER TUBE METAL
• Install the metal by hand.
CAUTION :
Use special care to prevent damage to the "Teflon" coated
surface of the anti ·friction metal when mounting it.
OUTER TUBE METAL. WASHER AND OIL SEAL
• Install the outer tube metal
washer ® and oil seal @
with the special tool.
CD.
09940-50113 : Front fork oil seal installer
CAUTION :
Use special care to prevent damage to the ' 'Tetlon" coated
surface of the anti-friction metal when mounting it.
OIL SEAL STOPPER RING AND DUST SEAL
• Install the oil seal stopper ring @.
•
CAUTION :
Make sure that the oil seal stopper ring fitted securely.
• Install the dust seal ®.
DAMPER ROD BOLT/DAMPING FORCE ADJUSTER
• In stall the oil lock piece to the damper rod .
• TIghten the damper rod bolt/damping force adjuster to the
specified torque .
Tightening torque : 35 N' m (3 .5 kg-m)
CAUTION:
Use a new gasket to prevent oil leakage.
-
•
I
I
OR350RISER ('94-MOOEl) 13·42
FORK OIL
• Place the front fork verticaUy with full compressed position .
• Pour fork oit until its flow from the hole CD on inner rod
as shown in the illustration. and then pour fork oil to the
inner tube .
• For the fork oil , be su re to use a front fork oil whose viscosity rating meets specifications below.
Fork oil type : Fork oil SS-05
99000-99001 -SS5: Fork oil SS-05
Capacity (each leg): 541 mII18.3/ 19.0 US/Imp oz)
• Cover the inner tube with palm . and move the inner tube
up and down 3 or 4 times .
!C....
1:"
'- ,~1r--.
i .. ··· .. ···1
iI!
• Hold the front fork vertical and adjust the fork oil level with
the special tool.
Oil level: 144 mm 15.7 in)
09943-74111 : Fork oil level gauge
NOTE:
When 8djusting the oil leve'; remove the fork spring and compress the inner tube fully.
FORK SPRING
• Install the fork spring as shown in the photograph.
NOTE:
Close·pitch end of spring should position bottom.
13·43 OR350RISER 1'94-MOOElI
INNER ROD AND LOCK NUT
• Install the special tool CD and pull up the inner rod .
09940· 52840 : Front fork inner rod holder
• Adjust the height @ of the inner rod by adju sting the lock
nut ®.
Height @: 14 mm 11 .57 in)
• TIghten the f ront fork cap with your finger. and tighten
the lock nut to the speci fied torque .
TIghtening torque: 20 N'm (2.0 kg-mJ
• When installing the front fork assembly , align the upper
line @ wi th the upper surface @) of the steering stem upper bracket.
ADJUSTMENT
After installing the front fork, adjust the damping force as
follows .
DAMPING FORCE ADJUSTMENT
Slowly turn in the adjuster and find out t he adjuster is seated . From that position , turn back and find out first click that
is l -position then tum back and count the specified position
as follow .
Standard setting: Tum back 9 -positions from
fully turned-in position
WARNING :
Be sure to adjust the damping force on both front fork legs
equally.
®
OR350RISER (,94-MOOEU 13-44
REAR SHOCK ABSORBER
Adjust the spring pre-load and damping force as follows .
DR350R
SPRING PRE-LOAD ADJUSTMENT
• Remove the shock abso rber .
• Loosen t he lock nut and adjust the spring tension o f t he
shock absorber by turning the adjuster ring with the spe-
cial tool.
Standard spring pre-set length : 267 .3 mm '10 .5 in)
09910-60611 : Universal c lamp wrenc h
CAUTION:
After adjusting the pre-load . tighten the spring adjust er lock
ring securely.
DAMPING FORCE ADJUSTMENT
COMPRESSION SIDE
Fully turn the damping force adjuster clockwise. It is at stiffest
posi tion and turn it out to standard setting position as fo11ows .
Stand ard : ' -turn out from fully turned -in pos ition
REBOUND SIDE
Fully turn the damping force adjuster clockwise. It is at stiffest
position and turn it out to standard setting position as follows .
Standard ; 2 h-turns out from fully turned -in position
'
REAR SHOCK ABSORBER SETTING
Sofftest
Spring pre-set length
STD
Stiffest
Damping force
272.0 mm (10.7 in l
267 .3 mm (10.5 inl
259.0 mm (10.2 inl
Compression
STD
, -turn out
Rebound
STD
2 'h-turns out
13-45 OR350R/SER ('94-MOOElI
DR350SER
SPRING PRE-LOAD AND DAMPING FORCE
ADJUSTMENT
Standard spring pre-set length:
DR350SER: 253.4 mm (10.0 inl
09910-606" : Universal clamp wrench
CAUTION:
After adjusting the pre-load, tighten the spring adjuster lock
ring securely .
SE I liNG TABLE
Spring length
STD
: 253.4 mm 110.0 inl
Softer : 258 .4 mm (10.2 in)
Stiffer : 235 .9 mm I 9 .3 in)
Damping force adjuster
Compression : :v.. tumed-out position from the
fully turned -in position .
NOTE:
Fully turned-in position provides stiffest damping force.
••3,
11
•
WIRING DIAGRAM (DR350SER)
.. .. ,. .. ..
~
•
•
,~
~
I
1: ...
DR350RISER 1'94·MODELI 13-46
I ....""3,,,., ..
i !
13-47 OR350RISER ('9I1-MOOEl)
WIRE ROUTING (DR350SER)
,
,
•
harness
Speedomelc, cable
" . . . . .,
Lead
COlt
cove,
Clamp
Clamp
harness
harness
Clamp
To nelltral
indicator
switch
Clamp
50,.",.:
111010'
genera tor
DR350R/SER {'94-MODEU 13·48
1__
-----\/ Staner motor lead wire
Clamp
Ganeralot
Battery ground WIfe
overflow hoso
If):cept f OI california model!
,",,.'1 indicator switch lead wire
13-49 OR350RISER {'94-MOOELI
CABLE ROUTING (DR350SER)
Clu lCh cable
hose
~~
\
Clutch
Cable
Throttle cable
1B'
harness
lu",h cable
harness
= _Throule Cable
harness
Harness
, guide
Wiring
cable guide
OR350RISER 1'94-MOOELI 13·50
CARBURETOR HOSE ROUTING
DR350R
Cytinder head breathe!" hose
Crankcase "!"eath'" hOse
Air vent
hose
vent
IL)
Pass
the air venl hose IRI
between
crankcase and frame.
LH
_.,~ vent hose III
RH
RH LH -
VIEW B
Wiring harness
VI EW A
Carburetor clamp position
DR350SER
Pass through the air vent hose Il ) in
front of the fuel
Cylinder
of the carburetor.
breat her hose
ven t
ILl
LH + l- RH
VI EW B
LH
-+- RH
VIEW A
Carburetor clamp posit ion
Air vent hose (l)
13-51 DR35DRISER ('94·MDDElI
CANISTER HOSE ROUTING (California model only)
(DR350SER)
Wiring harness
_
'uellank
PUlga air
harness
Purge
harness
Thronle
Roll-over volI,,e ~
Purge air
hose
Purge hose
Wiring harness
Surge ho,;e, ...
hose
100 - 200 mm
Purge ai, "ho,;.
UP
Surge hose (Red stripel
1
Roll-over
hose (Red stripe)
Purge hose
ho••
FOREWORD
This section describes service datB and servicing procedures which differ from those
of the OR350R/SER ( '94-MOOELJ.
NOTE:
Please refer to the sections 1 through 13 for details which are not given in this section.
, - - - - - - - - - - - - - - - - - - - CONTENTS - - - - - - - - - - - - - - - - - - - -
SPEC/FICA TIONS .............................. .... ................. , ................... 14- 1
SERVICE DA TA ................ .. ...... ....... ... ............ ... .. ............ .... ...... 14- 3
CARBURETOR ................................. .... ............... -......... " ........... 14- 19
WIRE ROUTING ................... ... , .... -, ............ ..... -,- .. .............. .. ...... 14-20
CABLE ROUTING ................... ......................... " ......................... 14 -2 1
14-1 DR350SISES 1'95-MDDELI
SPECIFICATIONS
DR350S
DIMENSIONS AND DRY MASS
Overall
length .. _ . . • . . • . . . . _ . . • . . . . . . • . . . _ ..
Overall wid th . _ . . . . . .
Overall
. ...... •. .•. . •.....
height . . . . . • . . . . . . . . . . . . • . . • . • •.. ...
Wheelbase . . . . ..... _ . . . . . . ••.•• _ .... • . _ . . . .
Ground clea rance ........• • . _ ............... .
Seal height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drv mass .•... " •. " , , •........ __ .. _ .•. _' ..
2 165 mm {85.2 inl
885 mm (34 .8 inl
1 250 mm 14 9 . 2 in)
1 4 50 mm 157 . 1 inl
310 mm (12 .2 inl
920 mm (36. 2 inl
113 kg 12491bll
ENGINE
Type ..•..•...•.......•.••••••••••••••.•••
Valve cleararn;l!. IN . . . . . . .. .• . .•.••.••.....
EX . . . . . • . • • . • • . • • . . • . . ••...
Number of cvlinder . . . . . . . . . . . . . . •..•..•. .....
Bote . . . . . . . . . . . . . . , . . . . . . . . • . . . . . . . • . . . . .
Stroke ••••.•••••.•.............•.••••.••.
Piston displacemen t ..........•..... •..•... . ..
Compression rati o .•....•..•. . •..•. .•.• .. •...
Carburetor ....•..... , ..•..•...•.••. , • .••..•
Air cleaner . . . . . . . . . . . . . . . • ..•..•.. . .••.....
Starter sys tem ...........•.....•..•.........
Lubrica tion system . . . . . . .. . . . . . . . . . . . . . . . . . .
TRANSMISSION
Clutch . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . ....
Transmission ........... .. • • . .•.• •.. .. ••....
Gearshift pauern . .........•. . •.••.. . . • •.•...
Primary redu<:t ion ratio ........•.....•.........
Gear ratios, Low ....•..............•.....•..
2nd ............................
3rd ..•.••.......... ........... .
4th .. . . . . . . .. . . . . . . . . . . . . . . . .
51 h .. . . . . . . . . . . . . . . . . . . . • . . . . . .
Top .. ... . .
Final reduction ralio ...........• . ••.•• . •. . • ...
Drive chain .............. •. . ...•..•. ••... ..
. .. ....... ........ .
CHASSIS
Front suspension .......•..
•
• • • • • • • • • • • ••
••
Rear suspension ............. . •. .•.. •.••.....
Front suspension strOke . . . . . . . . . . . . . . . . . . . . . . .
Rear wheel uaval . ................. . . ...... .
Caster .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .
Trail .....................•.• • ..•.. .. ....
Stet'lring angle ........••.••.••..• .. • . •• .... .
Turning radius .......• • ..... . ..•.. . ........
Front brake . . . . . . . . . . . . . . . . . . . . . . . . . ...... .
Rear brake •............. , ................. .
Front l ire lize ...•.......................•..
. ....... . . . . . . . . . . . . . . . . . . . . . . . .
Rear tire
5lze
FOUl-stroke, ail-cooled with SACS. OHC
0.05- 0. 10 mm 10.002 - 0 .004 lnl
0 .17 - 0 . 22 mm (0.007-0.009 inl
1
79.0 mm (3. 110 in)
71.2 mm (2. 803 in)
348 <:m' 121.2 cu . ii'll
9.5 : 1
TM33SS . lingla
Polyurethane foam element
Primary kick
Dry sump
Wet multi·plate type
6 ·speed cons ta nt mesh
I ·down, S·up
3 . 200 (64/ 201
2 .416 (2 9 / 12)
1.733 (261 151
1.333 (2 4/181
1.111 (201181
0 .952120/ 21)
0 .826 (19/ 231
2 .933 144/ 151
DIDS20VCS. 110 links
Telescopic. coil spring. oil damped. compression damping force 12·way
adjus table .... EO'. 03
Telescopi<:, call spring. oil damped. spring preload fully adjustable. com·
pression damping force adjus table .... E94
link type. coil spring, gasloil damped, spring preload lully adjustable .
compression and rebound damping force fully adjustable
280 mm 111 .0 in)
280 mm 111 .0 in )
62" 30'
1 18 mm (4 .65 in)
4 5" fright & left)
2 .3 m 17 . 5 It)
Dis<: brake, hydraulically operated
Disc brake, hydraulically operated
80/100·21 5 1M , tube
110/ 100· 18 64M . tube
ELECTRICAL
Ignil ion t ype •..•.....•...... ............. ..
Ignition timing ..... .•..... . . . . . . . . . . . . . . . . . .
Sperk plug .....•..•..•.....................
Generetor ......•.....•. • .. • . .• ........•...
Headlight . .. .......•.• • ..•.• • .••.••. . •.....
Taillight .....•.................•.••..•.•...
CAPACITIES
Fuel tank including reserve .•..•......... .......
Relerve . . . . . . . . . . . . . . • . . . . . .. . . . ..
Engine oil. oil change . . ...•..•.... •• . .• . .• ..•.
with 'ilter change .......••.••.•.....
overhaul . . . . . . . . . . . . . . . . . . . .. . ... .
Front fOlk oil leach legl •..•..••..... ..........
\
n;"~,"
(C Ol)
. above 4300 r lmin
Of NIPPQNOENSO U27ETR
9.5 l
1.8 L
1700
1900
~
2
100 m
m ll ;i:~~,i
~!
54 1 m l 18.3/ 19.0
..
DR350SISES ('95-MDDEU 14-2
DR350SES
DIMEN StQNS AND DRY MASS
Over.1 length
,
Ovtlfall widlh
Overall helghl ..
Wheelbase . .
Ground clearance
Seat helghl
Dry rna ..
ENG IN E
.. ..... ...
• •••
. . . .. .
E)( ••.
• • ••
••
TRANSMISSION
.
Tr.nsmi.afon • .. ..
..
Plimary reduc tion ratio .
Gear rllics, low
••••••••••••••• •
• • • • • • • • • • • • • •
· . .. .. . ..... .
· ..
.. .. ..
.• .• .• .• .• .• •. .• .• .• .• .• •. .• .
..
••
2nd _
".
41h .
•• • • •
..... - ..
..........
-_
• •• • •
.
..... .
· .. . .. ........ .
. .. . . . . . . . .
. . .. . .. ........ .
•
"h
Top ..
Fine' reduc tion rat io
Ort.... c h'ln
Four·suoke, alr·cooled w ilh SACS. OHC
0 .05 - 0 . 10 mm 10,002 - 0 .004 Inl
0 . 17 - 0 . 22 mm 10.007 - 0 .009 Inl
• • • ••
•••••• •
9.5 : 1
BST33. single
,
Polvurethane foam &lemenl
Electric
Dry sump
Wet multi·plile type
a.lpeed conllanl rnuh
I ·down , 5·up
3 . 200 1641201
2.416 1291'2)
1, 733126115)
1 333 (24 118)
1.111 (2011 8 )
0 .952120121)
0 . 826 (19/ 231
2. 733141115)
DIDS20VC5. 108 Imk l
. .....
. -
oIt d.mped , Ipring pl'eto.d fullV IKlJUllab4e .
.. .
F, on t lJuspenslon stloko .. ........... .......
· . ... ,....... ..
Resl wheel travel
Cas tel
...
· . .... ..
. . . . .. ....... .
TI. A •• • . •...•
St_log aogle
..· ........... .......
..
..... .
Turn log lad'\115
.. .. . . , .... ...
Front b,.ke
8· wav edjustable
gas/o il damped, spling preload lunV.dJustabie.
force lullV adjustabht
Roar I USpension ....
Re.r br.ke . ..
F,o nt til e .I~ • ..
Re.r lira Sll .
E18. 22
Others
•••••••••••••
· . . .... - .. .. .....
·..
.. ............ .
.... ... .- ..
..
Gearshift pan ern .. _ .
2335 mm (91.9101 ..
2 235 mm 1880101 ••
885 mm 134 . 8 inl
1 245 mm 1"9.0 Inl
1
mm (56. 7 Inl
mmlll .4lnl
mm 135,0 Inl
kg 1288 Ib.1
· . . •.... ....... .. ,
... ....... .. . 79.0 mm 13. I 10 Inl
71 . 2 mrn 12.803 Inl
.. ...
..... ..
. , ..... ..
..........
- . 3 48 em' 121.2 cu. Inl
•
Complostlon ,atio .
CHASSIS
F,ont ,ulJpension
•• • ••
• • • • • • • • • • • •
.. . ....... ..
- . .
. ..........,.......
Number 01 c ytlndm .
Bore •
•. •
51toke .
PislGO dllplacemenl
C.rburetor .....
Air cleaner . .
Su,rta' I'l'l tern ..
lubrication sys tem
••••
.. ,.' .....
.
-
,
Type ..... .
Valvo c lear once, IN ...
Clutc h . . . ..
,
-
.. ..........
..
. .... ..
. ..... ..
..,
............. ..
ELECTRICAL
Ignition type
• . • • .......
Ignition timing
• • . •• ., .•
•.
Spelle. plug ..
• •.• • .. ,'
, . , .••..
Balterv
•. , . . •. •.... . • ...
Gener.tol
..
...
....•...
Fuse .
. ..
. ...•..•...
Headligtn
• •
• •.
.•.
Position light
• . .• .• . _ • . .•. _ • ,
Tum signal Ught . ... . •.. _ . • . . • • • _ ••.••...
hiliBrake Ught . . .
. ......••. . .•. • ..
Lic Gfl.e plele light . . . . . . . . . . . . . . . . . . • . . . . . . . .
Speedomeler light . . ... • ...• , •• , •• , .. .. •.•
Tachometel light .... . . . . . . . . . . . . . . . . • . . . . . .
NeVlIII indM:..IOI' light . • . .. ...•...... . ......•
High bAm lndatOf light . •
• . • • • .• •• • •.
Turn slgnat indiutOf light .
, •.••• , •..•.
CAPAC ITI ES
Fuel tank , Includin g rese rve .
... ...
. ... .. .
..
ROlerve . .
.. .
."
Engine oil. oil c hange . ........
, . , • •• .. ,
,
w ith filter change ... ..
overllaul .
, . .... . . . . . . . . . . ..
F,on t fork oil (each legl .. ..... .,
-
.......
.
11
(4 . 53 in)
45 0 lright & lell )
2.30'117. 5 It )
Ollc bnlke, hvdraullcally operatod
OiIC brake, hVdr aullcelly ope reted
80(100-21 SIP
110190· 18 81P
Three· phale
'5' 60/55W
12V
. generator
"w
12V
12V 2'W
12V 5 f2 1W
12V 5W
12V 1. 7W III 2 pes'
12V 3W
12V 1.7W
12V 1.7W
12V 1.7W
8 .0 L 12 . 111 .8 USllmp gal ). . . E33
9 .0 L 12 .4/2.0 USllmp gall ... Otho rs
2.0 L 10. S/0 .4 USllmp gal)
1 700 mill 8 11 . 5 USllmp qt)
1 900 0'11 12.011 , 7 USflmp ql)
2 100 m1 12 211 8 US/lmp ql)
569 ml 119.2 / 20.0 US/lmp 0,1
14-3 DR350SISES ('95·MODEU
SERVICE DATA
DR350S
VALVE + GUIDE
Unit: mm (in)
STANDAiiD
I
~
e
IN .
