Suzuki DR250 & DR350 1990–1994 OEM Service Manual (P/N M476)

• 385-page PDF, Clymer manual M476: Covers the U.S. DR250 (1990-1993), DR250S (1990-1994), DR350 and DR350S (1990-1994), plus U.K. DR350 and DR350S models (1990-1994). The DR250 was not sold in the U.K.; the frame-number table maps L, M, N, P, and R model codes and gives starting serials where available.
• Separate maintenance schedules: Hour-based coverage for DR250/DR350 off-road models and mileage/time-based coverage for DR250S/DR350S, backed by procedures for valve-clearance checks, engine oil/filter and frame strainer service, fork-oil changes, chain care, cable adjustments, brake-fluid service, steering checks, and storage.
• Engine and transmission repair: Documents engine removal, top- and lower-end overhaul, camshaft/chain/tensioner service, valve and guide work, piston/cylinder inspection, crankcase splitting, crankshaft and balancer service, oil-pump work, clutch and kickstarter repair, and transmission/internal-shift overhaul.
• Fuel and emission-system variants: Separates the two Mikuni carburetor arrangements, including the single-cable 1990-1991 DR250S/DR350S setup and dual-cable later models; also covers the fuel shutoff valve, exhaust, spark arrester, crankcase ventilation, and California evaporative-emission equipment.
• Electrical diagnosis, not just component replacement: Includes charging-system leakage and output tests, alternator no-load and coil checks, CDI pickup/source-coil tests, starter-motor and solenoid service, switch-continuity diagrams, a starter troubleshooting table, system schematics, and year-specific full wiring diagrams.
• Chassis and brake repair: Covers wheel and hub service, spokes, tires, steering-head bearings, fork disassembly and seal replacement, shock linkage and swingarm service, pad/caliper/master-cylinder overhaul, brake hoses and discs, conventional and reverse-flow bleeding, plus inspection limits and torque tables.

Clymer states that the procedures, tables, and illustrations are arranged for a reader who may be working on the motorcycle or using the manual for the first time. In practice, this book is suited to a mechanically capable owner who understands basic shop work; major engine and transmission repair and precision electrical diagnosis still require proper measuring equipment, pullers, and the judgment to use a machine shop or dealer when the manual recommends it.

Engine, Transmission, and Model Changes

The engine section covers the air-cooled, single-overhead-cam, four-valve single from routine valve adjustment through cylinder-head, valve-guide, piston, cylinder, cam-chain, oil-pump, crankshaft, and balancer work. There is no liquid-cooling chapter. Cooling-related coverage is limited to cooling-fin inspection, the frame-based dry-sump oil circuit, external oil lines, and optional oil-cooler connections.

The transmission material goes well beyond a gear-ratio chart. It includes the Transmission exploded assembly, the Internal Shift Mechanism exploded view, mainshaft and countershaft disassembly and assembly, gear and shaft inspection, shift-fork clearance checks, and shift-drum inspection. It also distinguishes the 1990-1991 countershaft sixth gear from the sixth-gear-and-bushing arrangement used from 1992 onward.

Electrical Diagrams and Troubleshooting

The full wiring sheets are separated by configuration: 1990-1992 DR250 and DR350, 1993 DR250 and 1993-on DR350, 1990-1992 DR250S, 1993-on DR250S, U.S./Canada DR350S sheets for 1990-1991 and 1992, the 1993-1994 DR350S (U.S.) sheet, and the 1990-1992 DR350S (U.K.) diagram. Separate charging- and ignition-system schematics show the off-road AC lighting arrangement, battery-equipped S models, non-electric-start circuits, and the ignition/starting circuit used on 1993-on DR250S and 1994 DR350S electric-start models.

Diagnostic coverage includes meter use, connector and ground checks, charging leakage and output testing, pickup/source-coil resistance checks, switch continuity charts, starter inspection, and symptom/cause/remedy tables. Related specifications provide model- and year-specific electrical test ranges without forcing the technician to infer which circuit applies.

Tools, Scope Limits, and Repair Cautions

Major repair sections identify the Suzuki Crankcase Separator/Crankshaft Remover 09920-13120, Crankshaft Installer 09910-32812, flywheel puller 09930-34912, fork Damper Rod Attachment 09940-34530, and Oil Level Gauge 09943-74111. The tables collect component-specific torque settings, refill capacities, wear limits, clearances, transmission ratios, carburetor data, and electrical test values.

One U.K. DR350S version uses the optional hydraulic Suzuki Height Control system that links the front forks and rear shock; that SHC system is expressly outside this manual's repair coverage. The manual also warns that makeshift rotor removal can damage the rotor or crankshaft, and that incorrect neutral-switch lead routing can put the wire in contact with the drive chain or sprocket.

Because the book covers brake hydraulics, fuel-system work, major engine disassembly, and live electrical testing, secure the motorcycle properly, use the specified tools and test equipment, and verify the applicable torque table before returning it to service.