DR350 & DRZ400 FAQ - General Questions & Answers

Click noise driving me crazy!

I’ve got a 1996 DR350 with an auto decompression cam. Every time I turn the engine over by hand, I hear a click just after the intake valves close. It opens the exhaust valves and makes a click just before Top Dead Center (TDC). I’m just wondering if it's normal because it’s a pretty loud click it drives me crazy!

Though it may bother you, the sound is normal and there is nothing to worry about.

Starting procedures for DR350!

I recently purchased a 1993 Suzuki DR350. I managed to get it started once, but since then it has become incredibly difficult. I have tried many different techniques but nothing seems to work. My question is what can I do to the bike to make it start easier? Any help is much appreciated since this is the first bike I have owned and I really want to ride it!

Even a band new plug can become carbon fouled by unsuccessful starting attempts. Pull the plug and look at it. Is the center of black? If it is, replace it! When you buy the new one, purchase a couple of spares in case you foul another one while learning the starting drill. When you pull the spark plug to check it, hold the throttle wide open and kick the motor through several times to clear out any fuel that may be built up from earlier attempts to start it. (If it's flooded it won't start and will foul another plug.) DO NOT touch the spark plug cap while kicking the motor over. Then check the basics:

• Good spark plug
• Fresh fuel (yes, fuel goes bad!)
• Good spark
• Good compression
• Check the valve clearances - tight valves will bleed off compression making for hard starting

The starting procedure is also very important. You need to use the decompression lever for every kick of the lever.

1. Pull in decompression lever, it will stay down. (The decompression lever will tell you the correct position to start each kick. This will give you the best chance of starting the bike in the fewest number of kicks.)
2. Move kick start lever down slowly and stop the instant the decompression lever pops back up.
3. Let the kick start lever return to the top of the stroke.
4. Be sure you don’t give it any gas and give the kick start a good full kick all the way to the bottom.
5. Did not start? Return to Step 1 and repeat.

Kickstart lever won't come off!

I am trying to get the kick start lever off my 1997 DR350, but it doesn’t want to come off. Obviously I have removed the pinch bolt and the lever will not come off. It comes about halfway off and then stops and feels like it is hitting a screw or something.

I've recently removed the kick start lever off of two different DR350s and they were both very resistant to coming off the shaft. I ended up using a small gear puller to get them removed. Once you have the bolt out of the end of the shaft there's nothing holding it on but wear and age.

Can I get a wiring diagram for your dual sport wiring harness?

I have a strange request I'd be very grateful if you could help me with. I recently bought a Suzuki DRZ400E with one of your dual sport wiring kits installed, badly. I'm having trouble getting it all to work and it would be a huge help if I had a wiring diagram. Would it be possible to send me one (email best, but I'll happily pay postage), and/or the instructions for this kit? "Universal Wire Harness w/Handlebar & Key Switch"

We have never had a reason to actually draw out a wiring diagram. But I do have wiring keys that explain the function of each wire. I just need to know which handlebar switch you have. Older systems used the 'Combination handlebar switch' and newer systems use the 'Mini handlebar switch'. You can see pics of the two different switches on the website by clicking here. Let me know which one you have and I'll be happy to get a wiring key to you.