11. 20)
27 .0
1
EX.
~
UMiT
IN .
10.002 - 0 .004)
EX.
Valve._g~~de to
clearance
stem
Va'vestem~
rv,
guide 1.0 .
Valve stem runout
•
le
10.014)
5 .000 - 5 .012
10: 1969 - 0 . 1
IN.
~-0. 1965)
EX.
10. 1951 - 0 . 1957)
~
10.02)
,d:J;;
IN . & EX.
. 1.
10.035 - 0 .0431
IN . & EX .
Varve head radial runout
r;ee 'ength
ng
~
IN . & EX.
IN . & EX .
~ seat
~
EX .
IN . & EX .
Valve stem end length
~
10.0004 - 0 .0015)
IN . & EX .
Valve stem 0 .0.
~
IN.
•
IN . & EX.
1)
INNER
11.38)
OUTER
1~74~1
IIN.&Ex.
INNER
I
I
OUTER
atl
1 kg
DR350SISES ('95·MDDEL) 14·4
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
ITEM
Cam height
STANDARD
IN .
EX.
Camshaft journal oil clearance
Right side
Left side
Camshaft journal holder 1.0.
Right side
Left side
Camshaft journal 0 .0 .
Right side
Left side
LIMIT
33.450 - 33.490
11.3169 - 1.3185)
33.520 - 33.560
11.3197 - 1.3213)
0.032 - 0.066
10.0013 - 0.0026)
0.028-0.059
10.0011 - 0.0023)
22.012 - 22.025
10.8666 - 0 .8671)
17.512 - 17.525
10.6894 - 0.6900)
21.959 - 21.980
10.8645 - 0.8654)
17.466 - 17.484
10.6876 - 0.6883)
0.10
10.004)
Camshaft runout
Rocker arm 1.0.
Rocker arm shaft 0.0 .
IN . & EX.
IN. & EX .
12 .000-12.018
10.4724 - 0.4 731)
11 .973 - 11.984
10.4714 - 0.4718)
0.05
10.002)
0.05
10.002)
Cylinder head distortion
Cylinder head cover distortion
0- 2
10 - 0 .08)
De-compression lever play
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
Unit : mm (in)
STANDARD
0.055 - 0.065
10.0022 - 0.0026)
79 .000 - 79.015
13. 1102-3. 1108)
78.940 - 78.955
13.1079 - 3.1085)
Cylinder bore
Piston diam .
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
1
33. 150
11.3051)
33 .220
11.3079)
0.150
10.0059)
0.150
10.0059)
151
R
2nd
R
151
2nd
10.2
10.40)
11 . 1
Approx . 10.44)
0 . 15- 0.30
10.006 - 0.012)
0.35 - 0 . 50
10.014 - 0.020)
Approx .
I
LIMIT
0 . 120
10.0047)
79.075
13 .1132)
78.880
13. lOSS)
0.05
10.002)
8 .2
(0.32)
8 .9
(0 .35)
0 .70
10.0281
0 . 70
10.028)
14-5 DR350S/SES ('95·MODElI
ITEM
Piston ring to groove clearance
STANDARD
151
1s1
2nd
Oil
Piston ring th ickness
151
2nd
Piston pin bore
Piston pin 0 .0 .
1.01 - 1.03
(0.040 - 0 .041 1
1.01 - 1.03
(0.040 - 0 .041 1
2 .01 - 2 .03
(0.079 - 0 .0801
0 .97 - 0 .99
10.038 - 0 .0391
0 .97 - 0 .99
(0.038 - 0 ,0391
20.002 - 20.008
(0.7875 - 0 .78771
19 .996 - 20.000
(0.7872 - 0 .78741
CON ROD + CRANKSHAFT + BALANCER
ITEM
Conrad small end 1.0.
Conrod big end width
Crank web to web width
20.030
10.78861
1 ~ . 980
10.78661
Unit: mm (in)
STANDARD
LIMIT
20.006 - 20.014
(0.7876 - 0 .78801
20,040
10.78901
3.0
(0. 121
1.0
(0.041
Conrod deflection
Conrod big end side clearance
LIMIT
0 . 180
(0.0071
0 . 150
(0.0061
2nd
Piston ring groove width
I
0 . 10 - 0.55
(0.004 - 0 .0221
21 .95 - 22.00
(0.864 - 0 .8661
60.0 + 0 . 1
(2.362 ± 0 .0041
0 .05
10.0021
10.3
(0.4 11
Crankshaft runout
Bal ancer spring free length
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressu re (at 60 ° C, 1400F)
STANDARD
1.590 (35/221
Above 40 kPa 10.4 kg/em', 5.7 psil
Below 140 kPa ( 1.4 kg/cm 2 , 19.9 psi)
at 3 000 r/min .
LIMIT
DR350SISES 1'95·MODEL) 14-6
CLUTCH
Unit : mm (in)
ITEM
Clutch lever play
STANDARD
LIMIT
10 - 15
(0 .4 - 0 .6)
2 .72 - 2.88
(0 . 107 - 0 . 113)
15.8 - 16.0
(0.62 - 0 .63)
Drive plate thickness
Drive plate claw width
2.42
(0 .095)
15.2
(0 .601
0 . 10
(0.004)
29.5
(1.161
Driven plate distortion
Clutch spring free length
TRANSMISSION + DRIVE CHAIN
Unit: mm (in) Except ratio
--------~~~=---------
Shift fork to groove clearance
1- 0 .3
,,--- = = -0 .01
groove
(0. 197 - 0 . 200)
Shift fork thickness
No.1 ,No. 2
•
20-pitch length
Drive chain slack
25
1.0 - 1
19.4
(12 .
14·7 DR350S/SES 1'95·MODElI
CARBURETOR
1
turn back
0 .5 - 1.0 mm 10.02 - 0 .04 inl
cablel
ELECTRICAL
Unit: mm (in)
I
Spa rk plug
Type
NGK: CR9 EK
Gap
0 .6 - 0 .7
10.024 - 0 .0281
etm .
Ignition coil resistance
•
Primary
0 . 1 - 1.011
Termina l
Ground
Secondary
12 - 22 k!l
Terminal
cap -
Magneto coil resistance
More than 40 V (AC) at 5 000 r/min .
1
Y- 8
WATTAGE
I
Unit: W
ITEM
SPECIFICATION
55
5
Head~t
Tail!!i!lt
BRAKE + WHEEL
Unit: mm lin)
~
liMiT
STANilARo
Brake lever play
~
Ie. ' disctiii(
(0 ,2)
Front
(0, 138 ± 0 ,008)
Rear
(0 lii~ ~ g~8)
~ disc runout
Master cylinder bore
Master cylinde r piston diam .
Brake caliper cylinder bore
Front
Wheel rim runout
1
1- ,
(O, 5000 ~6, 5017)
Front
(604~~~ - 10~~~~.
Rear
(O~~~
Front
(1,0630 - ; :0650)
27 ,000 - 27,050
(1 .0630 - 1
Front
(1 ,0591 - 1.0610)
Rear
~60;go
1
1 -- 269~
1,061
Axial
Tire size
In.e treaddePth
3.5
(~))
(0,08)
Radial
Wheel axle runout
(03i~8)
1
Rear
Rear
Brake caliper piston diam .
±0:2
,
,
Front
10.010)
Rear
100~,~)
F.
~151M
~
'-!PIle . ~
Front
Rear
,
10,16)
SUSPENSION
Unit: mm (In)
ITEM
Front fork stroke
STANDARD
280
( 1 1 .0)
UMIT
551
(21.7)
608
(23.9)
Front fork spring free length
Front fork oil level
144
(5.67)
145
(5. 71)
Rear shock absOl bar 9 as pressure
1 000 kPa
(10 kg/cm2, 142 psi)
Rear shock absorber spring
pre-set length
Rear wheel travel
E-Ol,03
E-94
E-Ol ,03
E-94
267 .3
11 O. 5)
268.2
110.6)
280
(11.0)
E-Ol,03
E-94
0.3
(0.01 )
Sw ingarm pivot shaft runout
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
NOTE
•
kPa
kg/cm2
pSI
100
100
1.0
1.0
14
14
DR350SISES 1'95·MODEl) 14·10
FUEL+OIL
ITEM
SPECIFICATION
Use only unleaded gasoline of at least 87
Fuel type
NOTE
pump octane (" ; M method) or 91 octane or
higher rated by the research method.
Gasoline containing MTBE (Methyl Tertiary
Butyl Etherl. less than 10% ethanol , or
less than 5 % methanol with appropriate
•
cosolvents and corrosIon inhibitor IS
permissible .
Gasoline used should be graded 85-95
octane or higher. An unleaded gasoline is
recommended .
Fuel tank including reserve
reserve
Engine oil type
Engine oil capacity
Front fork oil type
Brake fluid type
E· 01 ,94
9 .5 L
12. 5/ 2. 1 US~mp gal)
1.8 L
10. 5/0.4 US/Imp gal)
SAE 10W/40, API SE or SF
1 700 ml
Change
11.8/ 1..5 US/Imp qtl
1 900 ml
Filter change
12 .0/ 1.7 US/Imp qtl
2 100 ml
Overhaul
12. 2/ 1.8 US ~ mp qtl
Fork oil SS05
Fork oil # 10
Front fork oil capacity (each leg)
E·03
541 ml
118.3/19.0 US~mp ozl
586 ml
119 .8/20.6 US /Imp ozl
DOT 4
I
E· 0 1,03
E-94
E·01 ,03
E-94
DR350SES
VALVE + G~
Valve di,
Unit: mm lin)
~
•
IN •
1~201
27
EX.
Valve clearance (when
,Idl
.! 0
10.002 - 0.0041
IN .
EX.
Valve guide to valve stem
clearance
Valve stem deflection
~gUide~
Valve stem 0 .0 .
Valve stem runout
~
Valve stem end length
~seat
~
liN . &
Valve sp ng
IQ
jIrOO length
~
17 -= g.22
IN.
10.0004 - 0.00151
EX .
0.0~g-~:~~21
10.001
•
IN. & EX.
10.0141
IN . & EX.
5.000 - 5.0 12
10. 1969 - 0 . 19731
IN .
Ji 1959 - 0.19651
EX.
4.955 - 4 .970
10. 1951 - 0 . 19571
•
IN. & EX .
10.0021
IN. & EX .
~<i21
IN. & EX .
0 .9 - 1. 1
10.035 - 0 .0431
IN . & EX .
Valve head radial runout
I
10~'
•
IN . & EX .
INNER
10.001)
35.
11 .
OUTER
1 .491
111.714.~,101 in
~
INNER
mm
13. 1 - 15.1 kg
OUTER
at
~9 - 33.3
1
31.5 mm 1:24 in
,
DRl50S/SES ('95·MOOELI 14-12
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
IN.
•
EX .
oil clearance
Right side
Left side
journal holder 1.0.
Right side
Left side
Camshaft journal 0 .0 .
11.30791
0 . 150
Right side
Left side
10,00 1 1 - 0 .00231
2 - 22.025
•
10.8666 - 0 .86711
-1
1
10,6894- 0 .69001
-2 1.980
2 1.
10.8645 - 0 .86541
- 1
1 •
6876 - 0 .68831
0 .10
runou t
Rocker arm
arm shaft 0 .0 .
1
10 .00591
IN . & EX .
IN . & EX .
1 .
- 1
10.4724 - 0.47311
11.973 - 11 ,984
10.4714 - .
10 .0021
Cylinder head cover distortion
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clea rance
Cylind er bore
Piston diam .
Unit: mm (in)
STANDARD
LIMIT
0 .055 - 0 .065
10,0022 - 0 .00261
79.000 - 79 .015
13 . 1102 - 3 ,11081
78.940 - 78.955
13. 1079 - 3 .10851
Measure at 15 mm (0.6 in) from the skirt end.
0.120
10,00471
79.075
13. 11321
Cylinder distortion
Pi ston ring free end gap
Piston ring end gap
151
R
2nd
R
151
2nd
10.2
Approx . 10.401
11. 1
Approx . 10,441
0 . 15 - 0 ,30
10,006-0,0121
0 ,35 - 0 ,50
10,014 -0, 0201
78.880
13. 10551
0,05
10.0021
8 .2
10 .321
8 .9
10,351
0 ,70
10.0281
0 .70
10.0281
ITEM
Piston ring to groove clearance
STANDARD
LIMIT
1st
2nd
Piston ring groove width
1.01 - 1.03
10.040 - 0 .041)
1.01 - 1.03
10.040 - 0 .0411
2 .01 - 2.03
10.079 - 0 .080)
0 .97 - 0 .99
10.038 - 0 .0391
0 .97 - 0 .99
10.038 - 0 .0391
20.002 - 20.008
10.7875 - 0 .78771
19.996 - 20.000
10.7872 - 0 .78741
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Pi ston pin 0.0 .
20.030
10.78861
19.980
10.7866)
CONROD + CRANKSHAFT + BALANCER
ITEM
I
l
0 . 180
10.007)
0 . 150
10.006)
Unit: mm (in)
STANDARD
20.006-20.0 14
10.7876 - 0 .78801
Conrad small end 1.0.
Conrad deflection
0 . 10 - 0 .55
10.004 - 0.022)
21 .9 5 - 22.00
10.864 - 0 .866)
60.0 ± 0. 1
12.362 ± 0 .004)
Conrad big end side clearance
Conrad big end width
Crank web to web width
I
LIMIT
20.040
10.78901
3 .0
10. 12)
1.0
10.041
0 .05
10.0021
10.3
10.41)
Crankshaft runout
Balancer spring free length
OIL PUMP
ITEM
STANDARD
Oil pump reduction ratio
Oil pressure (at 60°C . 140 oFJ
1. 590 135/22)
Above 40 kPa (0.4 kg /cm2, 5 . 7 psi)
Below 140 kPa I 1 .4 kg/em', 19.9 ps il
a t 3 000 r/min .
,
LIMIT
DR35DSISES ('95·MDDEU 14-14
CLUTCH
Unit: mm (in)
ITEM
STANDARD
LIMIT
10 - 15
Clutch lever play
(OA - 0 .6)
2 .72 - 2.88
(0.107 - 0 . 11 3)
15 .8 - 16.0
(0.62-0.63)
Drive plate thickness
Drive plate claw width
2042
(0.095)
15.2
(0.60)
0 . 10
(0.004)
29 .5
(1.1 6)
Driven plate distortion
Clutch spring free length
TRANSMISSION + DRIVE CHAIN
Unit: mm (in) Excep t r8tio
r-------~~~--------r---------~S=TA~N=D~A=R=D-----------
0 .5
(0.020)
Shift fork to groove clearance
groove
(0 . 197 - D.200)
Shift fork thickness
4 .8 - 4 .9
189 - 0 .
No. 1,No.2
3
--,--,-;-c -:--------t--'=& No .
20-pitch length
Drive chain slack
25 - 40
(1 .0 - 1.6)
(12 .57)
14-15 DR35DSISES r95·MDDElI
CARBURETOR
ITEM
14EK
5
-+----~ -m
~m~---+------~:-------4
PRE-SET
0 .5 mm
(0.02 - 0 .04 in)
(pulling cable)
ITEM
Carburetor type
80re size
1.0. No.
Idle r/min .
Float height
Main jet
Main air iet
Jet needle
Needle jet
Throttle valve
PiloUet
By-pass
Pilot outlet
Valve seat
Starter~t
Pilot screw
Throttle cable play
(pulling cable)
(M.J.)
(M.A.J .)
(J .N.)
(N .J .)
(Th.V.)
(P.J.)
(B.P.)
(P.O.)
(V.S.)
(G .S.)
(P.S.)
E-22.24
BST33SS
33 mm
14EM
I 500 ± , 00 r/min.
14.6+ 1.0 mm
(0.57 ± 0 .04 in)
#127 . 5
0 .6 mm
5CD56-4th
0 -5
# 115
#37 . 5
O.B.O.B.O.B
0 .8 mm
1.5 mm
#35
PRE-SET
( 1 Va turns back)
0 . 5 - 1.0
(0.02 - 0 .04 in)
mm
mm
SPECIFICATION
E-2B
-----
14ER
--
PRE-SET
(13A turn s back)
-
E- I B
--
14EL
1400+50 r/min. I
---
# 132. 5
0 -7
0 .9 mm
--
PRE-SET
(2.0 turns backl
14-16
ELECTRICAL
Unit: rnm (in)
-----,---.:...
NO: U27ETR
Spark plug
~__
TV_P_e__~____~N~GK :e R9~E~
K ____-+________~
-
Gap
Ignition coil resistance
.
10.024 - 0 .028)
•
0. 1 - 1.0 {J
Primary
I
Ground
Plug ca p-
1-__________--I_seCOnd_a"l
_-l--_ _ _ 1 2 - 22 kO _ _ _+--.:c
Te rmina" ,I_-l
Magneto
resistance
More than 60 V (AC) at 5 000 r/min .
y- y
Battery
1.320 .t 20 0 e 158°F)
WATTAGE
Unit : W
ITEM
1.7
14·17 OR350SISES 1'95·MOOEU
BRAKE + WHEEL
ITEM
Unit: mm (in)
Brake lever play
Rear brake pedal height
Brake di sc thickness
Front
Rear
STANDARD
0 .1 - 0 .3
10.004 - 0 .0101
5
10.21
3 .5 ± 0 .2
10. 138 ± 0 .0081
4 .0 ± 0 .2
10. 157 ± 0 .0081
LIMIT
Brake disc runout
Master cylinder bore
Front
Rear
Master cylinder piston diam .
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam .
Front
Re ar
Wheel rim runout
12.700-12.743
10.5000 - 0 .50171
12 .700-12.743
10.5000- 0.50171
12 .657 - 12.684
10.4983- 0 .49941
12.657 - 12.684
10.4983 - 0 .49941
27 .000- 27.050
11 .0630 - 1.06501
30.230-30.280
11.1902 - 1.1921 1
26.900 - 26.950
11.059 1 - 1.06 101
30. 160 - 30. 180
11 . 1874 - 1.18821
2 .0
10.081
2.0
10.081
0 .25
10 .0 10 1
0 .25
10.0101
Axial
Radi al
Wheel axle runout
Front
Rear
Tire s ile & type
Front
+
3 .0
10 .1181
3 .5
10. 1381
0 .30
10.0121
80/ 100-21 SIP
Dunlop D601J IE-03,28,331
Dunlop K560J lothers l
110/90-1861P
Rea r
Tire tread depth
Front
Rear
..L
Dunlop 0601 IE-03,28,331
Dunlop K560J lothers l
3 .0
10. 121
3 .0
10. 121
DR35DSISES ('95·MDDElI 14-18
SUSPENSION
Unit: mm (in)
gas pressure
110
11 0 .01
TIRE PRESSURE
COLD INFLATION
TI RE PR ESS:.:U",
R:::.E-+-;0 ;;--F
FUEL+OIL
Use only unleaded gasoline of at least
pump octane fA i M I or 91 octane or higher
Fuel type
rated by the research method .
