Question about 1993 Suzuki DR 350 S

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1993 Suzuki DR 350 S will not upshift from 2nd

Will not upshift from second gear @

Posted by Anonymous on

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1 Answer

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  • Suzuki Master
  • 53,355 Answers

Hi, Anonymous and the usual suspects are:
1. Improper clutch adjustment or not disengaging.
2. Bent shift shaft.
3. Shift fork bent or seized.
4. Gear seized on the shaft.
5. Gear positioning lever binding.
6. Shift return springs weak or broken.
7. Shift return spring pin loose
8. Shift mechanism arm spring is broken.
9. Shift mechanism arm is broken.
10. Shift drum is broken.
11. Shift lever loose on the shift shaft.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/forums/topic/1017029-dr350-owners-need-trans-help-fast
Bike won shift stuck in one of the upper gears
Suzuki DR350 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

Posted on Feb 21, 2019

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6 Suggested Answers

6ya6ya
  • 2 Answers

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Posted on Jan 02, 2017

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  • 2 Answers

SOURCE: bike wont shift in to gear from neutral

is your neutral safety switch connecting all the way?

Posted on Jun 04, 2009

  • 12 Answers

SOURCE: My bike is clutched

shift fork in trans is not engaging need to let someone open trans and sovle the issue those trans are not hard to fix but if you dont know how the shift fork needs to be to fuction seek pro help

Posted on Jun 09, 2009

  • 3567 Answers

SOURCE: I have a 2001 suzuki gsxr 600 shifting problems

One of two things is happening. One is the cost of a double oil change and filter. The other requires your banks loan officer.

Change gearbox oil and install a new oil filter. Dirt and grit in the oil is binding the gears and shift drum. Ride the bike for a couple of hours. Now drain the oil again and put in fresh oil. This will flush out the dirt and grit. Use 10w40 motor oil. Stick with the major brands; Pennzoil, Quaker State, Mobil or Shell. If dirty oil is not the problem at least we eliminated the possibility for only the cost of a few quarts of oil.

Now let's talk about that loan officer. The shop is going to charge around $1000 plus to replace a bent shift fork. This is not a repair for the untrained. Sorry.

Posted on Jul 07, 2009

  • 4 Answers

SOURCE: backfire during shifting between gears

could be few probs, carbon build up on piston crown try a good cleaner fuel additive, your exaust is leaking or blowing allowing air to be sucked back in on revdown as well as you could have a inlet fault overfueling leaving to much unburnt fuel to enter your exaust, might be simple fix by just replacing the air filter and checking for burn marks around the air intake.

Posted on Jul 10, 2009

1fastbob
  • 301 Answers

SOURCE: '92 SUZUKI 350 DR spark plug

According to NGK sparkplugs at www.ngksparkplugs.com .

You Suzuki uses an NGK # DPR9EA-9 standard plug or a
DPR9EIX-9 Iridium plug. They both gap at .035".

Hope this helps.

Bob

Posted on Nov 05, 2009

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Hi, Anonymous and the usual suspects are:
1. Improper clutch adjustment or not disengaging.
2. Bent shift shaft.
3. Shift fork bent or seized.
4. Gear seized on the shaft.
5. Gear positioning lever binding.
6. Shift return springs weak or broken.
7. Shift return spring pin loose
8. Shift mechanism arm spring is broken.
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Hi, Anonymous and the usual suspects are:
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2. Bent shift shaft.
3. Shift fork bent or seized.
4. Gear seized on the shaft.
5. Gear positioning lever binding.
6. Shift return springs weak or broken.
7. Shift return spring pin loose
8. Shift mechanism arm spring is broken.
9. Shift mechanism arm is broken.
10. Shift drum is broken.
11. Shift lever loose on the shift shaft.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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Hi, Anonymous and the usual suspects are:
1. Improper clutch adjustment or not disengaging.
2. Bent shift shaft.
3. Shift fork bent or seized.
4. Gear seized on the shaft.
5. Gear positioning lever binding.
6. Shift return springs weak or broken.
7. Shift return spring pin loose
8. Shift mechanism arm spring is broken.
9. Shift mechanism arm is broken.
10. Shift drum is broken.
11. Shift lever loose on the shift shaft.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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1991 Suzuki DR 350 S Cam drive gear bolt broke


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
How to Extract Broken Camshaft Bolt
DR350 timing alignment
Suzuki DR350 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e


Nov 06, 2017 | 1991 Suzuki DR 350 S

1 Answer

The shift arm broke and is just dangling and does not go in gear?


There is a part that is called the shifting fork. It is a pain to change. Where the shifter attaches to the shifting fork there are teeth on the shifter and the shifting fork. The shifter has a bolt through it to tighten the shifter. I would try taking the shifter off and cleaning both the shifting fork, which sticks out of the side of the motor, had teeth or knurl then a div-et then knurl. Clean it and the shifter up really good and reinstall the shifter. Tighten the bolt on the shifter really tight. If this don't fix it, then you can tack weld the shifter back on. But if you do this do it on the outside of the shifter where it can be ground back off, in case you ever have to split the case. The shifting fork goes all the way through the motor to the other side. 

Sep 04, 2010 | 1991 Suzuki DR 350 S

2 Answers

1978 suzuki dr 370 motorcyle just started having a problem. When in neutral the transmission makes a popping type noise intermittenly. when this occurs it tries to jump into gear. ant idea


The popping noise is gear dogs trying to engage a gear. You did not say that the bike doesn't shift smoothly so I would tend to rule out a bent shift fork. The neutral stopper pin may be worn or the stopper spring or other springs may be broken (see diagram). Another possibility is a broken stationary gear circlip which would let the gear wander a bit on the shaft. most the parts are available at Babbitt's. Go to www.babbittsonline.com/parts/viewbybrand/parts.aspx

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1 Answer

My 2001 Suzuki DR-Z250 can't shift from 2nd to 1st without getting stuck in neutral.


You have a bent shift fork. The gears themselves are fine. Only one shift fork needs to be replaced. Stop off at a dealership. They will confirm my diagnosis.

Please rate this answer. Thanks!

Apr 08, 2009 | 2001 Suzuki DR-Z 250

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