Suzuki DR200SE Service Manual

Suzuki DR200SE Service Manual

Suzuki dr200se
Table of Contents

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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.
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

FUEL AND LUBRICATION
SYSTEM
EMISSION CONTROL
INFORMATION
c COPYRIGHT SUZUKI MOTOR CORPORATION 1995
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2
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Summary of Contents for Suzuki DR200SE

  • Page 1: General Information

    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.
  • Page 3 SUPPLEMENTS DR200SEV/W/X/Y/K1/K2/K3 (’97,'98,'99,'00,'01,'02,'03-MODELS) DR200SEK4/K5 ('04, '05-MODELS) DR200SEK6 ('06-MODEL) DR200SEK7 /K8 ('07 &"08 -MODEL) DR200SEK9 ('09-MODEL)
  • Page 6  ...
  • Page 88  ...
  • Page 140  ...
  • Page 170  ...
  • Page 198  ...
  • Page 213 DR200SEK4 (’04-MODEL) 10-1 DR200SEK4/K5 (’04, ’05-MODELS) This chapter describes service specifications and servicing procedurers which differ from those of the DR200SEK3 (’03-MODEL). NOTE: * Any differences between the DR200SEK3 (’03-MODEL) and DR200SEK4/K5 (’04, ’05-MOD- ELS) in specifications are cleary indicated with an asterisk (*) mark. * Please refer to the capters 1 through 9 for details which are not given in this chapter.
  • Page 214: Specifications

    10-2 DR200SEK4/K5 (’04, ’05-MODELS) SPECIFICATIONS For E-03, 28, 33 DIMENSIONS AND DRY MASS Overall length ..................2 150 mm (84.6 in) Overall width ..................805 mm (31.7 in) Overall height ..................1 185 mm (46.7 in) Wheelbase ..................1 405 mm (55.3 in) Ground clearance................
  • Page 215 DR200SEK4/K5 (’04, ’05-MODELS) 10-3 For E-06, 24 DIMENSIONS AND DRY MASS Overall length ..................2 220 mm (87.4 in) Overall width..................805 mm (31.7 in) ..E-06 940 mm (37.0 in) ..E-24 Overall height ..................1 185 mm (46.6 in) Wheelbase ..................
  • Page 216: Service Data

    10-4 DR200SEK4/K5 (’04, ’05-MODELS) SERVICE DATA For E-03, 28, 33 VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.3) — (1.1) Valve clearance (when cold) 0.08 – 0.13 IN. & EX. — (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 217 DR200SEK4/K5 (’04, ’05-MODELS) 10-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 34.174 – 34.218 33.870 (1.3454 – 1.3472) (1.3335) 33.804 – 33.848 33.500 (1.3309 – 1.3326) (1.3189) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN.
  • Page 218: Oil Pump

    10-6 DR200SEK4/K5 (’04, ’05-MODELS) ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 — (0.040 – 0.041) 1.21 – 1.23 — (0.047 – 0.048) 2.01 – 2.03 — (0.079 – 0.080) Piston ring thickness 0.970 – 0.990 — (0.038 – 0.039) 1.170 –...
  • Page 219: Dr200Sek4/K5 Transmisstion + Drive Chain