Gasoline containing MTSE (M ethyl Tertiary
Butyl Etherl. less than 10% ethanol. or less
than 5% methanol with
cosol•
•
I
I
I unleaded gasoline of at least 87
octane (R ;M method) or 9 1 octane or
rated
E-03.33
E+28
the Research Method .
Gasoline used should be graded 85· 95
octane or higher. An unleaded gasoline is
recommended .
Fuel tank in cluding reserve
For the others
E-33
12. 1/ 1.8 USlimp gal)
For the others
reserve
Change
Overhaul
fork oil
Front fork oil capacity (each leg)
Qtl
2 100 ml
12 .2/ 1 .8
Qtl
14-
CARBURETOR
PILOT SCREW REMOVAL AND INSTALLATION
• Remove the plug by carefully punching a hole in it using
an awl or suitable tool.
• Before removing the pilot sc rew . determine the setting
by slowly turning it clockwise and count the number of
turns required to lightly seat the screw. Turn t he screw
counte rclockwise to remove it.
Plug
NOTE:
Th is counted number is important when reassembling pilot
screw to original position.
• When installing the pilot screw, turn it in fully but not tightIy. From that position turn it out the same number as
counted during removal.
• Install the new plug in the pilot screw hole .
screw
DR350SISES r 95·MODEll 14-20
WIRE ROUTING
30·
1_-------.1- -
Starter motor lead wife
aua,v ground w ire
Clamp
"b'''"to< overflow hose
(Ellcept for california model)
~-- Neutral Indicator switch lead w ire
14-21 DR350SISES 1'95·MODEll
CABLE ROUTING
Ilu",'; cable
,,,"! hose
~~
\
I cable
18 '
Clu tch cable
harness
=~ ThrOllle Cable
'--'W,,,,n
harness
Harness and cable guide
guide
cable
Wiring
, - - - - - - - - - - CONTENTS:- - - - - - - - - SPECIFICA TIONS .. ............... ..... .... ............................................. 15- 1
SERVICEDATA ........................ ..................... ........ ... ·· .. ············· 15- 3
15·1 DR350T/SET ('96·MDDELI
SPECIFICATIONS
DR350T
DIMENSIONS AND DRY MASS
Ove,.11 length ...
. . . . . .. . . ., .....•. .. ..
. . . . . . . . .. ..• •.. •. . ..
Dver,1I ~Ighl .
... . . .
..
• ..... _ .....
Wheelbase . __ . . • . .• .• _ . • • . • .• .•
• •••
Overall width . . . ..
Glound clearance • .. • _ ••.. ,.. . •..• . . •...
5fult height .. ... .. .......•.. . •.... .. ...
DrV mIss . . . . . ..
...
.. . ...
. . . . . . . . .. . . .
2 165 mm 185.2 In l
8SS mm 134.8 IIlI
1 250 mill (49. 2 Inl
1 450 nvn 157. 1 inl
310 mm 112. 2 IIlI
920 mm 136. 2 Inl
113 kg 1249 Ib,l
ENG INE
Type •• •. ••.•.. ••.• •.•••• • ••••••. ••.• • •. ••
Valve cle,lIfence, IN ... , .... _ .. _. . ..•... •... .
EX .. . •• .••.••.••.••. • • ...
Number of cytinder . , . . . . . . . .. • •••• •• • • • • • • •
Sofa •••••.••..•..•••••••••••••••.•• • •
Stroke .... __ . . . . . . __ ..
Piston displacement ..
.. _ .. _ .. _ .. _
. •.
..
. .
Compression rllio ........ . .•
. .......... .
• . . .... . .. .
Carburetor . . . . . . . . . .
. . ... • .••.• . .. . ....•.
Air cle8ner . . . .. . .....•...
. .
. ....
St8rter syltem ..
lubrlcetion Iystem .
.
•• • • • • • • • • • • •
·. . . . . . .
· .. ........... .... .... . .
. .
TRANSMISStON
Cluteh . . . . .
. • • . . • .. • ••... .
Ttansmission . . .
. . .•. .•
• • . • • . •• •• • •..
Ge!l1"Sllift penem
•• .•.••. • • • .• ..
Primary reduclion ralio . . • .. •• • .•• •• • • ....
Ge8r ratios. l ow ....
. ...• ..... • . •. .. •... .
21ld .. . .. . ... .. .. . . . . . . . . . . . .
.
..... .
3rd .
4,"
..
51" ..
Top ..
Alla l redUC lioll lalio
Drive chain . . .
. .. .. .........
...
.. ...... . .
· .............. .. ... .
· .. . . . . .. . . . . . .. . .
.......................
. .
CHASSIS
Front suspell,ioll
Reer suspension
• • ••
•
. . . ....
••••••••••••
. . .. .. ..... .
.. .... . . .. ..
. . .
Front suspension "toke
Rear wl"leel Ira vel ... .
• •
•• • • • • • • • •
.
CISler .... .
Tra il • . • . • • •
••
Steeting allgle . .
.
• •
. •.••••....•....
Tum1ng red lus ...... ••
.
• ••. • ..•..
Front brake . .
. . . • • ..•..•..•.•..••.••. . .
Rear brake . . .. ... ..•.•. • ....••. • •.. . ...
Front tife lite
• . . . . . . . •. • ....... .
Rear lile lize .. .... . ..
. ..
. •. .... .
ElECTRICAL
Ignitioll type . . . .
Igoitioll liming . . .
.. .. .
,
79.0 mm 13. 110 In)
71.2 mm 12.803 iIll
349 em ' 121.2 cu. illl
9.5 : I
TM33SS. ,ingle
Polyurethane foam element
Primary kick
Dry sump
Wei multi·plale type
6 ·.peed COilS Ian! me.h
l-down. 5·up
3 .200 (64 /20)
• 2 .500 (30112)
I. 733
. .. ...... .... ..
•
• •
FOUI ' ltroke, air·cooled with SACS, OHC
0 .05 - 0 . 10 mm 10,002 - 0 .004 inl
0 . 17 - 0 . 22 mm 10.007 - 0 .009 inl
..
.. ... .. .. .
. . . . . . . .. . . . . .. . . . . . . . . .
Spark plug . . • • • . . • . . .. ...... . . . . ••.••...
Generator . .
. . . •• .•.••. ., •.......
Headlight . . . . . .. . .... . . . . . . . • .
•.••.••.•
Tel1tig"" • .
. •• • .........•..•. . •........
link.
Tele.copic. coil spring, oil damped , comprenion dampil"lg fOfCe 12·way
adfu"able "" EOI , 03
Telesco pic. coil ,pdog. oil damped , Ipring preload fuUy adju5IlIble, com·
pre..ion damping fOlce edju"able .... E94
Unit type , coil .pring, g ..JoIi damped . ,pring p.eload fuily adjustable.
Comp.essioll and rebound damping force luily adj\.lslable
28Ommlll .0inl
2S0 mm 111 .0 IIlI
62° JO'
118 mm 14 .65 illl
4 So (right & leftl
2.3 m 17 . 5 Itl
ol.c brake, hydrauli cally ope rated
ol.c brake, hydrauli cally operated
801100·21 SlM , tube
1101100· 18 84M, tube
ElecllOflic ignition ICDII
30° B,T,D.C. above 4300 r/min
NGK CR9EK Of NIPPONoENSO U27ETR
Flywheel magneto
1 2V S5W
12V SW
CAPACITIES
fuel tank Including reserve ..•...........•..•...
Reserva . . . .. . .. . .. .. ., . . . . . . . . . . .
engine oil. oil dlal\Q8 ......•.....••.•.•••.•..
with liller change ...•...•..........•
OVefhaul .•...........••.. .• . •.... .
FrorH lark ojl leach legl .......••.••.•.•...•..•
,,
qt'
qt'
. qd
Im~: ozl ... E-O I , 03
1m
Asterisk marie ( · 1 Indicates the New " T" model spacificatlon.
ozl ... E· 94
DR350SET
DIMENSIONS AND DRY MASS
0"8'." ler\gl"
•
Overa" width
Overell helghl
Wheelb.,.
. ....
Ground cle~nee
Sea. heighl . . .
Dry mall
• •
ENGINE
Typo . ..
Valve clearance, IN
'X
Number 0 1 CVl1ndlti
BOI •
•
•
..... .....
............
.. . .. . . - ..
.
••
·•.
·
••
Suoke . . .
. ...
Pislon dia.placemenl
Compr... 1on 11110 ,.
e.,OO' OIOl .
Air c...nar .
Statter 'VII8m
..
,
.,
••
• • • • • . , •••
•
· '" .... - ...
.... .. .. ...
- ...
. .. .
· . . . . .. ... .. . .
· . . . . .. .
•
lubricel!on 'Vltam
•
1
..
79.0 mm 13. 110 in)
71.2 mm 12 .803 Inl
3 48 c m l 121.2 cu . InJ
9.5 : 1
BST33• • ingle
Polyurelhane loem etemenl
EIecHIC
Dry sump
• •
• • • • • • • • • • •
•••••••••••••••••
• • •••••••••••
•••
•••• • •••••••
E18, 22
Others
Four·strOko . air -cooled wrth SACS, OHC
0 .05 - 0 . 10 mm 10 .002 - 0 .004 inl
0 . 17 - 0 .22 mm 10.007 - 0 .009Inl
• • • ••• • •• • ••••
· . . . . .. . .. . . . . . .
,. . ............ .
· ....... - ... .
•• •
•
·
.. .. . .. - . . .
•
•
2 335 nvn 19 1 9 Inl
2 235 mm 188.0 inl .
885 nun 134 .8 inl
1 2 4 5 mm 149.0 inl
1 440 mm 156. 7 Inl
290 mm 11 1. 4 Inl
890 mm 135.0 Inl
130 kg 12861b,'
TRANSMISSION
Clutch . .
•.
T,.namlulon ..
G--.hlh ~ttern
•
• •• • • • • • • •
• • • •••
•
• •• •• • •• •
PI "'...ry redUChon 1800
••
. - ....
•
· - ...... .
·. .. ... ...
,.
..
,
. . , . . .. ..
., .,...... . .... ..
· ........
, .. , .
.. . ..... .
Gear 'eliOt . Low ..
2nd
••
"'d
4,"
•••••••
.
S.h
T"" .
FiRit! reduction 18" 0.
0"",. eN"n
CHASSIS
Fronl 'Ulpen,lon
..
·
Fro n! .Ulpenllon ' Hoke .
Rellr wheel trayel .
CaSio r .
Trail ..
.
•
S leating englo
Turning rad ius .
••
Fronl brake
Reer brake
Fronl tMe 'Iza
Rear tire .Ize
•
..
..
..
• • • • • •• • •• • ••
• • • • •• • ••
.. .. ..........
.......... .
.........
• •• ... .......
...... .... ........
•
•
•
"
•
•
.
••
••
••
......
ELECTRICAL
• • • •• •.
Ignition tYIM .
Ignition timing
."
•. • •...
Spa'" plug
. .. . •..
Bauery
.
,
.•.
. ...
GlIf'lua"II'
• .. •. • ..•.... " .. , ,
Fu", .
• • . •.•
•...•
HellClhgtu
. ,. , .••.••.• , .• , .,.
PoSition light .
• •.. ,. , .•.•..•
Turn .ignat light
• .•
• ....•.. • .•.. , ..
TaalBrltk, light . .
. . . . . . . . . • .. ..
Lken.e plete light
• . .. . .•..•.....•...•.
SpeedOlTlltltr Itght .. .. .... .' .•••. • .. • ..•.
Tachon'llter fighl ..
. ••...•.•.• , • • , •• , •.•...
Neutra' indicator light ...•..•..••• . .. . •. • • • ....
High beam Indica lo r IIghl . . . . . . . . . . . • . , •.... , .
Turn algnal indica tor Ught . . • . . . . . • . . . . . . . . . . . . .
CA PAC ITIES
Fuol lank , Including roserYo ..
............
Re.erye .
., • ,
. . . • . • . . .. •. .
Engine oil, oW c hange .. .... . , . . . . . . . . . . . . •.
whh filler chenge .
. ......... .
oyerhaul ,..
.. . . . . . . . . . . . . . ..
Front fork 011 leach legl
. . .
108 link,
Tete.copic . coit .pring . 011 damped , s prrng preload lully IIdjusleble.
comprossion damping lorco a · wey edjusleble
Link type , coil .prlng . ges /oll demped , sp ring proload Iu lly IIdjus lable ,
com proslion damping lo rc. lutlv edjul ill ble
280 mm (11. 0 Inl
255 mm 110.0 Inl
62 ° JO'
115mm 14 . 53 in)
4 5'" (right & le ltl
2.3 m (7.5 h )
OIIC brake. hydraullcallv operaled
alae: brake, hvdreuhceUv OQeraled
801100-21 S I P
110/90 18 61P
EleCltOOtC IQMian lCOII
JOo B.T. D.C. aboy. 4300 r/mln
NGK CA9EK Of N IPf"ONOENSO U27fTR
12V 2 1 6 kC (SAh)11 OHR
ThlH· ph... A.C . genllfllOl'
"A
12V 6O/S5W
12V 4W ". ExcfIC)t for [-03, 24. 28. 33
12V 21W
1 2V 512 1W
12V 5W
12V 1. 7W ht 2 pc.)
12V JW
12V 1. 7W
12V 1.7W
12V I 7W
8 .0 L (2 1/ 1.8 USllmp g.,I) ... E3J
9 .0 l 12 .4 /2.0 USllmp gill). . Othors
2 .0 L (0. 5/0.4 USfimp glill
1 700 mlll . e l 1. S USllmp ql'
1900 ml 12 .011 . 7 USllmp Qtl
2 100 ml (2 .211 . 8 USllmp qll
569 ml ( 19 2/ 20.0 US/Imp 011
Ast lfisk mIt,k , · )lndica t .. me Nllw "T" modeIspllcification.
15-3 DR350T/SET ('96-MDDEU
SERVICE DATA
DR350T
VALVE + GUIDE
Unit: mm (in)
~"'-----r--,
--
I
•
IN _
11 . 20)
_ --t-_E
_X_. _ - t - _ _ _
Valve clearance Iwhen
COidJ
~=
7.
. ,- ,
IN.
/0 .002 - 0 .004)
~_ =--,-:::;:-:::-:::-::-::---+-_EX_ ._ _---";;:.;
O~
: ~
~_ _ __
Valve
clearance
~?
to valve stem
IN .
(0.0004 - 0 .0015)
EX.
IN. & EX.
10.014)
IN .
EX.
Valve stem runout
0 .05
IN . & EX.
Valve h IdthiCCkn.S'--~;:-;;-;-I-----==--IN. & EX .
Valve stem end length
Valve sea'---width
Valve head radial runout
1.B
10.07)
IN . & EX .
IN . & EX.
----'-10.02)
'-
10.035 -ri:043)
003, )
IN . & EX.
tv;;~;;;;;;;;;-;;:;;;-;;;;;;:;;;;---r----j-------- ---";
\I~_'vE:! spring free length
liN . & EX.)
INNER
11.3B)
37.B
11.49)
OUTER
Valve spring 'ension liN. & EX.)
,-'--
5.3 - 6 .5 kg
11 1.7 - 14.3 Ibs)
inl I
I----f--'a""-"=
2B.0 mm 11.10--"-"---j-_ _ _ __
INNER
OUTER
L-_ _ _ _ _ _ _ _ _ _L-_ _ _L-..:a""-'.'''''
1
I~~)
12BJ = j3:j
31.5 mm 11.24 in)
DR35DT/SET /,96·MDDEl/ 15·4
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
STANDARD
ITEM
Cam height
IN .
EX.
Camshaft journal oil clearance
Right side
Left side
Camshaft journal holder 1.0.
Right side
Left side
Camshaft journal 0 .0.
Right side
Left side
33.450 - 33.490
11.3169 - 1.3185)
33.520 - 33. 560
11.3 197 - 1.3213)
0.032-0.066
10.0013 - 0.0026)
0.028 - 0.059
10.001 1 - 0 .0023)
22.012 - 22.025
10.8666 - 0.8671)
17 .512 - 17.525
10.6894 - 0 .6900)
21.959 - 21.980
10.8645 - 0 .8654)
17.466 - 17.484
10.6876 - 0 .6883)
0 . 10
10.004)
Camshaft runout
Rocker arm 1.0.
Rocker arm shaft 0 .0 .
IN . & EX .
IN . & EX .
12 .000 - 12 .018
10.4724 - 0.4 731)
11.973 - 11.984
10.4714 - 0.47181
0.05
10.002)
0 .05
10.0021
Cylinder head distortion
Cylinder head cover distortion
0- 2
10 - 0 .081
De·compression lever play
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
Cylinder bore
Piston diam .
Unit : mm (in)
STANDARD
LIMIT
0 .055 - 0 .065
10.0022 - 0.0026)
79.000 - 79.015
13 .1102 - 3.1108)
78.940 - 78.955
13 .1079 - 3 .1085)
0 . 120
10.0047)
79.075
13 .1132)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
LIMIT
33.150
11.3051)
33 .220
11.3079)
0.150
10.00591
0 . 150
10.0059)
1st
R
2nd
R
1st
2nd
10.2
10.40)
11. 1
Approx . 10.44)
0 . 15 - 0.30
10.006 - 0.012)
0 .35 - 0 .50
10.014 - 0 .020)
Approx .
78.880
13.1055)
0 .05
10.002)
8.2
10.32)
8 .9
10.35)
0.70
10.028)
0 .70
10.0281
15·5 DR35DT/SET (,96·MDDEl)
)TEM
)
Piston ring to groove clearance
STANDARD
lst
2nd
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin 0 .0 .
1.01 - 1.03
10.040 - 0 .041 )
1.01 - 1.03
10.040 - 0.04 1 )
2 .01 - 2 .03
10.079 - 0 .080)
0 .97 - 0 .99
10.038 - 0 .039)
0 .97 - 0 .99
10.038-0.039)
20.002 - 20.008
10.7875 - 0 .7877)
19.996 -20 .000
10.7872 - 0 .7874)
CON ROD + CRANKSHAFT + BALANCER
)TEM
Conrad small end I.D .
Conrad big end width
Crank web to web width
20.030
10.7886)
19.980
10.7866)
Unit: mrn (in)
STANDARD
LIMIT
20.006-20.014
10.7876 - 0.7880)
20.040
10.7890)
3 .0
10.12)
1 .0
10.04)
Conrad deflection
Conrad big end side clearance
LIMIT
0 . 180
10.007)
0 . 150
10.006)
0 .10- 0 .55
10.004 - 0.022)
21.95 - 22.00
10.864 - 0 .866)
60.0 + 0.1
12.362 + 0 .004)
0 .05
10.002)
10.3
10.41 )
Crankshaft runout
Balan cer spring free length
OIL PUMP
ITEM
Oil pump reduction ratio
Ojl pressure (at 60 ° C. 140° F)
STANDARD
1.590 (35/22)
Above 40 kPa (0.4 kg/cm2, 5.7 psi)
Below 140 kPa ( 1.4 kg/cm 2 , 19.9 psi)
at 3 000 r/min .
