Suzuki DR350 Manuals

Suzuki DR350 Manuals

Manuals and User Guides for Suzuki DR350. We have 2 Suzuki DR350 manuals available for free PDF download: Service Manual

Suzuki DR350 Service Manual

Suzuki DR350 Service Manual (399 pages)

DR350; DR350S

Brand: Suzuki | Category: Motorcycle | Size: 53.07 MB

Table of Contents

View of DR350L
3
General Information
4
Fuel and Oil Recommendations
5
VIN and Serial Number Locations
5
Brake Fluid
6
Break-In Procedures
6
Engine Oil
6
Front Fork Oil
6
Special Materials
7
Precautions and General Instructions
9
Replacement Parts
9
Specificatlons
10
Table of Contents
11
Periodic Maintenance and Tune-Up Procedures
11
Periodic Maintenance Schedule
12
Lubrication Points
13
- Cylinder Head Bolts and Nuts, Cylinder Nuts Exhxaust Pipe Bolts and Muffler Connections
  14
- Cylinder Heat and Cylinder
  14
- Exhaust Pipe and Muffler
  14
- De-Compression Lever
  15
- Valve Clearance
  15
  - Spark Arrester
    16
  - Spark Plug
    16
  - Air Cleaner
    17
  - De-Compression Lever
    17
- Engine Oil, Oil Filter and Oil Strainer
  18
- Carburetor
  19
- Throttle Cable Adjustment
  19
- Clutch
  20
- Drive Chain Checking
  20
- Fuel Line
  20
- Brake Fluid Level
  21
- Brakes
  21
  - Drive Chain Adjusting
    21
  - Drive Chain Cleaning and Lubrication
    21
  - Brake Lever Play
    22
  - Brake Pads
    22
  - Brake Pedal Height
    22
  - Bleeding Air from the Brake Fluid Circuit
    23
- Spoke Nipples
  24
  - Tire Pressure
    24
  - Tire Tread Condition
    24
- Tires
  24
  - Front Fork Inspection
    25
  - Rear Suspension Inspection
    25
  - Steering Maintenance
    25
  - Chassis Bolts and Nuts
    26
  - Engine
    28
- Engine Components Removable with the Engine in Place
  29
- Engine Removal Ano Remounting
  30
  - Engine Remounting
    32
  - Engine Oil Capacity
    33
  - Engine Disassembly
    34
  - Cylinder Head Cover Distortion
    42
  - Cylinder Head Cover Servicing
    42
- Engine Components Inspection and Servicing
  42
  - De-Comp. Shaft Reassembly
    43
  - Rocker Arm and Shaft Reassembly
    43
  - Rocker Arm I.D.
    43
  - Rocker Arm Shaft O.D.
    43
  - Cylinder Head Distortion
    44
  - Cylinder Head Servicing
    44
  - Valve Face Wear
    44
  - Valve Guide-Valve Stem Clearance
    45
  - Valve Head Radial Runout
    45
  - Valve Stem Runout
    45
  - Valve Stem Wear
    45
  - Valve Guide Servicing
    46
  - Valve and Seat Condition, Valve Seat Width
    47
  - Valve Seat Servicing
    47
  - Valve Stem and Condition
    48
  - Valve and Valve Spring Reassembly
    49
  - Valve Spring
    49
- Camshaft
  50
  - Camshaft Cam Wear
    50
  - Camshaft Journal Wear
    50
  - Cam Chain 20-Pitch Length
    51
  - Camshaft Runout
    51
  - Cylinder Bore, Piston Diameter
    51
  - Cylinder Distortion
    51
  - Piston Ring Free End Gap and Piston Ring End Gap
    52
  - Piston Ring-Groove Clearance
    52
  - Piston-Cylinder Clearance
    52
  - Oversize Oil Rings
    53
  - Oversize Piston Rings
    53
  - Oversize Rail
    53
  - Piston and Pin Bore
    53
  - Conrod Deflection and Conrod Big End Side Clearance
    54
  - Conrod Small End I.D.
    54
  - Crankshaft Runout
    54
  - Clutch Drive Plate
    55
  - Clutch Driven Plate
    55
  - Clutch Release Bearing
    55
  - Clutch Spring Free Length
    55
  - Clutch Release Pinion and Rack
    56
  - Transmission Disassembly
    56
  - Gearshift Fork-Groove Clearance
    57
  - Transmission Reassembly
    57
  - Balancer Shaft and Gears
    59
  - Crankcase Bearings
    59
- Crankshaft
  60
- Engine Reassembly
  60
- Oil Seals
  60
- Balancershaft and Gears
  61
- Oil Pipe
  61
- Gearshift Cam and Forks
  62
- Oil Pump and Oil Sump Filter
  63
- Crankcase
  64
- Cam Chain and Primary Drive Gear
  65
  - Cam Driven Gear and Gearshift Shaft
    65
  - Kick Starter Shaft
    66
  - Clutch Exploded View
    68
- Oil Filter
  69
- Magneto
  70
  - Oil Ring
    70
  - Top Ring and 2Nd Ring
    70
- Cylinder
  71
  - Piston
    71
  - Camshaft Installation
    72
- Cylinder Head
  72
- Cylinder Head Cover
  73
  - Cam Chain Tensioner Adjuster
    74
