Suzuki DR200SE - Cylinder Head Cover Distortion; Cylinder Head Cover Service; Engine Components Inspection and Service; Rocker Arm I.D.

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Electrical System1
General Information1
Group Index1
Periodic Maintenance1
Servicing Information1
Supplements3
Component Parts and Work to be Done4
How to Use the Manual4
Symbol5
General Information7
General Precautions8
Fuel and Oil Recommendations10
Serial Number Location10
Vehicle View (Suzuki DR200SET) ('96-Model)10
Break-In Procedures11
Information Labels12
Specifications14
Country or Area (Symbols)16
Periodic Maintenance17
Periodic Maintenance Schedule18
Lubrication Points19
Air Cleaner20
Exhaust Pipe Nuts20
Maintenance and Tune-Up Procedures20
Valve Clearance21
Carbon Deposit22
Fuel Line (Evap Hose - California Model Only)22
Spark Arrester22
Spark Plug22
Carburetor Maintenance23
Clutch Maintenance23
Idle RPM (Idling Adjustment)23
Throttle Cable Play23
Engine Oil and Oil Filter24
Drive Chain Adjustment25
Drive Chain Checking25
Drive Chain Maintenance25
Brake Fluid Level26
Drive Chain Cleaning and Lubricating26
Brake Lever Play27
Brake Pads27
Brake Pedal Height and Free Travel27
Air Bleeding the Brake Fluid Circuit28
Brake Light Switch28
Brake Shoe Wear28
Tire Pressure29
Tire Tread Condition29
Tires Maintenance29
Front Fork30
Rear Suspension30
Steering30
Chassis Bolts and Nuts31
Compression Pressure Check33
Compression Test Procedure33
High Oil Pressure34
Low Oil Pressure34
Oil Pressure Check34
Oil Pressure Test Procedure34
Engine35
Engine Components Removable with the Engine in Place36
Engine Removal37
Engine Reinstallation40
Exhaust Gas Sealer View42
Tightening Torque42
Cylinder Head43
Engine Disassembly43
Cylinder44
Generator and Starter Gears45
Piston45
Clutch Cover46
Neutral Switch46
Oil Sump Filter46
Clutch47
Clutch Release Camshaft48
Gearshift48
Oil Pump48
Crankcase49
Primary Drive Gear49
Gearshift Cam50
Transmission50
Crankcase Bearing/Oil Seal51
Crankshaft51
Cylinder Head Cover Distortion52
Cylinder Head Cover Service52
Engine Components Inspection and Service52
Rocker Arm I.D.52
Cylinder Head Service53
Rocker Arm and Shaft Reassembly53
Cylinder Head Distortion54
Valve Face Wear54
Valve Stem Runout54
Valve Guide Service55
Valve Head Radial Runout55
Valve Stem Deflection55
Valve Stem Wear55
Valve Seat Service57
Valve Seat Width57
Valve Stem End Condition58
Valve and Valve Spring Reassembly59
Valve Spring59
Camshaft Cam Wear60
Camshaft Journal Wear60
Camshaft Runout61
Cylinder Bore61
Cylinder Distortion61
Piston Diameter61
Piston Ring Free End Gap and Piston Ring End Gap62
Piston Ring-Groove Clearance62
Conrod Small End I.D.63
Oversize Rings63
Piston Pin and Pin Bore63
Conrod Deflection and Conrod Big End Side Clearance64
Crankcase Runout64
Oil Filter Removal64
Clutch Drive Plate65
Clutch Driven Plate65
Clutch Release Bearing65
Clutch Spring Free Length65
Starter Clutch66
Starter Clutch Disassembly66
Starter Clutch Reassembly66
Starter Driven Gear Bearing66
Transmission Disassembly67
Transmission Gears Diagram67
Countershaft and Driveshaft Reassembly68
Crankcase Bearing70
Shift Fork-Groove Clearance70
Engine Reassembly71
Oil Seal71
Crankshaft Diagram72
Gearshift Mechanism73
Crankcase Reassembly75
Clutch Release Camshaft Installation77
Oil Pump Mounting77
Clutch Diagram78
Clutch Release Screw Adjustment80
Cam Drive Chain, Starter Gears and Generator81
Oil Ring82