LIMIT
DR350TISET ('96·MDDEL) 15·6
CLUTCH
Unit : mm (in)
Clutch lever play
10 - 1
-+_--;;-; ;---1
=-:-:-::-_ _--j_ _ _ _ _ 10.4 - 0 .6) _ _ _ _
•
1
~~~~~__~~____~________~
10~.107 - 0. " ~
3~
) ________t-~10'·50J95!)__
Drive plate claw width
I.
distortion
~c--,------,----,;---,-----::____~__________________________
Clutch spring free length
0 .10
-+__-,-,;
10.004)
11 . 16)
TRANSMISSION + DRIVE CHAIN
Unit: mm (in) Except ratio
LIMIT
1 - 0 .3
- 0 .01
Shih fork to groove clearance
groove
Shift fork thi ckness
-;;-:- -.-- ::::=.:..-'
No. 1,No.2
= -,----t-----'=""--
(0 . 197 - 0. 200)
4 .8 - 4 .9
. 189 - 0 .1
•
I
20·pitch length
Drive chain slack
Asterisk mark (*1 indicates the New " T" model specification.
(12 .57)
15-7 oR350TISET 1'96-MooELI
CARBURETOR
ITEM
screw
Throttle cable
1 1/a turn back
0 .5 - 1.0 mm 10.02 - 0.04 inl
ELECTRICAL
Unit: mm (in)
Tvpe
Gap
NGK : CR9EK
0 .6 - 0 .7
atm .
•
I
Primary
0 . 1 -1 _0 11
Secondary
12 - 22 kll
Plug cap Terminal
0 . 1 - 1 .511
h~~rto",;:i()8diVc;rt,;g,;--i~~M~ore than 40 V lAC) at 5 000 r/min .
Regulated voltage
Terminal Ground
Y- 8
DR350TISET 1'96·MDDELJ 15·8
WATTAGE
Unit: W
ITEM
SPECIFICATION
55
5
Head~t
Taillight
BRAKE + WHEEL
Unit: mm (in)
ITEM
Brake lever play
Rear brake pedal height
Brake disc thickness
Front
Rear
STANDARD
0.1 - 0 .3
10.004 - 0 .010)
5
10. 2)
3.5 ± 0.2
10. 138 ± 0 .0081
4 .0 ± 0.2
10. 157 ± 0 .008)
Brake disc runout
Master cylinder bore
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper pi ston diam .
Front
Rear
Wheel rim runout
2.0
10.08)
2.0
10.08)
0 .25
10.0 10)
0 .25
10.010)
Axial
Front
Rear
Tire size
Front
Rear
nre tread depth
Front
Rear
3 .0
10.118)
3.5
10. 138)
0 .30
10.012)
11 .000 - 11.043
10.4331 - 0.4348)
12.700 - 12.743
10.5000- 0 .5017)
10.957 - 10.984
10.4314 - 0.4324)
12.657 - 12.684
10.4983-0.4994)
27.000 - 27.050
11.0630-1.0650)
27.000 - 27.050
11.0630 - 1.0650)
26.900-26.950
11.0591 - 1.0610)
26.900 - 26.950
11 .0591 - 1.06 10)
Radial
Wheel axle runou t
UMIT
80/ 100-21 51M
1101100-,864M
4 .0
10. 16)
4 .0
10.16)
15·9 DRJ5DT/SET 1'96·MDDELI
SUSPENSION
Unit: mrn (in)
----,-111.01
Front fork spring free length
E-Ol,03
123.91
144
Front fork oil level
E-94
E-Ol ,03
E-94
15.711
1 000 kPa
(10 kg/cm2, 142 psi)
Rear shock absorber gas
Rear shock absorber spring
pre-set length
267 .3
1-__ 10 .
E-Ol ,0 3
•
E-94
110.61
Rear wheel travel
runout
10.01 I
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
kPa
kg/cm2
pSI
FRONT
REAR
100
100
1.0
1.0
14
14
•
OR350T/SET ('96·MOOELJ 15·10
FUEL + OIL
SPECIFICAnON
Use only unleaded gasoline of at least 87
pump octane ( R i M m ethod) or 91 octane or
higher rated by the research method.
Gasoline contain ing MTBE (Methy l T ertiary
Butyl Ether), less than 10% ethanol, or
less than 5% methanol with appropriate
cosolven ts and corro sIon inhibitor is
permissible.
Gasoline used should be graded 85-95
octane or higher. An unleaded gasoline is
recommended.
Fuel tank including reserve
9 .5 L
(2. 5/2 . 1 usnmp gal)
reserve
1.8 L
(0.5/0.4 US/Imp gall
SAE 10W/40. API SE. SF or SG
Engine oil type
1 700 ml
Engine oil ca pacity
Change
(1.8/1.5 US/Imp qtl
1 900 ml
Filter change
(2.0/ 1.7 US/Imp qtl
2 100 ml
Overhaul
(2.2/ 1.8 US/Imp qtl
Front fork oil type
Fork oil 5S05
Fork oil # 10
Front fork oil capacity leach leg)
541 ml
(18.3/ 19.0 usnmp ozl
586 ml
(19 .8/ 20.6 US/Imp ozl
Brake fluid type
DOT 4
ITEM
NOTE
Fuel type
E·03
E-O l.94
E-Ol .03
E-94
E·O l .03
E-94
15·11 DRJ50TISET ('S6·MDDEU
DR350SET
VALVE + GUIDE
Unit: mm (in)
j(jijjffi I~
\131"..
..!!.1'.1.'!
IN .
11.201
.2
1
EX .
Valve~ cold)
IN.
(0.002 - 0.0041
~~
EX .
Valve guide to valve stem
clearance
1~1 51
IN .
~6g~~ .~
EX.
Valve stem deflection
Valve guide 1.0 .
~stem
0 .35
(0.0141
IN. & EX .
5.000 - 5.012
1969 - 0 . 1
IN. & EX.
•
IN.
10.1959 - 0 . 19651
4 .955 - 4 .970
(0. 1951 - 0 . 1S571
EX .
Valve stem runout
V,'vehead thick
Valve stem end leng th
~se.t~
Valve
IN . & EX .
(0.021
IN . & EX.
~O8
.
1
10.035 - 0 .0431
IN . & EX.
Valve head radial runout
~ifri9
0 .05
IN . & EX.
I nsth
•
IN . & EX .
INNER
(1 .381
OUTER
1~74~1
'ns tension IIN.&EX.I
INNER
I
(l~lF~~1
-
OUTER
I
128 . S - 33 . 3 , 11~
15·12
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
ITEM
Cam height
STANDARD
IN .
EX.
Camshaft journal oil clearance
Right side
Lett side
Camshaft journal hold er 1.0.
Right side
Left side
Camshaft journal 0 .0 .
LIMIT
33.450-33.490
11.3169 - 1.3 1851
33.520 - 33.560
11.3197 - 1.32131
0.032 - 0.066
10.0013 - 0 .00261
0 .028 - 0 .059
10.00 11 - 0.00231
22.012 - 22.025
10.8666 - 0.86711
17.5 12 - 17.525
10.6894 - 0.69001
21 .959 - 21 .980
10.8645 - 0.86541
17.466 - 17.484
10.6876 - 0 .68831
Right side
Left side
0 . 10
10.0041
Camshaft runout
Rocker arm I. D.
Rocker arm shah 0 .0 .
12.000 - 12.018
10.4724- 0.47311
11.973 - 11.984
10.4714 - 0.4 7181
IN . & EX.
IN . & EX.
Cylinder head distortion
0 .05
10.0021
0 .05
10.0021
Cylinder head cover distortion
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
(Automatic-decamp. actuated )
Unit: mm (in)
STANDARD
Approx.
LIMIT
kPa
C1 1100
kg /em
1
'5~~i
)
0.055 - 0.065
10.0022 - 0.00261
79.000- 79.015
13. 1102 - 3 .11 081
78.940 - 78.955
13. 1079 - 3. 10851
Piston to cylinder clearance
Cylinder bore
Piston diam .
Measure at 15 mm (0.6 in) from the skirt end .
Cylinder distortion
Piston ring free end gap
Piston ring end gap
33.150
11.30511
33.220
11 .30791
0 .150
10.00591
0 . 150
10.00591
1st
R
2nd
R
1st
2nd
10.2
10.401
11 . 1
Approx .
10.441
0.15 - 0.30
10.006 - 0.0121
0 .35 - 0 .50
10.014 - 0 .0201
Approx.
0 .120
10.00471
79.075
13.11321
78.880
13. 10551
0.05
10.0021
8 .2
10.321
8.9
10.351
0 .70
10.0281
0 .70
10.0281
15·13 DR350TISET 1'96·MDOElI
to groove
groove
0 .1
1st
10.D07}
2nd
1
(0.006)
1st
1}
1.01 - 1.03
(0.040 - 0 .04 1 )
2nd
•
Oil
Piston ring thickness
(0.079 - 0 .080)
- 0 .99
10.038-0.039}
1st
2nd
Piston pin bore
•
(0.038-0.039)
20.002 - 20.008
(0.7875 - 0 .7877)
1
(0.7872 - 0 .7874)
20.030
(0.7886)
1
(0.7866)
CONROD + CRANKSHAFT + BALANCER
Unit: mm (in)
LIMIT
small end 1.0 .
(0. 12)
big end side clearance
•
10.864 - 0 .866}
60.0 :t
362 :t
web to web width
run out
(0.002)
10.3
Balancer spring free length
OIL PUMP
ITEM
O i ~~mp reduction ratio
Oil pressure (at 60 oC. 140 0 F)
I
STANDARD
1. 590 135/22}
Above 40 kPa (0.4 kg/em', 5.7 ps i)
Below 140 kPa ( 1.4 kg/cm 2, 19.9 psi)
at 3 000 r/min .
I
LIMIT
DR35DTISET 1'96·MDDEl) 15·14
CLUTCH
Unit: mm (in)
ITEM
Clu tch lever play
STANDARD
LIMIT
10 - 1 5
(0 04 - 0.6)
2.72-2.88
10. 107 - 0 . 11 3)
15.8 - 16.0
10.62 - 0 .63)
Drive plate thickness
Drive plate claw w idth
2042
10.0951
15 .2
10.60)
0 .10
10.004)
29.5
(1 . 16)
Driven plate distortion
Clutch spring free length
TRANSMISSION + DRIVE CHAIN
Unit: mm (in) Except ratio
• 2 .866 (43 / 15)
ratios
•
Low
Shift fork to groove
groove
Shih fork thickness
No. 1.No .2
lriW!Chii - - - - - - ! - - - "& NO .3
(0.197 - 0 . 200)
4 .8 - 4 .9
_ _--' ~'89 - 0. '
20-pitch length
Asterisk mark (.) indica tes the New "T" model specifications .
(12.57)
15·15 DR350T/SET f 96·MODELJ
CARBURETOR
ITEM
IP.S.)
Pilot screw
0.5 - 1.0mm
10.02 - 0 .04 in)
Throttle cable play
(pulling cable)
ITEM
E-22
BST33SS
Carburetor type
Bore size
33 mm
!.D . No.
Idle r/min.
Float height
Main jet
Jet needle
Needle jet
Throttle valve
PilotJ!'t
Starter jet
Pilot screw
• PRE-SET
IM .J .)
IJ.N .)
IN .J .)
ITh.V .)
IP.J .)
IG.S.)
IP.S.)
'14DA
1 500 ± 100 (Imin .
14.6± 1.0 mm
10.57:t0.04 in)
#127 . 5
'5C027-4th
0 -5
# 115
I
#37.5
#35
PRE-SET
(1Va turns back)
Throttle cable play
(pulling cable)
0 . 5 - 1.0 mm
10.02 - 0.04 in)
PRE -SET
SPECIFICATION
E-28
-
E-18
14ER
14EL
1 400± 50 rlmin .
--
-
-
PRE-SET
( 1 Jtt turns back)
-
Asterisk mark (.) indicates the New " T " model specifications .
--
-
# 132. 5
---
0 -7
PRE-SET
12.0 turn s back)
-
DR350T/SET r96 ·MDDEl/ 15·16
CARBURETOR
SPECIFICATION
/
1TEM
Carburetor ..!}pe
Bore size
--
33 mm
1.0. No.
Idle ( Imin .
Float height
Main jet
Jet needle
Needle iet
Throttle valve
Pilot jet
Starter jet
Pilot sc rew
I
E·24
E·94
BST33SS
I
IM.J .)
IJ .N.)
IN.J .I
ITh.V.) )
IP.J .I
IG.S.I
IP.S.)
Throttle cable play
(pulling cable)
14EK
I 500 ± 100 r/min .
14 .6± 1.0 mm
10.57 ± 0 .04 in)
# 135
5C056·3rd
0·3
# 115
#42 .5
#35
PRE·SET
11 'Ia turn s back)
0 .5 - 1.0mm
10.02 - 0 .04 in)
14EM
-
#127.5
5C056· 4th
0 ·5
-
# 37.5
-
ELECTRICAL
ITEM
Ignition timing
Spark plug
Spark performance
Ignition coil resistance
Generator coil resistance
Unit : mm (in)
SPECIFICATION
30 o B.T .D.C. above 4 300 (Imin
NO: U27ETR
Type
NGK : CR9EK
0 .6 - 0.7
Gap
10.024 - 0.0281
Over 8 (0 .3) at 1 atm .
Primary
0 . 1 - 1 .0 !l
Secondary
12 - 22 k!l
Charging
0 . 1- 1.5 I!
350 - 650 !l
350 - 700 I!
350 - 700 !l
Power source I
Pick-up No .1
Pick-up No.2
Generator no-load voltage
(when engine is cold)
13.0 - 15 .5 V at 5000 r/min.
Generator Max. output
Approx . 125 W at 5 000 r/min .
Fuse size
Terminal Ground
Plug cap T erminal
I
Limit : 6 10.24)
limit : 0 .2 10.0081
3 - 7 I!
YTX7L·BS
12V 21 .6 kC 16Ahl/ 10HR
1.320 at 20°C 168 ° F)
20 A
y- y
W - Br
G - BI
y-Gr
y- y
More than 60 V (AC) at 5 000 r/min.
R ~ulated voltage
Starter motor brush le~h
Commut ator under-cut
Starter relay resistance
Battery
Type designation
Capacity
Standard
electrolyte S .G .
NOTE
-l-
15-17 DR35DT/SET ('96·MDDEU
WATTAGE
Unit : W
ITEM
Headlight
~~----~-------
-----
1.7
BRAKE + WHEEL
Unit: mm (in)
ITEM
STANDARD
Brake lever play
Rear brake pedal height
Brake disc thickness
Front
Rear
0.1-0.3
10.004 - 0 .0101
5
10.21
3 .5 + 0 .2
10. 138 ± 0 .0081
4.0 ± 0 .2
10.157 ± 0 .008)
Brake disc runout
Master cylinder bore
Front
Rear
Master cylinder piston diam .
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam .
Front
Rear
Wheel rim runout
Axial
Radial
Wheel axle runout
Front
Rear
LIMIT
3 .0
10.1181
3 .5
10.138)
0 .30
10.012)
12.700 - 12.743
10.5000- 0 .5017)
12.700 - 12.743
10.5000- 0 .50171
12 .657 - 12.684
10.4983 - 0 .49941
12.657- 12 .684
10.4983 - 0 .49941
27.000 - 27.050
11.0630- 1.0650)
30.230 - 30.280
11. 1902 - 1. 1921)
26 .900- 26.950
11 .0591 - 1.0610)
30. 160- 30. 180
11.1874 - 1.1882)
2.0
10.08)
2.0
10.081
0 .25
10.010)
0 .25
10.0101
DRJ5DTISET 1'96-MDDElI 15-18
ITEM
Wheel rim size
Front
Rear
Tire size & t vpe
Front
Rear
Tire tread depth
Front
Rear
SUSPENSION
STANDARD
21 x 1.60
18x2_ 15
80/ 100-21 51?
Dunlop D601J IE-03. 28. 331
Dunlop K560J (others)
110/90- 1861?
Dunlop 0601 IE-03. 28.331
Dunlop K560J (others)
LIMIT
3 _0
10_121
3 _0
10_ 121
Unit: mm (in)
~----r-
16_01
gas
ii'iiirSh?c:kill>SOri;e;-;;p;r.;g--- 11 0
TIRE PRESSURE
15·19 DR35DTISET 1'96·MDDELI
FUEl + Oll
Use on ly unleaded gasoline of at least 87
pump octane (R 2ItA I or 9' octane or higher
Fuel type
rated by the research method .
Gasoline containing MTBE (Methyl Tertiary
Butyl Ether), less than 10% ethanol , or less
than 5% methanol with appropriate cosol -
E-03 ,33
Use only
E-28
pump octane (
rated
Gasoline used should be graded 85-95
octane or higher. An unleaded gasoline is
For the others
recommended.
Fuel tank
reserve
L
12.1 / 1.8 US/Imp gal)
f-----L
E-33
For the others
re serve
oil
Engine oil capacity
Change
Riter change
Overhaul
2 1
. 2 / 1 .8~~ " - -_ _ _ _ __
oll
FOREWORD
This section describes sevice data and servicing procedures which differ from those
of the DR350T/SET ('96-MODEL).
NOTE:
• Any differences between DR350T/SET ('96-MODEL ) end DR350V/SEV 1"97-MOOEL)
in specifications and service data are clearly indicated with the asterisk marks (.).
" Please refer to the sections 1 through 15 for details which are not given in this section.
------------------- CONTENTS ------------------SPECIFICATIONS ....... _...................................................•_... ....... 16- 1
DR350V ................. . ............. ... .......... ........ .. .. .. ........... ...... , ..... 16- 1
DR350SEV ............. .......... ...................................................... 16- 2
SERVICE DATA ., .......... ................ .. ,... .................................... ... 16- 3
DR350V ............... ... ......... ... ................................................... 16- 3
DR350SEV ................................ .................. .. ....... .................. 16-1 1
FRONT BRAKE CALIPER (For DR350V) ..... .. .. .... .. .. .... ... ... ... ........ 16-20
FRONT FORK (For DR350Vj .........................•............ ............... . 16-2 1
SPECIFICATIONS
DR350V
DIMENSIONS AND DRY MASS
Ollerall length ..................•.. . .• .• ....
Ove rall width . . • . . . . . . . . . . . . . . . . . . • . . • . • . . . .
Overall height . _ .......•.............•.•....
Wheelbsse •.•. . •..•.•••••.•. . .. . •..•.• .. •..
Ground c learance . . . . . . . . . . . . . . . . . . . . . • . • . . ..
Seat height ...•... ..... • .. • .•..•.. . ..• • ....
Orymass .............. . ....•..•..•.•••....
2 165 mm 185. 2 inl
885 mm 134.8 Inl
1 250 mm 149 .2 in)
1450 mm (57. 1 Inl
3 10 mm 112.2 inl
920 mm (3 6 . 2 Inl
113 kg (2491bsl
ENGINE
Type .•...•••••••••••.•••.•••.•••.•••.....
ValliI'! chUIIHnC8 , IN • . . . . . . . • . . . . . • . . . . . . . . . . .
EX • . • • • • • • • • • . • • • . • •. . • • • • •
Number of cvlinder .•.....•. •• .•.••.••.••••.•.
Borll . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . .
Stroke ..... , ...............•.•........•...
Oisplacem.ent .. '.' . . . . . . . . . . . . . . . . . . . . . . . . . . .
