Question about 1991 Suzuki DR 350 S

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1991 DR 350 rat bike - oil is not returning to tank, instead gathering in the crank sump. Someone before us had evidently had the same issue and presumably continued to add oil to the tank in an effort to remedy. This resulted in us getting approx. 4 litres of oil from the sump during our initial draining! We renewed the oil filter and put 1700 mls of fresh oil in, replaced the spark plug and cleaned the carb. When we started the bike for the first time in a long time, (junker for free) it seemed to heat up quicker than I supposed it would. Upon restarting the compression increased dramatically to the point where it was very difficult to kick over. All the oil lines as well as the oil cooler are clear. The bike was obviously ridden hard and put away dirty to say the least. What is the probability of an oil pump failure, and is that an engine in frame operation? Looks like an engine removal to me. Of course I would like to avoid replacing the oil pump so I want to be sure i'm not over looking any thing.

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The pump should be accessible through the RHS cover, if the pump is not working it may have worn out the drive gear, oil pumps themselves are fairly reliable.

If it got real hot quickly, and it has an oil problem , there may be some damage to the cam and rockers, and again if it has a oil pressure problem the hard kicking could be the piston siezing against the bore, so the oil pump is the minor problem compared to the other damage that may have happened

Posted on May 27, 2011


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Posted on Jan 02, 2017


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1991 Suzuki DR 350 S oil flow diagram

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May 19, 2017 | 1991 Suzuki DR 350 S

1 Answer

My oil overflows from my oil tank, what could be the problem? and no, i do not have too much oil in the bike

If your Bike is dry sump I would suspect the oil pump is returning oil and not feeding it. Or the oil filter is blocked, if you have an oil cooler fitted check this too.

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How much oil to put in from empty

if you have a manual
it will tell you how many ML it will hold from empty
some bikes tell you one the oil cap
some bikes will tell you in a small window on the side of the engine which i beleive this is the solution in your case
under the window it may also tell you how many ML to put in
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un do the screw and top up the oil
until oil comes out of the screw hole

Oct 18, 2013 | 1991 Suzuki DR 350 S

2 Answers

Oil disappearing without visual leaking

Hi James, it would appear that the return side of your oil pump has failed so sorry.

Apr 10, 2013 | 2005 Harley Davidson FXST - FXSTI Softail...

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Why is my 1991DR350 blowing oil out oil breather hose

oil blow-back can sometimes be caused by a blockage causing the oil not to flow properly or you have a bad oil pump.
check all hoses if it continues then take the cover off the oil tank , remove spark plug then hand crank the engine over and watch for oil flowing back to tank, if it doesn't you need to rebuild or replace oil pump

Sep 25, 2011 | 1991 Suzuki DR 350 S

1 Answer

Help I have a dr 250s that is putting oil back through the drain line at the bottom of the air box ant one know why

make sure it is not overfull with oil(sometimes a flooding carb can put fuel into the sump) or it may be compression blowing past the rings and pressurising the sump,
a small amount can sometimes be normal on very rough terrain

Mar 15, 2011 | 1993 Suzuki DR 350 S

1 Answer

What is the oil fill hole in front of my gas tank on my 1991 Suzuki dr350 for

Your bike has motor oil stored in the frame instead of a " tank". there is a frame drain located at the lower portion of the front downtube of the frame and the engine. If you are changing the oil you should drain both the engine and the frame and then re-fill. since you bike has two pumps, one to feed the motor and one to push the oil back to the frame, you need to add some oil and then run the bike for 30 seconds or so. After you have run the bike for 30 seconds check the oil in the frame and add as needed.

thanks and I hope that this helps.

Jan 18, 2011 | 1991 Suzuki DR 350 S

1 Answer

I have a Honda XR250 dirt bike, When the bike is running oil is pumping out of the crank case breather. can you tell me how to stop it?

Sounds like one of two possible problems.
1.) You have overfilled the oil level.
2.) You have a faulty oil pump.

The 98 xr250 is a dry sump model and the oil pump, pumps oil back to the frame/tank (oil in frame).If you have too much oil in your system the oil tank overflows back into the engine the excess oil can affect the internal pressure in the engine this can cause some of the excess to be vented through the crank case breather. A more severe and urgent problem could be a failure of the oil pump to return oil to the tank , this could lead to severe engine damage as your oil system could be starved. Firstly drain all your oil and measure what comes out , should be no more than 1.4 litres, if you have more you have found the problem !! If the amount of oil is correct, then i am afraid you will have to open the engine and have the oil pump / lubrication system examined / replaced by a professional.
Hope this helps

Oct 08, 2010 | 1998 Honda XR 250 R

2 Answers

How much oil does it hold and how do you check it with the dipstick on the upper frame?

1.7 litres if you change it without the filter and around 1.9 when you change both oil and filter. run the engine for five minutes then turn off the bike and leave for a minute and a half. unscrew the dipstick, wipe it and put it back in without screwing it and check that its within the lines on the dipstick

May 15, 2010 | 1991 Suzuki DR 350 S

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