Top Ring and 2Nd Ring83
Cylinder Head Installation84
Cylinder Mounting84
Camshaft85
Cylinder Head Cover86
Cam Drive Chain Tension Adjuster87
Cam Timing Inspection Cap and Generator Cover Cap87
Valve Inspection Cap and Spark Plug87
Fuel and Lubrication System89
Fuel Filter Cleaning90
Fuel Tank and Fuel Valve90
Fuel Tank Removal90
Fuel Valve Removal90
Carburetor Exploded View91
Carburetor Disassembly92
Carburetor ID Number92
Carburetor Specifications92
Carburetor Cleaning94
Pilot Screw Removal95
Carburetor Jet Inspection96
Float Height Adjustment96
Needle Valve Inspection96
Reassembly and Remounting96
Engine Lubrication System Chart97
Oil Sump Filter Cleaning98
Chassis99
Frame Cover and Seat Removal and Remounting100
Fron Wheel Removal101
Front Wheel Diagram101
Front Axle Inspection102
Spoke Nipple102
Wheel Bearings Inspection102
Wheel Rim Inspection102
Front Wheel Reassembly and Remounting103
Wheel Hub Bearing Installation103
Brake Disc104
Front Axle Nut104
Speedometer Gearbox104
Front Brake Diagram106
Brake Fluid Replacement107
Brake Pad Replacement107
Caliper Removal and Disassembly108
Caliper Inspection109
Caliper Reassembly and Remounting109
Disc Inspection110
Disc Servicing110
Master Cylinder Removal and Disassembly111
Master Cylinder Inspection112
Master Cylinder Reassembly and Remounting112
Front Fork Diagram114
Front Fork Removal and Disassembly114
Fork Springs Inspection116
Damper Rod Ring117
Front Fork Reassembly and Remounting117
Inner and Outer Tubes117
Tube Metals and Seals117
Damper Rod Bolt118
Fork Oil118
Fork Spring118
Stopper Ring118
Steering Diagram120
Steering Removal and Disassembly120
Steering Inspection123
Steering Stem Nut124
Steering Stem Reassembly and Remounting124
Handlebars125
Rear Wheel and Rear Brake Diagram126
Rear Wheel and Rear Brake Removal126
Brake Shoe128
Rear Brake Drum128
Rear Sprocket128
Rear Wheel and Rear Brake Inspection and Disassembly128
Rear Wheel Reassemby and Remounting129
Rear Brake Installation130
Rear Sprocket Installation130
Rear Axle131
Rear Suspension Diagram132
Rear Suspension Removal133
Cushion Lever Inspection135
Swingarm Inspection135
Shock Absorber Inspection136
Swingarm Pivot Shaft Inspection136
Rear Suspension Reassembly and Remounting137
Swingarm Installation137
Final Inspection and Adjustment139
Shock Absorber Spring Pre-Load Adjustment139
Shock Absorber Spring Setting Table139
Electrical System141
Caution on Clamp142
Caution on Coupler142
Caution on Fuse142
Electrical System: Cautions in Servicing142
Caution on Battery143
Connecting Battery143
Using Pocket Tester143
Wiring Procedure143
Location of Electrical Components144
Charging System Description145
Function of Regulator145
Electrical System Troubleshooting147
AC Generator No-Load Performance148
Battery Leak Current Inspection148
Charging Output Check148
Generator Stator Coil149
Regulator/Rectifier149
Starter System Description150
Starter System Troubleshooting151
Carbon Brush Inspection152
Starter Motor Inspection152
Starter Motor Removal and Disassembly152
Armature Coil Inspection153
Commutator Inspection153
O-Ring153
Starter Motor Reassembly153
Starter Motor Relay Inspection154
Side-Stand/Ignition Interlock System Description155
Diode156
Interlock System Inspection156
Neutral Switch Inspection157
Side-Stand Switch Inspection157
Side-Stand/Ignition Interlock Relay Inspection157
Ignition System Description158
Ignition System Troubleshooting158