CompreSSIon fatlO ... . ..........•. . •..•..... .
Carbure tor . : ......... . .•.•••.• •••• .••......
Air cleaner . . . . . . . • . . . . . . . . . . . . . • . • . . • . . . . . .
Starter system . . . . . . . . . . . . . . . . . . . . . . . . . • . . . .
LUbrication system .•.......•.................
TRANSMISSION
Clutch ...............
•... .. . .• .... . ...•...
..
T ransm lSSlon ..•.....•..•...•..........•....
Gearshift pattern . ..•.. .. .....•.••.... • .•....
Pl'imary reduction r atio ....•...................
Geal ratios, Low . .............. • .....•.. , ...
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 rd .........• . ....••..•.••.•...
4th . ..............••.. • ..•... . .
51h ...... . . . . . . . . . . . . . . . . . . . . . .
Top . . . .. . . . . . . . . . . • . . • . . . . • .
Final reduction ratio ...........•.. • .•..•......
Drive chain ...................••....•......
CHASSIS
Front suspension .............•.......••.....
Rear suspension . . . . . . . . . . . . . ..
. ...••.
... ..
Front suspension stroke .... . .•.•....••.••...•.
Rear wheel travel ...... ..... • . .• ..•.••.. . .••.
CaSler . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . .
Trail ................. . .................. .
Steering angle ... ... .........•....•..•...•..
Turning radius ....... . .. .. . .•......•.•..•..
Front brake ......... ••.. • . •.. •..•.•••••....
Rear brake .......... •....... •..... •..•.....
Front tire siza . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear tire size .................•..•..•.
... ..
ELECTRICAL
Ignilion type ................•....•...•.....
Ignition timing ........................•...
Spark plug ..................••.••..••.....•
Generator ............•..•..•.... • .........
Headlight ...........•.• . .•.••..•.•.........
Taillight ...•................•..•. •• .. , .....
CAPACITIES
Fuel tank Including reserve ......•.•••••.••.•...
Reserve . . . . . . . . . . . . . . . . . . . . . . . . . ..
Engine all. oil change ........ . ...•...••. •. ....
with filler change ... . .. • . . .•..••....
overhaul ...............••.........
Front fork oil (each leg\ ....... . . ... .•.....•...
Four·stroke. alr-Gooled with SACS. OHC
0.05 - 0 . 10 mm 10.002-0.004 inl
0 . 17 - 0 . 22 mm 10.007 - 0 .009 inJ
,
79.0mm(3.110inl
71.2 mm 12.803 inl
348 cm) 12 1. 2 cu . inl
9.5 : 1
TM 33SS. single ... E·Ol ,03, 28
• 6ST33SS. single ... E·33
Polyurethane ' oam element
Primary kick
Ory sump
w'" ..m"ultl'constant
Plate type
mesn
1-"
10 links
Tele scopic, coli spring, 011 damped, rebound damping force 17· way ad·
jus table, compression damping ' orce 13· way adjustable
Unk type , coli spring , gasl oil damped, spring preload fully adjustable.
compression and rebound damping force fully adjustable
280mm 111.01nl
280 mm n 1.0 inl
27 ° 30'
118 mm (4 .65 inl
45° Ir ight & left)
2.3 m 17. 5 ft)
Disk brake
Disk brake
801100· 2 1 51M. tube
1 10 / 100· 18 64M, tube
Electronic ignitIon ICOI)
30 0 B.T .D.C. above 4300 r/m in
or NIPPONDENSO U27ETA
9.5 L 12.5/ 2. 1 US/Imp. gal)
1. 8 L 10.5 /0 .4 USlimp . gall
1700 ml 11.8/1.5 USlimp. Qt)
1900 mI12.0/ 1.7 US/lmp . Qt)
2100 ml 12.2/1.8 USllmp. Qt)
495 ml (16.7/ 17.4 USlimp. all
DR350V/SEV ('91·MODEU 16·2
DR350SEV
[HMEN510N5 ANO DRY MASS
Overall length • . . . . . . . . . . . ,
•
•
. .. . . . . . . . . .
Overall width .••.. , . . . . •.
Ov~all
heighl .
. .•.. • • • • • • • • • • • •
. .... . . . ...• . •.....•.. _. .
Wheelbase . .• ...
. . .•. .•
• .••..•.. • ....
Ground clearance . . • . . . • • • • • • • .•
.... . .
Seal heigh l ...•.
Ory rna" ... ..
.-
. ••.••.••
- .......... .. .... .
. - .. -....... .
• ••••••••
ENGINE
TVpe
··· ·················· · ·· ··· ··· · ·· ····
Valve clea rllnce. IN ...... •. . . •..•.••.• • .••..•
EX •••••. . •.•• .• . , ......... .
Number of cylinder . _ ....... _ ....... _ ..••••.•.
Sore • . . . • . . " ............•.......•...
Stroke .•.•••••. , .•.............•..•..• . •.
Olsplacem.ef11 ...•••.•••• • •••••••••••.••. • •••
COfTIpression rado .•..•.•.•••• _ • •.••. • • .••.. _
Ca rburetor ....•.......... • ...•.•••••. . • ...•
Air cleaner. ••.• , , , ' , . , . . . . . . . . . . . . . . . . . . . . .
Starter system ... , . . . . . . .. •. • •.•••...••..•
lubticotion sys tem ... . . ..... . .. . .• •.. • .....••
TRANSMISSION
.......... .
Clutch ..................•.....
Transmission .
. ....... . ...•..•..•..•.•....
Geershift pattern .,........... . ............ .
Primery reduction ratio •..... ..,., .•••..•.•.
Gear rat ios, lo ..... .............. . . . . . . . . . . . . . .
2nd ..... .. . . ........... ....... .
3rd .............. . .. . ......... .
..
4th .
5th ..............•••.• .. •...•••
Top . . . . . . . . . . . . . . • . . . ... • ..•.
Final reduction r.t lo ........•.. , • • • • . . • . • .. .
................... .
Drive chain •.•.•
. ............ ...... .. .
CHASSIS
Flont suspension ...........•• , • , .. , . , ..... .
Rear suspension ..•.... .. ....• , .••..•..• .. ..
Fron t suspension stroke . • .. ... ..... . •....
Rear wheel tr.vel . • . . • . . . . .. ... . .....•..•.
C.Sler . . . . . . .. •.••.•..•.•. . . • .. • .. •. .. ..
Tr. il . . . . • . • • • • , •....•....• •• ..•. • • . . .
Steering Ingle ••....... . ..•.. •..••••••• .. , ..
Turning radIus ........ . ..... . ......... .. ....
F,on t brlke .......... . .....• ........ .......
Relr brake . . • . . , . . . .. .. .. ......... ...... .
From tire size .... . ..... ,..... • .• , ....... .
Aear lire size . . . . . . . • • . • • . • . . • . • • . • • . • • . ..
ELECTRICAL
ignition type ............. ...
, . . ........
Ignition timing .... . ••.•..........•.....•...
Splrk plug ...••••••••.••.••.•.••.••.••.....
Battery ..••.•....•.... • . • .• • •••. • •. • • . • • , .
Generator ........... ... • ..• , •••. , • ..... ...
Fuse .. . . . . .. .. . . . . . . . . . . . . . . .. . . . . . . . . ...
Headlight ••••.•.•........... . . . .... _ ......•
Position light . _ ..•.. _ •..•....• . ... , .•.......
Tum signal fight ..•....•••••••• . . ••••• . •.. ...
TeillBteke light ••.•..••..••••.•• _ . • • . •.• • •...
license ptale light .............. . ..•.... . ...
~Utf light •.••••..•.•.••.............
Techofneter nght .........•...•• ,........ ..
Neutral Indlcltor lig ht ....•. _. .•... . ........ .
High belm Indicator light ...... . •. ...... ..... . .
Turn signal Indicator light ... •..••... .. • •. • •.. . .
CAPAcmES
Fuel tank. inclvdlng reserve ... _ . . •.
• .••....•..
ReSClf'lle ... __ ... ... • ........ ..
Engl.... 011, 011 change . . . . . . . • . . .. . •.••. • .••..
with filter chenge . . .. .••.. ...•.• .
overhaul . . . . . . .. •. • ., ••.•.•..•
Fro m fOlk 011 loach leg) . . . . . . . . . . • • . .,.. • ••
2335 mm 191.9 In, . . . . E18. 22
2 236 mm IB B.O In) ... . . Others
885 mm (34. 6 inl
1 245 mm 149.0 In,
1 440 mm (56.7 Inl
290 mm ( 11 .4 Inl
890 mm (35.0 Inl
130 kg (286 fbsl
Four· s troke, alf·cooled with SACS, OHC
0 .05 - 0 . 10 mm (0.002 - 0 .004 in)
0 . 17 - 0.22 mm (0 .007 - 0 .009 In)
,
79.0 mm (3. 110 in)
71.2 mm (2.803Inl
348 em' (21 . 2 cu. inl
9.5 : 1
BST33SS, single
Polyu rethane foem elemen t
Elec tr ic
Dry sump
We i multi·plalO typo
6·speed constant mesh
l -down, S-up
2.818 (62/ 221 .•. E02,04 ,22. 34
3 .200 (64/ 201 ... Others
2.500 (30/ 12)
1.733 (26115)
1.333 (24/18)
1 , 111 (20118)
0 .952120/ 21 )
0 .826 119/ 23'
2 .867 143/15) .. _ E02. 0 4. 22,34
2 . 733 1411151 ... Others
OID520VC5. 108 links
Tolescopic. coil spring , oil damped. spring pleload full y adjustable,
compression damping fOlce 8· way ad justable
Unk type, coil spring, ga./oll damped , spling pleload fully adjustable ,
comprassion damping fOlce fully edjustable
280mml l' .0In)
255 mm (10.0 inl
27 " 30'
t 15 mm 14 . 53 In)
45° (right & lefO
2. 3 m (7.5 III
,,
51P
6' P
Electronic igni tion (COl)
30° B.T.O.C. above 4 300 rlmin
NGK CR9EK or NIPPONOENSO U27ETR
12V 21.6 kC (6Ahl/l0HR
Three-phase A.C. generator
20A
12V 60f55W
12V 4 W ... E02. 04 . 18 , 22, 34 . 94
12V 21W
12V5/ 2 1W
12V 6W
12V 1. 7W Ix :2 pesl
12V 3W
12V 1.7W
12V 1.7W
12V 1.7W
8 .0 l 12. 1/ 1.8 US/lmp gall ... E33
9 .0 l I2.4 /2 .0 US/lmp gal) .•• Olhers
2.0 l lO.5/0 .4 US/lmp gall
1 700 mll1.8/ 1 . 5 US/lmp qt)
1 900 mI12.0 11 . 7 US/lmp qll
2 100 mI 12.211.8 US/lrllp qll
569 ml 119. 2120.0 US/lmp ozl
16·3 DR35DV/SEV ('97·MDDELI
SERVICE DATA
VALVE+GUIDE
Unit: mm (in)
ITEM
Valve diam .
STANDARD
IN .
EX .
Valve clearance (when cold)
IN .
EX .
Va lve guide to valve stem
clearan ce
IN .
EX.
Valve stem deflection
Va lve guide I.D.
Va lve stem 0.0.
IN .
EX .
Valve stem runout
Va lve head thickness
Va lve stem end length
Va lve seat w idth
Va lve head radial runout
Va lve spring free length
(IN . & EX.I
0 .35
10.0141
IN. & EX .
IN . & EX.
5 .000 - 5.012
(0.1969 - 0 .19731
4 .9 75 - 4 .990
(0. 1959 - 0 .19651
4 .955 - 4 .970
(0. 1951 - 0 .19571
0.05
(0.0021
0 .5
10.021
1.8
(0.071
IN . & EX.
IN . & EX.
IN . & EX .
IN . & EX .
0 . 9 - 1. 1
(0.035 - 0 .0431
0.03
(0.0011
35 .0
(1.381
37 .8
( 1.491
IN . & EX.
INNER
OUTER
Valve spring tension (IN . & EX .'
INNER
OUTER
LIMIT
30.6
(1.201
27 .0
(1 .061
0.05 - 0 .10
10.002 - 0.0041
0 . 17 - 0 .22
10.007 - 0 .0091
0.010 - 0 .037
(0.0004 - 0 .00151
0.030 - 0.057
(0.0012 - 0 .00221
5.3 - 6.5 kg
(11.7 - 14.3Ibsl
at length 28.0 mm ( 1. 10 in)
13.1- 15.1 kg
(28.9 - 33.3Ibsl
at length 31 . 5 mm (1.24 in)
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
- - - - - . . ,S::::T"A'"'N::;Oo:"A"R"'=
O - - - --
ITEM
Cam height
Camshaft journal oil clearance
IN.
33.450 .3 169 - 1.
EX.
(1. 3 197 - 1. 32 13)
Right side
Left side
Camshaft journal 0 .0 .
11 .3079:":')---1
Right side
Left side
Camshaft journal holder 1.0 .
---,--;-;-
-
( .
(0.001 1 - 0.0023)
22.025
- 0 .867 1 _ _
10.0059)
+-____--1
(0.6894 - 0 .6900)
Right side
Left side
Camshaft run out
arm
IN. & EX .
Rocker arm shaft 0 .0 .
10.4724 - 0 .473 1 )
IN. & EX.
0 .05
10.002)
Cylinder head cover distortion
10-0.08)
CYLINDER + PISTON + PISTON RING
Unit: mm (in)
: - --
-
---,--;-
Piston to cylinder clearance
•
13. 1102 - 3 . 1108)
78 .940 - 78.955
13. 1079-3 .1085)
Piston diam.
at 15 mm (0.6
from the
10.0047)
79 .075
(3 .1132)
78.880
13.1055)
10.002)
gap
gap
15t
R
2nd
R
15t
2nd
10 .2
Approx . 10.40)
11 . 1
Approx.
- 0.30
10.006 - 0 .0 1 2)
10.35)
0 .70
10.028)
ITEM
Piston ring to groove
clearance
LIMIT
STANDARD
0 . 180
(0.007)
0.150
(0.006)
1st
2nd
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin 0 .0 .
1.01 - 1.03
(0.040 - 0 .041)
1.01 - 1.03
(0 .040 - 0 .041)
2.0 1 - 2.03
(0.079 - 0 .080)
0.97 - 0 .99
(0.038 - 0 .039)
0.97 - 0 .99
(0.038 - 0 .039)
20.002 - 20.008
(0.7875 - 0 .7877)
19 .996 - 20.000
(0.7872 - 0.7874)
CONRaD + CRANKSHAFT + BALANCER
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
: - - ----,---
(0.7876 - 0 . 7880)
(0.7890)
Conrad deflection
•
(0 .004 - 0 .022)
(0.04)
Conrad big end width
to
±
(2 .362 ± 0 .004)
Crankshaft runout
I
(0.41)
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 oC.140 0 F)
STANDARD
1.590 (35/22)
Above 40 kPa (0.4 k9/em'. 5.7 psi)
8elow 140 kPa ( 1 .4 kg/em'. 19.9 psi)
at 3 000 r/min.
LIMIT
DR35DV/SEV ('97·MDDEl) 16·6
CLUTCH
Unit: mm (in)
STANDARD
ITEM
Clutch lever play
LIMIT
10 -15
10.4- 0 .61
2 .72 -2. 88
10. 107 - 0 .113)
15.8-16.0
10.62 - 0.63)
Drive plate thickness
Drive plate claw width
2.42
10.095)
15.2
10.60)
0.10
10.004)
29.5
11.16)
Driven plate distortion
Clutch spring free length
TRANSMISSION + DRIVE CHAIN
STANDARD
ITEM
j
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
No . 1,No .2
& No.3
No . l ,No . 2
& No.3
Type
Links
0 . 1 - 0 .3
10.004 - 0.012)
5.0 - 5. 1
10. 197 - 0.200)
4.8 - 4 .9
10. 189 - 0.193)
0 .1.0. 520VC5
110
20~ pitch length
Drive chain slack
LIMIT
3.200 (64 /20)
2.933 (44 / 15)
2 .500 (30/ 12)
1. 733 (26 / 15)
1.333 (24 / 18)
1.111 (20/ 18)
0.952 (20 /21)
0 .826 119/23)
Prima~reduction ratio
Final reduction ratio
Gear ratios
Unit : mm (in) Except ratio
25-40
11.0-1 .61
0 .5
10.0201
319.4
112.57)
CARBURETOR
I
ITEM
Carburetor type
Bore size
~
1.0. No
Idle r/min .
Float height
(M .J .I
(J .N.I
(N.J .I
(P.J .I
(G.S.I
(Th .V .1
(P.S.)
Main jet
Jet needle
Needle jet
Pi1o~t
SPECIFICATION
E-33
E-Ol. 03. 2S
TM33 SS
"SST33SS
33 mm
1400
"140S
1 400 ± 100 rlmin
"1 500± 100 rlmin
14. 2 ± 1.0mm
·14.6± 1.0 mm
(0.56 + 0 .04 in)
(0.57 ± 0 .04 inl
# 127.5
"#/22.5
5FP96-3rd
"5C016
P-S
"P-/
#37.5
"#35
-#35
#42 .5
"# 115
1 Va turn back
"PRE-SET
Starter jet
Throttle valve
Pilot screw
Throttle cable play
(pulling cable) 0 .5 - 1.0 mm (0.02 - 0 .04 inl
ELECTRICAL
ITEM
Ignition timing
Spark plug
~rk performan ce
Ignition coil resistance
Magneto coil resistan ce
Unit: mm (in)
I
SPECIFICATION
30 o B.T .D.C. above 4 300 rlmin
NO: U27ETR
Type
NGK : CR9EK
0 .6 - 0 .7
Gap
(0.024 - 0 .02SI
Over 8 (0.31 at 1 atm.
Primary
0. 1 - 1.0 !l
Secondary
12 - 22 k!l
~ting
0 . 1- 1.50
350 - 650 !l
350 - 700 !l
350 - 700 !l
Power source
Pick-up No . 1
Pick-up No .2
Magneto no-load voltage
(when engine is cold)
Regulated voltage
~
More than 40 V (AC) at 5 000 r/min .
12 - 14 V at 5000 r/min .
NOTE
Terminal Ground
Plug capTermina l
V-B
W - Br
G - BI
Y - Gr
V- B
I
ORJ50V/SEV ('9)·MOOELI 16·8
WATTAGE
I
ITEM
Unit: W
SPECifiCATION
I
Taillight
BRAKE + WHEEL
Unit: mm (in)
STANDARD
ITEM
Brake lever play
Rear brake pedal height
Brake disc thickness
Front
Rear
0.1 - 0.3
(0.004 - 0.0101
5
(0 .21
.. 3.0 + 0.2
+ 0 .0081
(0.118 4 .0 -+ 0.2
(0 . 157 -+ 0.0081
Brake disc runout
Master cylind er bore
Front
Rea r
Master cylinder piston diam.
Front
Rea r
Brake caliper cylind er bore
Front
Rear
Brake ca liper piston diam .
