1990-1994 Suzuki DR250 DR350 Motorcycle Repair Manual by Clymer

Description

This 1990 1991 1992 1993 1994 Suzuki DR250-350 Repair Manual by Clymer provides detailed service information, step-by-step repair instruction and maintenance specifications for 1990-1993 Suzuki DR250, 1990-1994 Suzuki DR250S, 1990-1994 Suzuki DR350, and 1990-1994 Suzuki DR350S motorcycles.

Although it is not documented in this book – some owners have told us this title can be used for 1995 DR250S as well as 1995 & 1996 DR350 motorcycles.

Includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, cooling system, ignition system, steering and suspension, wheels, brakes and tires, frame and body, electrical system and includes wiring diagrams. Features 374 illustrated pages.

Table of Contents

QUICK REFERENCE DATA

ONE, GENERAL INFORMATION
Manual organization, Notes, cautions and warnings, Safety first, Service hints, Washing the motorcycle, Torque specifications, Fasteners, Lubricants, Expendable supplies, Parts replacement, Basic hand tools, Precision measuring tools, Special tools, Mechanic’s tips, Riding safety

TWO, TROUBLESHOOTING
Operating requirements, Troubleshooting instruments, Starting the engine, Starting difficulties, Engine starting troubles, Engine performance, Engine noises, Excessive vibration, Clutch, Transmission, Ignition system, Front suspension and steering, Brakes

THREE, LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-checks, Tires and wheels, Lubricants, Battery (DF250S and DR350S), Periodic lubrication, Periodic maintenance, Engine tune-up, Storage

FOUR, ENGINE TOP END
Engine principles, Servicing engine in frame, Cylinder head cover and rocker arms, Camshaft and tensioner, Cylinder head, Valves and valve components, Cylinder block, Camshaft chain guide and tensioner, Piston, Piston rings

FIVE, ENGINE LOWER END
Servicing engine in frame, Engine, Starter clutch and reduction gears, Oil pump, Camshaft chain, Crankcase and crankshaft, Break-in procedure

SIX, CLUTCH, KICKSTARTER AND EXTERNAL SHIFT MECHANISM
Clutch cover, Clutch, Clutch release mechanism, Primary drive gear and oil pump drive gear, Kickstarter, External shift mechanism, Clutch cable

SEVEN, TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation, Transmission overhaul, Internal shift mechanism

EIGHT, FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS
Carburetor service, Carburetor adjustments, Throttle cable replacement, Fuel shutoff valve, Exhaust system, Exhaust system repair, Evaporative emission control system (DR250S and DR350S California models), Crankcase ventilation control system

NINE, ELECTRICAL SYSTEMS
Electrical troubleshooting, Charging system (DR250S and DR350S), Charging system (DR250 and DR350), Alternator, Voltage regulator/rectifier (DR250S and DR350S), Voltage regulator (DR250 and DR350), Ignition system, Ignition coil, Spark plug, Starting system, Starter, Starter solenoid, Lighting system (DR250S and DR350S), Lighting system (DR250 and DR350), Electrical components, Switches, Horn (DR250S and DR350S), Fuse (DR250S and DR350S)

TEN, FRONT SUSPENSION AND STEERING
Front wheel, Wheel spoke service, Front hub, Tire changing, Tire repairs, Handlebar, Steering head, Front fork

ELEVEN, REAR SUSPENSION
Rear wheel, Wheel spoke service, Rear hub, Sprockets, Drive chain, Tire changing and tire repairs, Rear suspension, Shock absorber, Shock linkage, Swing arm

TWELVE, BRAKES
Disc brake, Front brake pd replacement, Front brake caliper, Front master cylinder, Rear brake pad replacement, Rear brake caliper, Rear master cylinder, Brake hose replacement, Brake disc, Bleeding the system, Rear brake pedal

THIRTEEN, FRAME AND BODY
Sidestand, Footpegs, Fenders, Seat, Frame

INDEX

WIRING DIAGRAMS