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Suzuki DR200SE User Manual

Suzuki DR200SE
262 pages
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FOREWORD
This manual contains an introductory description on
SUZUKI DR200SE and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is
not included.
Read GENERAL INFORMATION section to famil-
iarize yourself with outline of the vehicle and MAIN-
TENANCE and other sections to use as a guide for
proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of your optimum
and quick service.
* This manual has been prepared on the basis
of the latest specification at the time of publi-
cation.
If modification have been made since then,
differences may exist between the content of
this manual and the actual vehicle.
* Illustrations in this manual are used to show
the basic principles of operation and work pro-
cedures.
They may not represent the actual vehicle ex-
actly in detail.
* This manual is intended for those who have
enough knowledge and skills for servicing
SUZUKI vehicles. Without such knowledge
and skills, you should not attempt servicing
by relying on this manual only.
Instead, please contact your nearby autho-
rized SUZUKI motorcycle dealer.
c COPYRIGHT SUZUKI MOTOR CORPORATION 1995
IMPORTANT
All street-legal Suzuki motorcycles with engine dis-
placement of 50 cc or greater are subject to Envi-
ronmental Protection agency emission regulations.
These regulations set specific standards for exhaust
emission output levels as well as particular servic-
ing requirements. This manual includes specific in-
formation required to properly inspect and service
DR200SE in accordance with all EPA regulations. It
is strongly recommended that the chapter on Emis-
sion Control, Periodic Servicing and Carburetion be
thoroughly reviewed before any type of service work
is performed.
Further information concerning the EPA emission
regulations and U.S. Suzuki’s emission control pro-
gram can be found in the U.S. SUZUKI EMISSION
CONTROL PROGRAM MANUAL/SERVICE BULLE-
TIN.
GROUP INDEX
1
2
3
4
5
GENERAL INFORMATION
6
7
8
EMISSION CONTROL
INFORMATION
PERIODIC MAINTENANCE
ENGINE
FUEL AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION

Table of Contents

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Suzuki DR200SE Specifications

General IconGeneral
Bore x Stroke66.0 mm x 58.2 mm
Compression Ratio9.4:1
IgnitionElectronic ignition (CDI)
Transmission5-speed constant mesh
Front SuspensionTelescopic, coil spring, oil damped
Rear SuspensionSwingarm type, coil spring, oil damped
Rear BrakesDrum
Engine Type4-stroke, air-cooled, single-cylinder
Fuel SystemMIKUNI BST31SS, single
Front BrakesSingle disc
Fuel Tank Capacity13.0 L (3.4 US gal.)
Overall Width805 mm (31.7 in)
Wheelbase1, 405 mm (55.3 in.)
Ground Clearance260 mm (10.2 in)
Curb Weight126 kg (278 lbs)

Summary

General Information

Warnings, Cautions, and Notes

Explains special information symbols and their meanings for safe operation.

General Precautions for Servicing

Lists essential safety measures and guidelines for servicing the vehicle.

Periodic Maintenance

Periodic Maintenance Schedule

Outlines intervals for essential service tasks to maintain the vehicle.

Maintenance and Tune-Up Procedures

Details specific procedures for routine maintenance tasks like tune-ups.

Valve Clearance Adjustment

Instructions for checking and adjusting valve clearance for engine performance.

Spark Plug Servicing

Guidance on inspecting, cleaning, and replacing the spark plug.

Carburetor Adjustment

Explains how to adjust the carburetor for optimal engine running.

Engine Oil and Oil Filter Maintenance

Procedures for changing engine oil and replacing the oil filter.

Drive Chain Inspection and Adjustment

How to check drive chain slack and perform adjustments for proper tension.

Brake System Checks

Information on inspecting brake hoses and brake fluid levels.

Air Bleeding the Brake Fluid Circuit

Steps for purging air from the hydraulic brake system.

Chassis Bolts and Nuts Tightening Torque

Lists critical torque specifications for chassis fasteners for safety.

Compression Pressure Check

Method for measuring engine compression to assess internal condition.

Oil Pressure Check

Procedures for verifying engine oil pressure.

Engine

Engine Removal and Reinstallation

Step-by-step guide for safely removing and reinstalling the engine assembly.

Engine Disassembly Procedures

Detailed instructions for taking apart the engine for inspection or repair.

Cylinder Head Service

Procedures for inspecting and servicing cylinder head components.

Clutch Assembly Servicing

Procedures for servicing and disassembling the clutch.

Crankcase Bearing and Oil Seal Replacement

Instructions for replacing crankcase bearings and oil seals.

Cylinder Head Cover and Rocker Arm Servicing

Procedures for servicing the cylinder head cover and rocker arms.

Cylinder Head Service Procedures

Detailed steps for servicing the cylinder head.

Valve and Valve Spring Reassembly

Steps for correctly reassembling valves and their springs.

Fuel and Lubrication System

Carburetor Disassembly Steps

Detailed instructions for disassembling the carburetor.

Chassis

Brake Pad Replacement

Instructions for replacing brake pads.

Caliper Removal and Disassembly

Steps for removing and disassembling the brake caliper.

Master Cylinder Removal and Disassembly

Steps for removing and disassembling the front brake master cylinder.

Front Fork Removal and Disassembly

Procedures for removing and disassembling the front fork components.

Steering System Removal and Disassembly

Steps for removing and disassembling the steering system.

Steering System Reassembly and Remounting

Steps for reassembling and remounting the steering system.

Rear Suspension Reassembly and Remounting

Steps for reassembling and remounting the rear suspension.

Electrical System

Cautions in Servicing Electrical Components

Important safety warnings for working with electrical parts.

Battery Servicing and Connecting

Guidelines for battery maintenance and proper connection.

Charging System Description

Explains the function and circuit of the motorcycle's charging system.

Troubleshooting Electrical System Issues

A flowchart for diagnosing common electrical problems.

Battery Leak Current and Charging Output Checks

Methods for checking battery leak current and charging output.

Generator Stator Coil and Regulator/Rectifier Tests

How to test generator stator coil and regulator/rectifier.

Starter System Description

Explains the components and operation of the starter system.

Starter Motor Troubleshooting

Diagnosis guide for issues related to the starter motor.

Starter Motor Removal and Disassembly

Steps for removing and disassembling the starter motor.

Starter Motor Inspection

Guidance on inspecting starter motor components like brushes and commutator.

Ignition System Description and Troubleshooting

Overview of the ignition system and troubleshooting steps.

Spark Plug Inspection and Replacement

Detailed guide for spark plug inspection and replacement.

Servicing Information

Troubleshooting Engine Issues

Lists common engine complaints and their causes and remedies.

Carburetor Troubleshooting

Diagnosing and resolving carburetor-related running problems.

Electrical Troubleshooting

Common electrical complaints and their potential causes and fixes.

Battery Troubleshooting

Common battery issues, causes, and recommended remedies.

Brakes Troubleshooting

Common brake problems, their causes, and solutions.

Wiring Diagram

A comprehensive schematic of the motorcycle's wiring system.

Engine Tightening Torque Specifications

Lists critical torque values for engine fasteners.

Chassis Tightening Torque Specifications

Lists critical torque values for chassis fasteners.

General Tightening Torque Chart

A chart for torque values based on bolt diameter.

Emission Control Information

DR200SEK4/K5 ('04, '05-MODELS)

DR200SEK6 ('06-MODEL)

DR200SEK7/K8 ('07&'08-MODELS)

DR200SEK9 ('09-MODEL)

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