Front
Rear
Wheel rim runout
Front
Tire size
Tire tread depth
Front
Rea r
Front
Rear
Front
Rear
.. 2.5
(0.0981
3 .5
(0. 1381
0 .30
(0.0121
2 .0
(0 .081
2 .0
(0.081
0 .2 5
(0 .0101
0 .25
(0 .0101
Axial
Re ar
Wheel rim size
LIMIT
11 .000 - 11 .043
(0.4331 - 0.43481
12 .700 - 12 . 743
(0.5000-0.50171
10.957 - 10.984
(0.4314 - 0.43241
12 .657- 12 .68 4
(0.4983 - 0.49941
27.000 - 27.050
( 1.0630 - 1.06501
27.000 - 27.050
( 1.0630 - 1.06501
26 .900 - 26 .950
(1.0591 - 1.06101
26 .900 -26.950
(1.0591 - 1.06101
Radial
Wheel axle run ou t
I
55
5
Headlight
J21 x 1 .60
J18 x2. 15
80/100-2151M
110/ 100-18 64M
4 .0
(0 . 161
4 .0
(0. 161
16·9 DR350V/SEV ('97·MDDEU
SUSPENSION
Unit : mm (in)
ITEM
Front fork stroke
STANDARD
280
(11.0)
LIMIT
Front fork spring free length
"525
(20.7)
Front fork spring characte ristic
"7 .65 N '/mm
(0.78 kg/mml
Front fork oil level
144
(5 .67)
Rear shock absorber gas pressure
1 000 kPa
(10 kg/em'. 142 psi)
Rear shock absorber spring
267.3
pre-set length
(10.5)
Rear wheel travel
280
( 11.01
0 .3
(0.01)
$wingarm pivot shaft runout
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
kPa
kg /cm2
p SI
NOTE
DR35DV/SEV"97·MDDEL) 16·10
FUEL + OIL
Fuel type
Use only unleaded gasoline of at least 87
pump octane (R 2tv! method) or 91 octane or
higher rated by the research method .
Gasoline containing MTBE (Methyl Tertiary
Butyl Etherl. less than 10% ethanol . or
less than 5% methanol with appropriate
cosolvents and corr osion inhibitor is
I
gasoline of at least 87
method) or 91 octane or
aso i
octane or higher.
recommended .
Fuel tank including reserve
reserve
Change
change
Overhaul
Front fork oil
Front fork oil capacity (each leg)
Fork oil 5505
gasoline is
E-03, 33
E-28
E-Ol
16·11 DR350V/SEV I'S7·MDDEL)
DR350SEV
VALVE + GUIDE
Unit: mm Hn)
ITEM
Valve diam .
IN.
Valve clearance (when cold )
Valve guide to valve stem
clearance
tyaive stem deflection
Valve guide 1.0 .
tyaive stem
•
•
Valve stem runout
Valve head thickness
tyaive stem"'Ondlength
Valve seat width
~
EX.
~766)
IN.
0 .05 - 0.1
10.002 - 0 .004)
EX.
~~
IN.
(0.0004 - 0 .0015)
EX.
100~~~=g:g6~2)
Valve spring free length
(IN . & EX.)
0 .35
10.014)
IN . & EX.
IN. & EX.
5.000-5.0 1 ;3)
. 1969 - 0 . 19
IN.
(0 . 1959 - 0 . 1965)
EX.
~1~~t.6m7)
IN . & EX.
0 .05
10.002)
IN . & EX.
lci>(52)
IN. & EX.
1 cB_
10.07)
IN . & EX.
run out
~~)
..!o'M'T
10.g:i~ =6:643)
IN . & EX .
0 .03
(0.001 )
INNER
Ir:i~J
OUTER
11.49)
Valve spring tension (IN , & EX .)
INNER
OUTER
53 - 6 .53kp~~l
( 1.7 - 14.3 1
I in
at I ~2B . O mm
.10
13. 1 - 15. 1
(2B.9 -33.3 I
at
31.5
il
DRJ50V/SEV 1'97·MDDELI 16·12
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
ITEM
Cam height
STANDARD
33.450- 33.490
(1 .3169 - 1.31851
33.520- 33.560
(1.3197 - 1.32131
0.032 - 0.066
(0.0013 - 0 .00261
0.028 - 0.059
(0.0011 - 0 .00231
22.012 - 22.025
(0.8666 - 0 .8671 I
17 .512 - 17.525
(0.6894 - 0 .69001
21.959 - 21 .980
(0 .8645 - 0 .86541
17.466 - 17.484
(0.6876 - 0 .68831
IN .
EX .
Cam shaft journal oil clearance
Right side
Left side
Cam shaft journal holder 1.0 .
Right side
Left side
Camshaft journal 0.0 .
I
Right side
Left side
Rocker arm shaft 0 .0 .
12.000 - 12.018
(0.4724 - 0.47311
11.973 - 11.984
(0.4714 - 0.47181
IN . & EX .
IN . & EX.
0 .05
(0.0021
0 .05
(0.0021
Cylind er head distortion
Cylinder head cover distortion
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
(Automatic-decamp . actuated )
Unit: mm (in)
STANDARD
LIMIT
1100kPa
Appro x .
C1156kg /cm
psi
2
)
0.055 - 0 .065
(0.0022 - 0 .00261
79.000 - 79 .015
(3.1102 - 3 . 11081
78.940 - 78.955
(3 .1079 - 3 . 10851
Piston to cylinder clearance
Cylinder bore
Piston diam.
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
I
33 .150
(1.30511
33.220
(1.30791
0 . 150
(0.00591
0 . 150
(0.00591
0 . 10
(0.0041
Camshaft runout
Rocker arm 1.0 .
LIMIT
1st
R
2nd
R
1st
2nd
10. 2
Approx . (0.401
11 .1
Approx . (0.441
0.15 - 0 .30
(0.006 - 0.0121
0 .35 - 0 .50
(0.D14 - 0.0201
0 . 120
(0.00471
79.075
(3. 11321
78.880
(3. 10551
0.05
(0.0021
8 .2
(0.321
8 .9
(0.351
0 .70
(0.0281
0 .70
(0.0281
I
16·13 DR350V/SEV ('97·MDDEL/
ITEM
Piston ring to groove clearance
STANDARD
0 .180
10.007)
0 .150
10.006)
1st
2nd
Piston ring groove width
15t
2nd
Oil
Piston ring t hickness
15t
2nd
Piston pin bore
Piston pin 0.0 .
1.01 - 1 .03
10.040- 0 .04 1 )
1.0 1- 1 .0 3
10.040 - 0.04 1 )
2. 01 - 2.03
10.079 - 0.080)
0.97 - 0.99
10.038 - 0 .039)
0.97 - 0 .99
10.038 - 0.039)
20.002 - 20.008
10.7875 - 0 .7877)
19 .996 - 20.000
10.7872 - 0.7874)
CONROD + CRANKSHAFT + BALANCER
ITEM
Conrad small end I. D.
Conrad big end width
Crank web to web w idth
STANDARD
LIMIT
20.006 - 20.014
10.7876 - 0 . 7880)
20.040
10.7890)
3.0
10. 12)
1.0
10.04)
0 . 10 - 0 .55
10.004 - 0 .022)
2 1.95 - 22.00
10.864 - 0.866)
60.0 ± 0 .1
12.362 ± 0.004)
0.05
10.002)
10.3
10.41)
Crankshaft runout
Balancer spring free length
OIL PUMP
Oil pressure (at BooC, 1400 F)
20.030
10.7886)
19.980
10.7866)
Unit: mm (in)
Conrad deflection
Conrad big end side clearance
LIMIT
Above 40 k Pa (0.4 kg/cm2, 5.7 psi)
Below 140 kPa ( 1.4 kg/cm2, 19.9 psi)
at 3 000 r/min.
DR350V/SEV ('91·MOOELI 16·14
CLUTCH
Unit: mm (in)
:-------,------,-
ITEM
Clutch lever play
I
2 .42
•
(0.107 - 0.1131
15.8 - 16.0
Drive plate claw width
(0.601
0 . 10
-=----,_--,----,-----,_-::-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _-+_-";
(0.004-'' --l
Clutch spring free length
(1 . 16)
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction
ratio
STANDARD
E-02 ,04,
22, 34
2.818 (62 /22)
The others
3.200 (64/20)
E-02,04,
22, 34
The others
Gear ratios
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
Final reduction ratio
Shift fork groove width
Drive chain
No . l ,No .2
No. 1,No.2
& No.3
Type
Links
2.733 (41115)
2: 500 (30112)
1. 733 (26115)
1.333 (24/ 18)
1.111 (20118)
0.952 (20/ 21)
0 .826 (19 / 23)
0 . 1- 0.3
(0.004 - 0.012)
5.0 - 5.1
(0 . 197 - 0.200)
4 .8 - 4 .9
(0 . 189 - 0.193)
0 .1.0 . 520VC5
108
20· pitch length
Drive chain sla ck
LIMIT
2.866 (43 / 15)
& No.3
Shift fork thickne ss
Unit: mm (in) Except ratio
25 - 40
(1.0 - 1.6)
0.5
(0.0201
319.4
(12 .57)
16-15 DR350V/SEV 1'97·MDDEl}
CARBURETOR
ITEM
•
~
~
.~
~
.~
~
~
~
~
~
~
~
~
~
SPECIFICATION
E-22
E-18
~
~
~
~
mm
•
10.02-0.04 in}
ITEM
Carburetor type
Bore size
1.0 . No.
Idle r/min.
Float height
Main~t
Jet needle
Needle~t
Throttle valve
Pilot iet
StarterJ!lt
Pilot sc rew
Throttle cable play
(pulling cable)
IM.J.}
IJ .N.}
IN .J .}
ITh.V_}
IP.J .}
IG.S .}
IP.S.}
E-02.04.34
8ST33SS
33 mm
1409
1 500 + 100 r/min .
14.6 ± 1.0 mm
10.57±O.04 in)
# 127.5
5CD27-4th
0 -5
# 115
#37.5
#35
PRE-S ET
(1 3/4 turn s back)
0 .5 - 1.0 mm
10_02 - 0 .04 in }
14DA
14EL
~
1 400 ± 50 rImin.
~
~
~
~
~
~
~
~
# 132.5
5CD56-4th
0 -7
~
--
PRE-SET
PRE-SET
(1 Va turn s backl
12.0 turns back)
~
~
DR35DV/SEV ('97·MDDEL) 16·16
CARBURETOR
SPECIFICATION
E-94
BST33SS
33 mm
14EK
1 500+ 100 r/min .
ITEM
Carburetor ty pe
Bore size
I.D. No.
Idle r/min .
Fl oat height
M ain jet
Jet needle
Needle jet
Throttle valve
Pilot j~t
Starter jet
Pilot scre w
E-24
--
14EM
-
14.6+1 .0 mm
IM.J.)
IJ .N.)
IN.J.)
ITh.V.)
IP.J .)
IG.S.)
IP.S.)
Throttle cable play
(pulling cable)
10.57 + 0 .04 in)
# 135
5CD56-3rd
0 -3
# 115
#42 . 5
#35
PRE-SET
(1 Va turns back)
#127.5
5CD56-4th
0-5
-
#37 .5
0 .5 - 1 .0 mm
10.02 - 0.04 in)
ELECTRICAL
ITEM
Ignition timing
Spark plug
Spark performance
Ignition coil resistance
Generator coil resistance
Unit: mm (in )
SPECIFICATION
30 o B.T.D.C . above 4 300 r/ min
ND: U27ETR
Type
NGK : CR9EK
0.6 - 0.7
Gap
10.024 - 0 .0281
Over 8 (0.3) at 1 atm.
Primary
0.1 - 1.0n
Secondary
12 - 22 kfl
Terminal Ground
Plug cap Terminal
Charging
0 .1 - 1.5n
350 - 650 Il
350 - 700 n
350 - 700 Il
W - Br
G - BI
V - Gr
Power sou rce
Pick-up No. 1
Pick-up No. 2
Generator no-load voltage
(when engine is cold )
Regulated vol t ~e
Generator Max . o utput
Starter motor brush l e~h
Commutator under·cut
Starter relay resistance
Batte ry
Type designa tion
Capacity
Standard
electrolyte S.G.
Fuse size
NOTE
More than 60 V (Ae) at 5 000 r/ min .
13.0 - 15.5 V at 5 000 r/min .
Approx . 125 W at 5 000 r/min .
Limit : 6 10.24)
Limit : 0.2 (0.008)
3 - 711
VTX7L-BS
12V 21.6 kC 16Ahl/l0HR
1.320 at 20°C 168° F)
20 A
v- v
V-V
WATTAGE
Unit: W
ITEM
-
-.---
1.7
BRAKE + WHEEL
Unit: mm (in)
ITEM
STANDARD
Brake lever play
Rear brake pedal height
Brake disc thickness
Front
Rear
0 . 1 - 0 .3
(0.004 - 0.010)
5
(0.2)
3.5 + 0 . 2
(0. 138 ± 0 .008)
4 .0 ± 0 .2
(0. 157 ± 0 .008)
Brake di sc runout
Master cylinder bore
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam .
Front
Rear
Wheel rim runcut
Axial
Radial
Wheel axle runout
Front
Rear
LIMIT
3 .0
(0. 11 8)
3.5
(0.138)
0 .30
(0.012)
1 2 .700 - 1 2 .743
(0.5000- 0 .5017)
12 .700 - 1 2. 743
(0.5000 - 0 .5017)
12 .657 - 12.684
10.4983 - 0 .4994)
12.65 7 - 12.684
10.4983 - 0.4994)
27 .000 - 27 .050
11.0630 - 1.0650)
30.230 - 30. 280
11. 1902 - 1. 1921)
26.900 - 26.950
11.0591 - 1.0610)
30. 160 - 30. 180
11 . 1874 - 1. 1882)
2.0
10.08)
2 .0
10.08)
0 .25
10 .010)
0 . 25
10.010)
ITEM
Wheel rim size
Front
Rear
Tire size & type
Front
STANDARD
J21 x 1.60
J18 x2. 15
801100-21 51P
Dunlop D601J IE-03.28.331
LIMIT
Dunlop K560J (others)
Rear
110/90-18 61P
Dunlop 0601 IE-03. 28.331
Ounl ~ K560J (others)
Tire tread depth
3.0
10.121
3.0
10. 121
Front
Rea r
SUSPENSION
Unit: mm (in )
ITEM
STANDARD
280
111.0J
Front fork stroke
LIMIT
602
123.71
front fork spring free length
152
16 .01
Rear shock absorber gas pressure
1 000 kP.
(10 kg/cm2, 142 psi)
Rear shock absorber spring
253.4
pre-set leng th
110.01
Rear wheel travel
255
11 0 .0J
Front fork oil level
0.3
10.01 I
Swingarm pivot shaft ru nout
TIRE PRESSURE
CO LD INFLATION
TIRE PRESSURE
FRONT
REAR
I
SOLO RIDIN G
•
kP. ~c m 2 pSI
150
1.50
22
22
150
1.50
DUAL RIDING
kP. kg /cm 2 ~i
150
1.50
22
1.75
175
25
NOTE
FUEL+OIL
Use only unleaded
of at
pump octane (R iM ) or 91 octane or higher
rated by the research method .
Gasoline containing MT8E (Methyl Tertiary
Butyl Ether) , less than 10% ethanol, or less
Fuel type
E-03,33
than 5% methanol with appropriate cosolvents and corrosion inhibitor is
Use only
gasoline of at least
octane
method) or 91 octane or
gasoline is
8 .0 L
I
(2.1 / 1.8
Fuel tank including reserve
E-28
For the others
E-33
For the others
reserve
.I
.~~----~--~~~~~
I
Engine oil capacity
Change
change
Overhaul
(19.2120.0
DOT 4
oz)
DR350V/SEV ('9)·MOD ElI 16·20
FRONT BRAKE CALIPER (For DR350V)
t!l
ITEM
N 'm
kg -m
®
26
5.5
2.5
18
23
13
2.6
0.55
@
(;)
It}J
e
: Bl'ake fluid IDOT4)
~ : SUZUKI SIUCONE GREASE (99Ooo-251OOI
<E>
•
: TH READ LOCK ." 342" 199000-32050 )
rE!
0 .25
1.8
2.3
1.3
Ib·1t
19.0
4.0
1.8
13.0
16. 5
9.5
16·21 DR350VISEV ,'9)·MODELI
FRONT FORK (For DR350V)
CD D-ring
@ Washer
,•
I /
@ Spring
@ Damper
® Inner tube
® Dust seal
(j) Stopper ring
® Oil seal
® Oil lock picce
@ Outer tube
kg-m
Ib-ft
ITEM
N 'm
®
®
<0
23
2.3
16.5
35
3.5
25.5
35
3.5
25.5
@
12
1.2
8.5
REMOVAL AND DISASSEMBLY
• Remove the front wheel.
~ : SUZUKI SUPER GREASE " A " 199000-25030)
DR350VISEV ('9) ·MOD El) 16·22
• Remove the front brake caliper mounting bolts.
• Remove the brake hose holder and speedometer cable
guide.
• Remove the front fork by loosening the upper and lower
clamp bolts.
NOTE:
Slightly loosen the front fork cap facilitate later disBssem·
bly, before loosening the lower clamp bolts.
• Remove the front fork cap CD.
• Remove the washer ® and spring @.
•
• Inven the fork and stroke the inner tube and inner rod
several times to drain fork oi1. Hold the fork inverted for
a few minutes to drain oil.
16·23 DR350V/SEV ('97·MODEL)
• Remove the damper rod bolt/damping force adjuster CD and
gasket @.
•
• Remove the damper assem bly .
Do not attempt to disassemble the damper assembly.
It is not serviceable.
• Remove the boot by loosening t he clamp screws.
,
• Remove the dust seal <ID.
• Remove the oi l seat stopper ring 0.
,
• Separate the inner t ube from t he outer tube .
• When separating the inner tube from the outer tube.
both anti·friction metals may be damaged and must
be replaced with new ones.
• The removed oil seal should be replaced with a new
DR350V/SEV ('97-MDDEU 16-24
INSPECTION
DAMPER
Inspect the damper rod ring for wear or damage.
Move the inner rod by hand to inspect it if operating smoothly.
DAMPER ROD BOLT/DAMPING FORCE ADJUSTER
Inspect the damper rod bolt /damping force adjuster for wear
or damage.
INNER AND OUTER TUBE
Inspect the inner t ube an d outer tube sliding surfaces for any
scuffing or flaws .
FORK SPRING
Measure the fork spring free length. If it is shorter than the
service limit, replace it with a new one .
Service Umit: 525 mm (20.7 in)
16·25 DR350V/SEV ('9)·MODEl)
REASSEMBLY AND REMOUNTING
Reassemble and remount the front fork in the reverse order
of removal and disassembly. and also carry out the following steps:
INNER TUBE METAL
• Install the metal by hand.
Use special care to prevent damage to the "Teflon"
coated surface of the antl.friction metal when mount-
ing it .
OUTER TUBE METAL. WASHER AND OIL SEAL
• Install the outer tube metal
washer ® and oil seal @
<D.
with the special tool .
09940·50113 : Front fork oil seal installer
[ A CAUTION [
Use special care to prevent damage to the "Teflon"
coated surface of the anti-friction metal when mount-
ing it .
• Apply grease to the lip of oil seal.
..@I99000-25030 : SUZUKI SUPER GREASE "A"
OIL SEAL STOPPER RING AND OUST SEAL
• Install the oil seal stopper ring @ .