  - Oil Pipe Installation
    75
  - Valve Inspection Cap
    75
  - Magneto Cover
    76
  - Fuel and Lubrication System
    77
  - Fuel Cock Inspection and Cleaning
    78
  - Carburetor Construction
    79
  - Carburetor Specifications
    80
  - Carburetor Disassembly
    81
  - Carburetor Removal
    81
  - Carburetor Inspection
    83
  - Float Height Adjustment
    83
  - Needle Valve Inspection
    83
  - Carburetor Reassembly and Remounting
    84
  - Lubrication System
    84
  - Oil Pressure
    84
  - Engine Lubrication System Chart
    85
  - Engine Lubrication System Diagram
    86
  - Electrical System
    87
  - Ignition System Description
    88
  - Magneto Coil Inspection
    88
  - CDI Unit
    89
  - Ignition Coil Checking with Electro Tester
    89
  - 12 - 14 (AC) at 5000 R/Min
    90
  - Lighting Cock Output Check
    90
  - Lighting Performance Check
    90
  - Lighting System
    90
  - Engine Stop Switch
    91
  - Lamps, Headlight View
    91
  - Regulator Check
    91
  - Taillight View
    91
  - Chassis
    92
  - Front Wheel Diagram
    93
  - Front Wheel Removal
    93
  - Axle Shaft
    94
  - Front Wheel Inspection and Disassembly
    94
  - Wheel Bearing
    94
  - Wheel Rim
    94
  - Front Wheel Reassembly and Remounting
    95
  - Spoke Nipple
    95
  - Tire Service Limit
    95
  - Front Brake Exploded View
    97
  - Brake Pad Replacement
    98
  - Caliper Removal and Disassembly
    98
  - Caliper and Disc Inspection
    99
  - Caliper Reassembly and Remounting
    100
  - Master Cylinder Removal and Disassembly
    100
  - Master Cylinder Inspection
    101
  - Master Cylinder Reassembly and Remounting
    101
  - Front Fork Exploded View
    102
  - Front Fork Removal and Disassembly
    102
- Removal Ano Disassembly
  102
  - Damper Rod Bolt/Damping Force Adjuster
    104
  - Damper Rod Ring
    104
  - Front Fork Inspecton
    104
  - Inner Tube and Outer Tube
    104
- Inspection
  104
  - Fork Spring
    105
  - Front Fork Reassemby and Remounting
    105
  - Inner Tube Metal
    105
  - Oil Seal Stopper Ring and Dust Seal
    105
- Reassembly and Remounting
  105
  - Fork Oil
    106
  - Fork Spring Installation
    106
  - Front Fork Remounting
    106
  - Damping Force Adjustment
    107
  - Front Fork Adjustment
    107
  - Spring Pre-Load Adjustment
    107
  - Steering Stem Diagram
    108
  - Steering Stem Removal and Disassembly
    108
  - Steering Stem Inspection
    110
  - Steering Stem Reassembly and Remounting
    110
  - Handlebar
    111
  - Steering Stem Nut
    111
  - Rear Wheel Diagram
    112
  - Rear Wheel Removal
    112
  - Rear Sprocket
    113
  - Rear Wheel Inspection and Disassembly
    113
  - Rear Wheel Reassembly and Remounting
    113
  - Wheel Hub Bearing
    113
  - Rear Brake Diagram
    115
  - Brake Pad Replacement (Rear Wheel)
    116
  - Caliper Removal and Disassembly (Rear Wheel)
    116
  - Caliper and Disc Inspection (Rear Wheel)
    117
  - Caliper Reassembly and Remounting (Rear Wheel)
    117
  - Master Cylinder Removal and Disassembly (Rear)
    118
  - Master Cylinder Inspection (Rear)
    119
  - Master Cylinder Reassembly and Remounting (Rear)
    119
  - Rear Swingarm and Suspension Exploded View
    120
  - Rear Swingarm and Suspension Removal
    121
  - Rear Swingarm Inspection and Disassembly
    122
  - Cushion Lever
    123
  - Rear Swingarm and Suspension Reassembly and Remounting
    124
  - Shock Absorber Spring Pre-Load Adjustment
    124
- Reassembling Information
  125
  - Servicing Information
    127
  - Troubleshooting - Engine
    128
  - Troubleshooting - Carburetor
    131
  - Troubleshooting - Electrical
    132
  - Troubleshooting - Chassis
    133
  - Troubleshooting - Brakes
    134
  - Wiring Diagram
    135
- Wire, Cable and Hose Routing
  136
- Special Tools
  140
Maintenance and Tune-Up Procedures
14

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Suzuki DR350 Service Manual

Suzuki DR350 Service Manual (427 pages)

Brand: Suzuki | Category: Motorcycle | Size: 82.7 MB

Table of Contents

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