Ignition Coil Check with Electro Tester159
Ignition Coil Check with Pocket Tester159
Ignition System Inspection159
Signal Generator Coil Check159
Carbon Deposit Check160
Electrode's Condition160
Spark Plug Gap Check160
Spark Plug Inspection160
Ignition Unit Check with Digital Ignitor Checker161
Speedometer and Indicator Light Inspection163
Speedometer and Indicator Light Removal and Disassembly163
Headlight Diagram164
Lamps164
Tail/Brake Light Diagram164
Turn Signal Light Diagram164
Switches165
Side-Stand/Ignition Interlock Relay166
Starter Motor Relay166
Turn Signal Relay166
Battery Specifications167
Filling Electrolyte167
Initial Charging167
Battery Servicing168
Recharging Operation169
Servicing Information171
Engine Troubleshooting172
Carburetor Troubleshooting174
Electrical Troubleshooting175
Battery Troubleshooting176
Chassis Troubleshooting176
Brakes Troubleshooting177
Wiring Diagram178
Wire Routing179
Wire, Cable and Hose Routing179
Cable Routing181
Carburetor and Air Cleaner Hose Routing182
Front Brake Hose Routing183
Heat Shield Adhering184
Mud Flap, Fuel Tank Cushion and Side-Stand Spring Set-Up184
Special Tool185
Tightening Torque - Engine188
Tightening Torque - Chassis189
Tightening Torque Chart for Other Bolts and Nuts190
Service Data - Valve + Guide191
Service Data - Camshaft + Cylinder Head192
Service Data - Cylinder + Piston + Piston Ring192
Service Data - Clutch193
Service Data - Conrod + Crankshaft193
Service Data - Oil Pump193
Service Data - Carburetor194
Service Data - Transmission + Drive Chain194
Service Data - Electrical195
Service Data - Wattage195
Service Data - Brake + Wheel196
Service Data - Suspension196
Service Data - Fuel + Oil197
Tire Pressure Table197
Emission Control Information199
Emission Control Carburetor Components200
Evaporative Emission Control System (California Model Only) Diagram201
Canister Hose Routing (California Model Only) Diagram202
DR200SEV/W/X/Y/K1/K2/K3 ('97, '98, '99, '00, '01, '02, '03-Models)203
DR200SEV/W/X/Y/K1/K2/K3 ('97, '98, '99, '00, '01, '02, '03-Models) Specifications204
DR200SEV/W/X/Y/K1/K2/K3 ('97, '98, '99, '00, '01, '02, '03-Models) Service Data206
Table of Contents213
DR200SEK4/K5 ('04, '05-Models)213
For E-03, 28, 33214
Specifications for E-03, 28, 33214
For E-06, 24215
For E-06, 24216
- Service Data - for E-03, 28, 33216
- Oil Pump218
- Dr200Sek4/K5 Carburetor219
- Dr200Sek4/K5 Transmisstion + Drive Chain219
- Service Data for E-06, 24223
- Dr200Sek4/K5 Tire Pressuer/Fuel + Oil229
- DR200SEK4/K5 ('04, '05-Models) Tightening Torques230
- Generator Rotor Nut Reassembly231
- DR200SEK6 (’06-Model)233
- DR200SEK6 (’06-Model) Specifications234
- DR200SEK6 (’06-Model) Service Data236
Brake Light/Taillight247
Fuse247
Headlight247
High Beam Indicator Light247
Neutral Indicator Light247
Speedometer Light247
Turn Signal Indicator Light247
Turn Signal Light247
Engine Oil Change249
Fuel Tank, Including Reserve249
L (3.4/2.9 Us/Imp Gal)249
- DR200SEK7/K8 ('07 & ’08-Models)251
- DR200SEK7/K8 ('07 & ’08-Models) Specifications252
- DR200SEK7/K8 ('07 & ’08-Models) Service Data253
- Dr200Sek7/K8 Suspension259
- Dr200Sek7/K8 Tire Pressuer Fuel + Oil259
- DR200SEK9 (’09-Model)261
- DR200SEK9 (’09-Model) Specifications262

Suzuki DR200SE - Cylinder Head Cover Distortion; Cylinder Head Cover Service; Engine Components Inspection and Service; Rocker Arm I.D.

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