[ A CAUTION [
Make sure that the oil s8al stopper ring fitted securely .
• Install the dust seal ®.
DAMPER ROD BOLT/DAMPING FORCE ADJUSTER
• Install the oli lock piece ® with the damper rod Q) to the
outer tube .
•
• Tighten the damper rod bolt/damping force adjuster to the
specified torque .
~ Damper rod bolt/damping force adjuster :
35 N'm 13.5 kg -m . 25. 5 Ib-ftl
I A CAUTION I
Use a new gasket to prevent oil leakage .
-
,
DR350V/SEV 1'97·MOOEL) 16·26
FORK OIL
• Place the front fork vertically .
• Pour fork oil t o the in ner tube.
• For t he fork oil, be sure to use a front fork oil w hose viscosity rating m eets specifications below .
~
oil type : Fork oil 55 -05
99000-99001-885: Fork oil 88-05
\::
Capacity : 495 ml 116.7/ 17 .4 US/Imp oz)
• Cover the inner tu be wi th palm, and m ove the inner tu be
u p and down 3 or 4 times.
• Hold t he front fork vertical and adjust the fork oil level w ith
t he special t ool.
Oil level : 144 mm 15.7 inl
09943-74111: Fork oil level gaug e
NOTE:
When adjusting the oil level, remove the fork spring and compress the inner tube fully.
FORK 8PRING
• In stall the fo rk spring as show n in the photog raph.
NOTE:
Close-pitch end of spring should position bottom.
.......
Bottom
• Tighten the front fork cap to t he dam per asse mbly to the
specified torque .
~ Front fork cap: 35 N'm (3 .5 kg-m . 25.5 Ib -ftl
.L,/
16-27 DR35DV/SEV ('97-MODEl!
<D
• When installing the front fork assembly . align the line
of the inner tube with the upper surface ® of the steering
stem upper bracket .
• TIghten each boh to the specified torque.
t!l
@ Front fork cap: 23 N-m 12_3 kg-m . 16.5 Ib-It!
@) Frontforkupperclampbolt: 26 N'm 12 .6 kg-m . 19.0 Ib-It!
® Front fork lower clamp bolt : 26 N'm (2 .6 kg-m , , 9.0 Ib-ft)
® Front brake caliper bolt : 26 N'm {2 .S kg-m . 19.0 Ib-ft}
o Front axle : 65 N'm 16.5 kg-m. 47 _0 Ib-It!
® Fron t axle holder nut : 12 N' m (1 . 2 kg-m , 8 . 5 Ib-ft)
When remounting the axle holder on the front fork . first
tighten the upside nuts 8 S shown in photo .
ADJUSTMENT
After in stalling the front fork. adjust the both damping force
as follows .
DAMPING FORCE ADJUSTMENT
Slowly turn in the adjuster and find out the adjuster is seated . From that position . turn back and find out first click that
is 1-position then turn ba ck and count the specified position
as follow.
Standard setting
: Tum back 7·positions from
(Compression & ReboUnd) fully tumed-in position
AWARNING
Be sure to adjust the damping force on both front fork
legs equally .
@ : Compression damping force adjuster
@: Rebound damping force adjuster
DR350W/X
'
DR350SEW/SEX (98,'99-MODELS)
FOREWORD
This section describes sev;ce da ta and servicing procedures which differ from those
of the OR350V/SEV ('97-MOOELI.
NOTE:
• Any differences between OR350V/SEV ('97-MOOELI and OR350W/ X/SEW/SEX
('98, '99-MODELSJ in specifica tions and service data are clearly indica ted with the
asterisk marks (*).
" Please refer to the sections 1 through 16 for details which are not given in this section.
, - - - - - - - - - - - - - - - - - - - CONTENTS- - - - - - - - - - - - - - - - - - - ,
SPEC/FICA TIONS ....................................................................... 17- 1
DR350W/X ··············· ··········· ········ ······· .. ···· · .. · .. ················· ······· 17- 1
DR350SEW/SEX ..... _... _..... .......... ..... -......... ....... .. .................... 17· 2
SERVICE DATA ......................................................................... 17- 3
OR350W/ X ................... ....................... -........... .. ..................... 17- 3
DR350SEW/SEX ......................................................... ............ 17- 11
FRONT FORK (For DR350SEW/ SEX E-03, 28 and 331 ................ 17-20
REAR SUSPENSION SETTING
(For DR350SEW/ SEX E-03,28 and 33) ...................................... 17-21
COUNTRY OR AREA
E- 18: Switzerland
E-Ol: General
E-02: U.K.
E- 22: Germany
E- 24: Australia
E-03: U.S.A .
E-28: Canada
E-04: France
E-33: California (U.S.A.)
E·34 : Italy
E-94: Barbad os
17-1
SPECIFICATIONS
DR350W/X
DIMENSIONS AND DRY MASS
Overall length _ ... . . . . . . . . • . . . . . . . . . . . . . . . . .
"2
2
Overall width . . . . . . . . . . . . . . . . . . . . . . . • . . • . • . .
Overall height ......... _ •..•• _ . • .•...• . • ....
Wheelba se •• _ ••....•.....•... . .• _ .•... . ...•
Ground clearance .• _ ..••.............. . .. .. ..
Seat height ... .. . . . . . . . . . . . . . . • . . . . . . . . . • • .
,,
Valve clesfllnce. IN ••..•.............. _ .... . .
ex ........ " .... " .... , ... .
Number of cyli nder ..... _ . •..•..•..•..•...... _
601"0 ... . . • . .•..•.••.•. • •••••••• • •• • .•••.•
.. . E· 24
... Others
310 mm
920mm
113 kg
Otymass .•...•.. . ..... . . .. . .. . . .. . .. .. ....
ENGINE
TVpe ..... . . . . . . . . . . . .. . .....•.. . .. . •••••.
mm
mm
mm
mm
mm
Four· stroke, eir-eooled with SACS. OHC
0.05 - 0 . 10 mm (0.002-0.004 In)
0 .17 - 0 . 22 mm 10.007 - 0.009 in)
,
Air cleaner ............• • . .. . .•••... • .. • ....
Starter system .........• . •..•. . ••••.••.•....
Lubrication system .. . .....•..• • ..•.... . .•....
79.0 mm (3.110 Inl
71.2 mm 12.803 In)
348 cm' (21 . 2 cu. Inl
9 .5 : 1
'65T33S5 ... E· 33
TM33S5. single ... Others
Polyurethene loam elemant
Primary k ick
Dry sump
TRANSMISSION
Clu tch ........... . ......•... . .............
Transmission ..............•..•...... .. .....
Gearshi ft pattern . . .....•..•..•.. • .. • .• • .....
Primary reduction ratio ......•.....•.. • ..•...•.
Gear ratios. Low ... . ....... . ... ... .....•....
2nd . . . .. . . . . . . . . . . . . . . . . . ..... .
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41h .. ......... . . . . . . . . . . . . . . . . ,
5th .. . ....... • ..... . . . . . . . . . . . .
Top . . . . . . . . . . • . . • . . • • . • . . • ••...
Final reduc tion ratio .. .. . .. • .. . •. .• ..•. . •.....
Drive chain •............•..•...... . . .. .. . ..
Wet multl·plate type
6-speed constant mesh
l -down, S,up
3 . 200 (64 /20)
2 .500 (30(12)
1. 733 (2 6 / 151
1.333 (2 4 /18)
1.111 (20f 18)
0.952 (20/21)
0.826 119/231
2 .933 (441151
DIDS20VCS, 110 Units
Stroke . . . . . . . . . . . . . . . . • . . •. • • ..• . .•.• • . . ..
Displacem ent . . .. . . . .. .•. • •. _ •• .• • _ • ••••••.•
Compression ratio .......•..•..•. . ..... .• ....
Carburator .......... . .. . . •. .. . .. . .... . .....
CHASSIS
Fr ont suspension .... . ........•..•. • •.••. . ...
'Raar suspanSlon
. ..... . ........ .• . . • • •.. • . • ...
Front suspension stroke .. . ............... . ... .
Rear wh&el tra vel .......•............. . . . ....
Caster .............. , ....•..•.. • ..•.. . • .•.
Trait .........•......•....••.••. •• ..•.•...
Steering angle . . . ............•..••.•..• • ....
Tumlng radius .... , ............. . .. . .. . .... .
Front brake ....•...••..•..•..•..•..........
Rear br ake . . .... .. . . .. • .. • ..•...•..•..•. •••
Front tira size .........•.. • .• . ... '.....•.. .. .
Rear tire size .. . .. . ....... • .. .. . .. .. • .••. . ..
ELECTRICAL
Ign!t!On ~y~ ...... . .••..•..•..•..••........
Ignition timing . .......•..•.....•.. •.•. •• . .. .
Spark plug . . . . . . . . . . . • . . . . . . . . . . . . . . . . .....
Generator •.•.... . . . . .. .... . .. .• .. • ........
Headlight . . . ..........•..•...•............•
Telescopic . coil spring, oil damped , rebound damping lorce 17· way ad·
Justable. compre ssion damping l orce 13· way adjustable
Unk type. coil spring. gas/oil damped, spring preload lully adjustabl e.
compression and rebouod damping loree fully adjustable
280 mm (11 .0 in)
280 mm (11 .0 In)
27 ° 30'
112 mm 14.41 in)
45 ° Iright & leltl
2 .3 m (7. 5 ftl
Disk brake
Disk brake
·3.00-21 51P, tube ... E·24
80f l00- 2 1 51M. tube ... Othars
" 120/ 90- 18 55P, lube ... E· 24
110/ 100· 18 64M. l Ube ... Others
Brake UghtITaUtight ..• . . . .••.••.. • .. • .. • . . .•.
Taittight . . .. . . . . .. . .........•..••...••.•. . .
Turn signal light ........ . .. . ... •..•. .•..... ..
Speedometer light .•.••..•..•..•.............
Nootral IndicatOf tight .... . . . . . . . . . . . . . . . . . . . . .
Tum signal indic ator light .... . .. .. . . ......• . .. .
High beam indicator light .... . ... • . .• •. ••. . •...
license tight .......•.••........ • . . . • •.••...
Electronic ignition (COl)
30° B.T .D.C . above 4300 r/m in
NGK CR9 EK or DENSO U27ETR
Flywheel magneto
"1 2V 60/ 5SW ... E· 24
12V SSW ... Others
·, 2V 21 /SW ... E· 24
12V SW
·12V 21W ... E· 24
"12V 3W ... E- 24
"12V 2W ... E· 24
"12V 2W ... E·24
"12V 2W ... E·24
"1 2V 5W ... E· 24
CAPACITIES
fuel tank inc::1uding raserve .........•...........
Reserve ...... . ....... . ..•..• . .... .
Engine oil. ott change .... , .....•.• •.• •••..•.•.
with fitl er c hanQtl ....•..•. . ••• , .•. . .
overhaul ...........•......... . ....
Front fork oit (each legl ......•....•.•..•..•..•
9 .5 L (2 .5 /2.1 U5f1mp. gall
1.8 L (0.5 f0.4 U5{1 mp. gall
1700 m( (1 .8 / 1.5 US{1mp. qtl
1900 ml 12.0 / 1. 7 USllmp. qtl
2100 ml 12 .2/ 1.8 U5l1mp. qtl
4S S mII16.7/ 17.4 US /Imp. oz)
17-2
DR350SEW/SEX
DIMENSIONS AND DRY MASS
Overall length . . . . . . . . . . . . . . . . . . . . . . . . • . . • . .
Overall w idth . . . . . . . . . . . . _ ......•.•.........
Overall height ........•...•.••.••.••. , •.•...
Wheolbase . . . . . . . . . . . . . . . . . .. . . .. . ..•. • •.. •
Gtoood clearan ce ............•..•..•.........
Seat height ...•.......... , . . . . . . . . . . . . . . . . .
Dry mess ....... . ....•-.....•... . ...........
ENG IN E
T vpe . • • • . • • . . • • . . . . . • • . . • . • •.• ••.••••• ..•
Valve clearance, IN . . . . . . . . . . • . . • . . • . . . . . . . . .
EX . • . • • • • . . . . .•.•.•...•..•.
Number of c yl inder . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bore ..........................•..... . ..•.
Stroke ...................•.. . . •.. • . .••....
Oisplacement . . . . . . . . . . . , .•.• .• • . ••.• •. ••. ..
Compression rat io . . . . . . . . . . . . . . • •.••..•. . ...
Carbure tor ..........•...•.. • .••... . ........
Air cleaner ....... .. . . . . . . . . . . . . . . . . ....... .
Starter sys tem . . . . . . . . • . . . . . . . . . . . . . . . . . . . . .
l ubrication system ....... •. ..•... .. ••....• ...
TRANSMISSION
Clutch . . . . . . . . . . . • . . . . . • . . . . . . . . . . . . • . . . . .
-- n ...•..... , .... , .• • , ..........•.
TransmlsSlo
Gaarshift pa ttern . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary reduction ra tio ......•.• . ....•..•..•...
Gear ratios. low ..........•..•.••..•..•. , .. .
2nd . . . . .. . . . . . . • . . • . . .. . .. . . . . .
3 rd . . . . . . . . . . . . . . . . . . . . . . . . . . ..
4 til ... . • . . . . . . . . . . . . . . . . . . . . . . .
5tll ...... . . . . . . . . . • . . . . . . . . ... .
Top . . . . . . . . . • . . • . . • . . . . . . . . ..•.
Final , educ tion , atio ... _ ....••.•• • ...•..•. . ...
Drive chain . . . . . . . . . . . . . . . . . . . . . . • _ .. _ .....
2335 mm 191 .9Inl ... E· 18, 22
2 235 mm (88 .0 inl ... Others
885 mm (34.8 in)
1 245 mm (4 9.0 ilil
144 0 mm (S6.7 Inl
290 mm ( 11 .4 in l
690 mm (35.0 Inl
130 kg (2861bsl
Four-s troke. air-COOled with SACS. OHC
0.OS - 0 . 10 mm fO.002 ~ 0 . 004 in)
0 . 17 - 0 . 22 mm 10.007 - 0.009 in)
1
79.0 mm 13. 11 0 inl
71.2 mm (2. 803 inl
348 cm' 121.2 c u . Inl
9 .S : I
8ST33. s ing le
Polyurethane foam element
Electric
Dry sump
Wet multi-plate typ!!
6 · speed constant mesh
l-down. Soup
2.818 162 /22) ... E-02.0 4 . 22, 34
3. 200 164/201 ... Others
2. 500 130('21
1 .733 {26(1SI
1 .333 124(181
1. 111 120{181
0 .952120f2 11
0 . 826 n 9 /23)
2. 867 (4 3{lSI ... E-02.04. 22.34
2. 733 141 {lSI ... Others
DIDS20VCS, 106 links
CHASSIS
Front suspension . . . . . . . . . . . . . . . . . . . . . • . . . . . .
rebound damping fo rce 17· way ad 13 ·way adjustable ... E·03. 28.33
_""
spring preloed fu lly adiustable,
"
8· way adjustable . .. Others
Rear sus pension . . . . . . . . . . . . . . . . . . . . . . • . . . . . .
fo rce fully adjustable
Front suspension s tr oke . . . . . . . . . . . . . . . . . . . . . . .
Rear wheel travel ...........•..•....•. . • . • ...
Caster ...... . ...•........••.••.••.•.••....
Trail . . . . . . . . . . . . . . . . . . . . . . . . ..•....••....
Steering engle . . . . . . . . . . . . . . . . . . . . . . . •..•...
Turning radIUs •..••..•.....•..•...• _ ....... .
Front brake ........ • . . . . . • . . . . . . . . . . . . . . . . .
Rear brake .........•...•.• . .•.••..•.••.•...
Front [ire size .. ....••. • •. . •.••.•..•.• _ .•...
Rear tire size .......•.....•........•. . .. . ...
115 mm (4. S3 inl
45 ° (right & laft)
2.3 m (7.S 't)
Disk brake
Disk brake
80/100-2151P
110f90-1861P
ELECTRICAL
Ignition typ!! .... ... • . . •..• • ..•.........•...
Ignition timing .....•.•.••.••. •• .• • .•..•.•...
Spark plug ...............•..••.• • .•.• • . •...
Battery .......... ....... ..... . . . •..•.. . ...
Generator ...•... _ .. _ ... , ...•.... • .. . . . .. . .
Fuse . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . .. .
Headlight .. , ............•..• , . , . . . ......•• •
Position light .•....... . . , • • •.••.• •. , ... . •...
Turn signal light ...........•...•.•• • • ••• .•...
Brllke lIght/TaiUight .......••..•..••. • .••.•...
Ucense plate light . . . . . . . . . . . . • . . _ .....•.••..
Speedometer light . . . . . . . . . . . . . . • . . . . . . . . • . . .
Tac homete r light . . . . . . . . . . . . . •.. ..... . ......
Neutral indic ator Ught . . . . . . . . . . , , . . . . . . . . . . . . .
High beam Indicator Ughl .......• ' . ••. . • • . ..•..
Turn signal indicato r light . _ ......•. •• .••• _ .... .
1
kC !6Ah){lOHR
Thrett-phase A.C. genera tOT
20A
12V 60fSSW
12V 4W ... E-02. 04.18, 22, 34, 94
12V 2 1W
l2V 21/SW
12V SW
12V 1 .7W Ix 2 pcsl
12V 3W
12V 1 .7W
12V 1.7W
12V 1.7W
CAPACITIES
Fuel tank . Including res erve ........••. , ....... .
Reserve . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oil. oil c hange .............••..•. . .•...
with lilter c hange ....•..••. . ....•...
Olfarhaul . . . . . . . . . . . . . . . . . . . . . . . . _
Fro nt lo rk oil (eac h leg) ...........•.......•..•
mm
JO'
.,
8 .0 l (2.11 1 .8 USlimp gall ... E· 33
9 .0 l (2 .4J2 .0 US /Imp gall ... Others
2.0 l (0.5fOA UStlmp gall
I 700 ml (1 .8 f l . S US/lmp qtJ
1 900 101 (2.011 . 7 US/lmp qtl
2 100 101 (2 .2f 1.8 US/lmp qtl
·494101 /16 .7f 17.4 USflmp ozl ... E·03.28, 33
,
n
,
17·3
SERVICE DATA
DR350W/X
VALVE+GUIDE
Unit: mm (in)
ITEM
Valve diam .
IN .
EX .
Valve clearance (when cold)
IN .
EX .
Valve guide to valve stem
clearance
IN.
EX.
Valve stem deflection
Valve guide 1.0 .
Valve stem 0 .0 .
IN. & EX .
IN .
V alve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
liN. & EX.)
0.05
10.002)
0.5
10.02)
1 .8
10.07)
IN . & EX .
IN. & EX .
0 .9 - 1.1
10.035 - 0.043)
0 .03
10.001)
35.0
11.38)
37.8
11.49)
IN . & EX.
INNER
OUTER
Valve spring tension (IN . & EX .)
INNER
OUTER
LIMIT
5 .000 - 5 .012
10. 1969 - 0 .1973)
4.975 - 4.990
10. 1959 - 0 . 1965)
4 . 955 - 4 .970
10. 1951 - 0 . 1957)
IN . & EX .
IN . & EX.
I
0.35
10.014)
IN . & EX.
EX .
Valve stem run out
STANDARD
30.6
11. 20)
27 .0
11 .06)
0 .05 - 0 . 10
10 .002 - 0 .004)
0 . 17 - 0.22
10.007 - 0.009)
0 .010 - 0.037
10.0004 - 0.0015)
0 .030 - 0.057
10.0012 - 0.0022)
5.3 - 6 . 5 kg
111.7 - 14.3Ibs)
at length 28 .0 mm (1 . 10 in)
13. 1 - 15. 1 kg
128.9 - 33.3Ibs)
at length 31.5 mm 11 .24 in)
17·4
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
STANDARD
ITEM
1
Cam height
IN .
EX.
Camshaft journal oir clearance
Right side
left s ide
Ca msha ft journal holder 1.0 .
Right side
Left side
Camshaft journal 0 .0 .
Right side
Left side
LIMIT
33.450 - 33.490
11.3169 - 1 .31 85)
33.520 - 33. 560
11 .3 197 - 1 .32 13)
0 .032-0.066
10.0013 - 0 .0026)
0.028 - 0 .059
10.0011 - 0.0023)
22.012 - 22 .025
10.8666 - 0.86711
17 .512 - 17 .525
10.6894- 0 .6900)
21.959 - 21.980
10. 8645 - 0.86541
17 .466 - 17.484
10.6876 - 0.6883)
0.10
10.0041
Camshaft (unout
Rocker arm I.D.
IN . & EX.
Rocker arm shaft 0 .0 .
IN . & EX .
12.000 - 12 .0 18
10.4 724 - 0.4 731)
11 .973 - 11 .984
10.47 14 - 0.4718)
0 .05
10.002)
0.05
10.002)
Cy linder head distortion
Cylinder head cove r distortion
0- 2
10 - 0 .08)
De-compression lever play
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylind er clea rance
Cylinder bore
Piston diam .
Unit : mm (in)
STANDARD
LIMIT
0.055 - 0.065
10.0022 - 0 .0026)
7 9.000 - 79.0 15
13. 1102 -3. 1108)
78.940 - 78 .955
13. 1079 - 3.1085)
0 . 120
10.0047)
79 .075
13.1132)
M easure at 15 mm (0.6 in) trom the skirt end.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
33.150
11 .3051)
33.220
11 .3079)
0 . 150
10.0059)
0 . 150
10.0059)
151
R
2nd
R
151
2nd
10.2
Approx . 10.40)
11 . 1
10.44)
0 .15 - 0.30
10.006 - 0 .012)
0 .35 -0. 50
10.014 - 0 .020)
Approx .
78.880
13. 1055)
0.05
10.002)
8 .2
10.321
8.9
10.35)
0.70
10.028)
0.70
10 .028)
17·5
ITEM
Piston ring to groove
clearance
STANDARD
15t
2nd
Piston ring groove width
15t
2nd
Oil
Piston ring thi ckness
15t
2nd
Pi ston pin bore
Pi ston pin 0 .0 .
1,01 - 1.03
(0,040 - 0 ,0411
1,01 - 1,03
(0.040 - 0 ,0411
2,01 - 2.03
(0,079 - 0,0801
0 ,97 - 0.99
(0.038 - 0.0391
0 ,97 - 0 ,99
(0.038 - 0 ,0391
20,002 - 20 ,008
(0,7875 - 0 ,78771
19,996 - 20,000
(0 ,7872-0.78741
CON ROD + CRANKSHAFT + BALANCER
ITEM
Conrad sma ll end 1.0 .
Conrad big end width
Crank web to web width
20,030
(0,78861
19.980
(0,78661
Unit : mm (in)
STANDARD
20 ,006 - 20,014
(0,7876 - 0 ,78801
Conrad deflection
Conrad big end sid e clearance
LIMIT
0 . 180
(0 ,0071
0 , 150
(0,0061
0,10 - 0 ,55
(0,004-0,0221
21,95 - 22,00
(0,864 - 0 ,8661
60,0 + 0,1
(2 ,362 + 0.0041
Crankshaft run out
LIMIT
20,040
(0,78901
3 ,0
(0,121
1.0
(0,041
0 ,05
(0,0021
10,3
(0.4 11
Balan ce r spring free length
OIL PUMP
ITEM
Oil pump reduction ratio
Oi l pressure (at 60 oC, 140 0F)
STANDARD
1,590 (35 /221
Above 40 kPa (0.4 kg/cm2, 5 .7 psi)
Below 140 kPa ( 1 .4 kg/cm2, 19 .9 psi)
at 3 000 r/min .
LIMIT
I
17·6
CLUTCH
Unit: mm (in)
Clutch lever play
10.4 - 0 .61
Drive pl ate claw width
15.2
10.60)
Clutch spring free length
29.5
11.16)
TRANSMISSION + DRIVE CHAIN
ratio~_ __
Final
Gear ratios
Unit : mm linl Except ratio
l-_____
1
1
Shift fork groove width
10.004 - 0 .0121
5.0 - 5 . 1
10.0201
No . l,No .2
& No .3 +-_---'I.::.
o .:...:l.::.
97 - o . 2~
0::::
01~_ _ _ _ _ _ _-{
3
10. 189 - 0 . 1931
0.1 .0 . 520VC5
Drive chain
2o-pitch length
I
I
25 - 40
1.0 - 1.
319.4
112.
11·)
CARBURETOR
ITEM
'1
ELECTRICAL
Unit: mm (in)
ITEM
Ignition timing
Spark plug
Spark...,E!!rformance
Ignition coil resistance
Generator coil resistance
Generator no-load voltage
(when engine is cold)
Regulated voltage
SPECIFICA nON
NOTE
30oS ,T .D.C. above 4 300 rl min
OENSO: U27ETR
NGK : CR9EK
0 .6 - 0 .7
Gap
(0.024 - 0.02B)
Over 8 (0.3) at 1 atm .
0.1 - 1.00
Primary
(Terminal - Ground)
12 -22 kll
Secondary
(Plug cap - Terminal)
0 . 1- 1.511 (Y-B)
Lighting
0 .1 - 1.51lIY - Y)
350 - 6501lIW - Br)
Power source
350 - 70011 (G - Bil
I Pick-up No .l l
Pick-'!!'..No .2
350 - 70011 (Y - Gr)
• More than 65 V lAC) at 5 000 r/min.
Type
(V - V)
More than 40 V lAC) at 5 000 r/min .
IY - B)
'13 - 15 V at 5 000 r/min .
12 - 14 V at 5 000 r/min .
E-Ol .03.2B.33
E-2 4
E-24
E-Ol .03.2B.33
E·24
E-Ol .03.28.33
17·8
WATTAGE
Unit : W
ITEM
Headlig ht
55
BRAKE + WHEEL
Unit: mm (in )
,------ - - , -<0.004 - 0 .0101
5
10.2,1_
Rea r brake pedal height
Front
E· 24
Rear
10.118 + 0 .0081
10.0981
43 .5±
. 1 38 ;=±=="--+-----''::';
+
10. 157 ± 0 .0081
Bra ke disc runout
10 . 1381
0 .30
0 .012
•
10.4331 - 0.43481
Front
E· 24
....,.,_ _--,:--,._-;-_-:;-_-t_ _R_e._r_~C7,....;,1=0=.c:.
5000 - O. 50 1 71
Master cylinder piston diam .
E-0 1.03 ,
Front
28.33
E· 24
12.6 5 7 - 12.684
'Oi;e;:atip.;c;fu1ciOrbo;e-I-;R:;;e;::.;;r-I-:10~.~49Q183 - 0.4994!..1_ _+-____-1
sr
cylind er bore
Front
R
.050
3r8kE;ca~;rpiStC;n;: am~I---::-e_a-:-r11_-:11. 0630 - 1.0",60;5:;;0!..1_ _/--_ _ _--1
I
Front
Rear
17·9
STANDARD
ITEM
Wheel rim runout
LIMIT
2 .0
(0.08)
2.0
(0.08)
0 .25
(0.0 10)
0 .25
(0.010)
Axial
Radial
Wheel axle (unout
Front
Rear
Wheel rim size
J21 x 1.60
J18 >12. 15
Front
Rear
nre size
Front
Front
Tire tread depth
E-Ol.03.
28.33
E-24
E-Ol .03.
28.33
E-24
80/ 100-21 51M
·3.00-21 51P
110/ 100-18 64M
·120/90-1865P
4 .0
(0. 16)
4 .0
10. 16)
Front
Rear
SUSPENSION
Unit: mm (in)
---,----,
111 .0)
Front fork spring free length
Front fork oil level
gas
110
Rear wheel travel
pivot shaft run out
(10.5)
280
111 .0)
17·10
TIRE PRESSURE
For E·O 1,03,28 and 33
COLD INFLATION
TIRE PRESSURE
kP.
kg/cm2
PSI
FRONT
REAR
100
100
1.0
1.0
14
14
kPa
kg/cm2
pSI
"ISO
*1.50
*1.50
"22
"22
For E-24
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
*150
•
FUEl + Oll
type
-;."t:le;SC'
I
pump octane (R '2 M methodl or 91 octane or
higher rated by the research method .
Gasoline containing MTBE (Methyl Tertiary
Butyl Ether), less than 10% ethanol. or
less than 5% methanol with appropriate
and corrosion inhibitor is
E-03. 33
at
method) or 9 1 octane or
Research Method .
Gasoline used shou ld be graded 85·95
octane or higher. An unleaded gasoline is
recommended .
Fuel tank includ ing reserve
1
reserve
10. 5/0 .4
= :...::::...: C'O"-_ _ _ _ _ _ _ _.::S:..:
A=E 1 OW/ 40, API SF o r SG
oil capacity
Change
I
Overhaul
116.7/ 17.4
fluid
DOT 4
ozl
E-28
E- Ol . 24
1)·11
DR350SEW/SEX
VALVE + GUIDE
Unit: mm (in)
valve~
I
IN .
11 .201
27
1.
EX.
Valve clearance~ coirl'
Valve
to valve stem
clearance
V, lestem~
Valve guide 1.0 .
•
IN .
10.002 - 0 .0041
EX.
~Z~
IN .
10.0004- 0.00151
EX .
~06gf~ =g:g~~
•
IN. & EX.
10.0141
5.000 - 5.012
0.1
IN . & EX .
Valve stem
~ 1969 -
IN.
10. 1959 - 0.19651
~4 . 955 - 4 .970
EX.
Valve stem runout
Valve head thickness
Valve s tem end length
Valve seat width
Valve head
1951 - 0.~
.
IN . & EX.
10.0021
?~21
IN. & EX.
IN . & EX.
10~:i;-: 66431
IN . & EX .
run out
Valve spring free length
(IN . & EX.)
I
•
IN. & EX .
d~71
o:m
-
10.0011
INNER
OUTER
11.49)
Valve spring tension (IN. & EX.)
5.3 - 6 .5
INNER
at I
OUTER
at I
28.0 mm .10
13.1 - 15. 1 kg
128.9 - 33.3Ibs)
31 . 5 mm (1.24 in)
11·12
CAMSHAFT + CYLINDER HEAD
-
-----,
IN .
11.3169 - 1.3185)
33.520-33.560
1.3197 - 1.321
EX.
Right side
33.220
11 .
10.0013 - 0 .0026)
0 . 150
Left side
Right side
Unit: mm (in)
•
10.8666 - 0 .8671 )
Left side
Right side
•
10.8645- 0.8654)
Left side
runout
10,004)
Rocker arm 1.0 .
arm
IN . & EX.
)N . & EX.
•
10.4714 - 0.4718)
head distortion
cover
,
10.002)
.
CYLINDER + PISTON + PISTON RING
"
Unit: mm (in)
STANDARD
ITEM
( A~tomatW;fecomp. actuated)
Approx. ( 11 kg/cm 1 )
156 psi
0 .055 - 0 .065
10.0022 - 0 .0026)
79.000 - 79.015
13,1102 - 3 .1108)
78.940 - 78.955
13. 1079 - 3 .1085)
Piston to cylinder clearance
Cylind er bore
Piston diam .
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
LIMIT
1100kP.
70mpressiPn pressure
151
R
2nd
R
15t
2nd
10. 2
10.40)
I 1. I
Approx .
10.44)
O. I 5 - 0 .30
10.006 - 0 .012)
0 .35 - 0 .50
10.014 - 0 .020)
Approx .
0 . 120
10.0047)
79.075
13. 1132)
78.880
13. I 055)
0 .05
10.002)
8 .2
10.32)
8 .9
10.35)
0.70
10.028)
0 .70
10.028)
17·13
ITEM
Piston ring to groove clea rance
STANDARD
1 sl
2nd
Piston ring groove width
1sl
2nd
Oil
Piston ring thickness
l SI
2nd
Piston pin bore
Piston pin 0 .0 .
1.01 - 1.03
fO.040- 0 .041 1
1.01 - 1.03
fO.040 - 0 .041 1
2 .01-2.03
fO.079 - 0 .0801
0 .97 - 0 .99
fO.038 - 0 .0391
0 .97 - 0 .99
fO.038 - 0 .0391
20.002 - 20.008
fO.7875 - 0 .78771
19.996 - 20.000
fO .7872 - 0 .7874)
CONROD + CRANKSHAFT + BALANCER
ITEM
Conrod small end 1.0.
Conrad big end width
Cran k web to web width
20 .030
fO .7886)
19.980
fO .7866)
Unit: mm (in)
STANDARD
LIMIT
20 .006 - 20.014
fO. 7876 - 0 . 7880)
20.040
fO .7890)
3 .0
fO. 121
1.0
fO.04)
Conrod deflection
Conrad big end side clearance
LIMIT
0 . 180
fO.0071
0 .150
fO.0061
0 . 10- 0 .55
fO.004 - 0 .022)
21 .95 - 22.00
fO.8 64 - 0.866)
60.0 ± 0 . 1
f2 .362 + 0 .004)
0 .0 5
fO.0"(2)
10.3
f0.41 )
Crankshaft runDut
Balancer spring free length
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 oC, 1400F)
STANDARD
1.590 f35 /22)
Above 40 kPa fO .4 kg/em', 5 .7 psi)
Below 140 kPa f 1.4 kg/em', 19.9 psi)
at 3 000 r/min .
LIMIT
1)·14
CLUTCH
Unit: mm (in)
ITEM
Clutch lever play
STANDARD
LIMIT
10- 15
10.4- 0.6)
2 .72 - 2 .88
10. 107 - 0 . 113)
15.8 - 16.0
10.62 - 0.63)
Drive plate thickness
Drive plate claw width
2.42
10.095)
15.2
10.60)
0.10
10.004)
29 .5
11 . 16)
Driven plate distortion
Clutch spring free length
TRANSMISSION + DRIVE CHAIN
Unit: mm (in) Except ratio
2 .818 162122)
ratio
I reduction ratio
2.866 143115)
ratios
•
10.004 - 0 .012)
10.020)
Shift fork groove width
No.1.No.2
5.0 -,-,-".--_ _ _\_; & No . 3 +-_----'=1 97
10. 189 - 0 . 193)
0 .1.0. 520VC5
Drive chain
1
20-pitch length
319.4
112.
17·17
WATTAGE
Unit: W
ITEM
-----
1.7
BRAKE + WHEEL
Unit: mm (in)
STANDARD
ITEM
Brake lever play
Rear brake pedal height
Brake disc thickness
Front
Rear
0 . 1 - 0 .3
10.004 - 0 .0101
5
10.21
3 .5 ± 0 .2
10. 138 ± 0 .0081
4 .0 ± 0 .2
10. 157 ± 0 .0081
Brake disc runout
Master cylinder bore
Front
Rear
Master cylinder piston diam .
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper pi ston diam .
Front
Rear
Wheel rim runout
Axial
Radial
Wheel axle ru nout
Front
Rear
UMIT
3.0
10. 1181
3.5
10 . 1381
0 .30
10.0121
12.700 - 12 .743
10.5000 - 0 .50171
12.700- 12.743
10 .5000- 0 .50171
12.657 - 12.684
10.4983 - 0.49941
12.657 - 12 .684
10.4983 - 0 .49941
27.000 - 27.050
11 .0630 - 1.06501
30.230 - 30.280
11 . 1902 - 1.19211
26.900 - 26.950
11.0591 - 1.06101
30. 160- 30. 180
11 .1874 - 1. 18821
2.0
10.081
2 .0
10.081
0 .25
10 .010)
0.25
10.0101
17·18
ITEM
Wheel rim size
Front
Rear
Tire size & type
Front
STANDARD
J21 x 1.60
J1Bx2 . 15
BO/ l00-21 51P
Dunlop D601J IE-03.2B.331
LIMIT
Dunlop K560J (others)
Rear
Tire tread depth
110/90-1861P
Dunlop D601 IE-03.2B.331
Dunlop K560J lothersl
3 .0
10.12)
3.0
10. 12)
Front
Rear
SUSPENSION
ITEM
Front fork stroke
Unit: mm (inl
STANDARD
2BO
111.0)
Front fork spring free leng th
LIMIT
NOTE
·525
E-03.28.33
120.7)
602
123.7)
·147
15.8)
152
16.0)
Rear shock absorber gas pressure
1 000 kPa
11 0 kg /em'. 142 psi)
Rear shock absorber spring
253.4
pre-set length
110.0)
Front fork oil level
Rear wheel travel
For the others
E-03.28.33
For the others
255
110.0)
0.3
10.01 )
Swingarm pivot shaft runout
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
25
1]·19
FUEL+ OIL
Use only unleaded gasoline of at least 87
pump octane (RiM) or 91 octane or higher
rated by the research method.
Gasoline containing MTBE (Methyl Tertiary
Butyl Ether). less than 10% ethanol, or less
than 5% methanol with appropriate cosol·
vents
corrosion inhibitor is
=;=':":
Use only
Fuel type
octane (
E-28
gasoline is
8.0 L
12. 111.8 US/ Imp
Fuel tank including reserve
E-03.33
For the others
E-33
9.0 L
For the others
_ _ _--j_ _ _ _-'---'---; US/Imp
reserve
Change
1 900 ml
Filter change
.0/ 1.7
Overhaul
12.2/ 1.8
2 100
Front fork oil type
azl
E-03.28.33
For the others
17·20
FRONT FORK ... For DR350SEW/SEX IE-03.28 and 33)
I
/
•
a -ring
,.
Washer
Spring
Damper
/ I
Inner tube
Dust seal
Stopper ring
Oil seal
Oil lock piece
Outer tube
10
~
ITEM
N 'm
kg-m
Ib-te
®
23
35
35
12
2.3
3.5
3.5
1.2
16.5
25.5
25.5
8.5
<Ill
0
(!)J
e
Fork oil type : Fork oil 5505
Capacity: 494 ml
Oil level: 147 mm
REMOVAL AND DiSASSEMBLy .. . .. . . Same as DR350V front fork
REASSEMBLY AND REMOUNTING . . ... Same as DR350V front fork
Refer to pages 16-2 1 through -27.
Prepared by
SUZUKI MOTOR CORPORATION
Motorcycle Service Department
11th Ed . July, 1999
lsi Ed. Marc h, 1990
Part No. 99500-43019-03E
Printed in J apan
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