    DR200SEK4/K5 (’04, ’05-MODELS) 10-7 TRANSMISSTION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.157 (60/19) — Final reduction ratio 3.000 (45/15) — Gear ratios 3.000 (33/11) — 1.933 (29/15) — 1.437 (23/16) — 1.095 (23/21) —...
  • Page 220 10-8 DR200SEK4/K5 (’04, ’05-MODELS) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug DENSO: X24ESR-U Type NGK: CR8EA 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 mm (0.3) at 1 atm. 100 – 140 Ω Signal coil resitance G –...
  • Page 221 DR200SEK4/K5 (’04, ’05-MODELS) 10-9 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Brake lever play 0.1 – 0.3 — (0.004 – 0.010) Rear brake pedal free travel 20 – 30 — (0.8 – 1.2) Rear brake pedal height — (0.10) Brake drum I.D.
  • Page 222 10-10 DR200SEK4/K5 (’04, ’05-MODELS) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (8.1) Front fork spring free length — (22.1) Front fork oil level 179.5 — (7.07) Rear shock absorber spring — pre-set length (9.1) Rear wheel travel —...
  • Page 223 DR200SEK4/K5 (’04, ’05-MODELS) 10-11 For E-06, 24 VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.3) — (1.1) Valve clearance (when cold) 0.08 – 0.13 IN. & EX. — (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 224 10-12 DR200SEK4/K5 (’04, ’05-MODELS) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 34.174 – 34.218 33.870 (1.3454 – 1.3472) (1.3335) 33.804 – 33.848 33.500 (1.3309 – 1.3326) (1.3189) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN.
  • Page 225 DR200SEK4/K5 (’04, ’05-MODELS) 10-13 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 — (0.040 – 0.041) 1.21 – 1.23 — (0.047 – 0.048) 2.01 – 2.03 — (0.079 – 0.080) Piston ring thickness 0.970 – 0.990 — (0.038 – 0.039) 1.170 –...
  • Page 226 10-14 DR200SEK4/K5 (’04, ’05-MODELS) TRANSMISSTION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.157 (60/19) — Final reduction ratio 3.916 (47/12) — Gear ratios 3.000 (33/11) — 1.933 (29/15) — 1.437 (23/16) — 1.095 (23/21) —...
  • Page 227 DR200SEK4/K5 (’04, ’05-MODELS) 10-15 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 7°B.T.D.C. Below at 1 500 r/min Spark plug DENSO: X24ESR-U Type NGK: CR8EA 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 mm (0.3) at 1 atm. 100 –...
  • Page 228 10-16 DR200SEK4/K5 (’04, ’05-MODELS) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Brake lever play 0.1 – 0.3 — (0.004 – 0.010) Rear brake pedal free travel 20 – 30 — (0.8 – 1.2) Rear brake pedal height — (0.10) Brake drum I.D.
  • Page 229: Dr200Sek4/K5 Tire Pressuer/Fuel + Oil

    DR200SEK4/K5 (’04, ’05-MODELS) 10-17 TIRE PRESSUER E-24 SOLO RIDING COLD INFLATION TIRE PRESSURE kgf/cm FRONT REAR E-06 SOLO RIDING DUAL RIDING COLD INFLATION TIRE PRESSURE kgf/cm kgf/cm FRONT REAR FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 85 – 95 octane or higher.
  • Page 230: Tightening Torque

    10-18 DR200SEK4/K5 (’04, ’05-MODELS) TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt Camshaft sprocket bolt Cylinder head nut 8 mm Diam. 19.5 Cylinder head nut 6 mm Diam. Cylinder base nut Starter clutch securing bolt 18.0 Cam drive chain tension adjuster bolt Generator rotor nut Crankcase bolt Primary drive gear nut...
  • Page 231 DR200SEK4/K5 (’04, ’05-MODELS) 10-19 GENERATOR ROTOR NUT REASSEMBLY • Hold the generator rotor using the special tool, and tighten the generator rotor nut to the specified torque. " 09930-44511: Rotor holder # Generator rotor nut A: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
  • Page 233 DR200SEK4 (’04-MODEL) 10-1 DR200SEK6 (’06-MODEL) This chapter describes service specifications and servicing procedurers which differ from those of the DR200SEK4/K5 (’04, ’05-MODELS). NOTE: * Any differences between the DR200SEK4/K5 (’04, ’05-MODELS) and DR200SEK6 (’06- MODEL) in specifications are cleary indicated with an asterisk (*) mark. * Please refer to the capters 1 through 10 for details which are not given in this chapter.
  • Page 234 11-2 DR200SEK6 (’06-MODEL) SPECIFICATIONS For E-03, 28, 33 DIMENSIONS AND DRY MASS Overall length ..................2 150 mm (84.6 in) Overall width ..................805 mm (31.7 in) Overall height ..................1 185 mm (46.7 in) Wheelbase ..................1 405 mm (55.3 in) Ground clearance................
  • Page 235 DR200SEK6 (’06-MODEL) 11-3 For E-06, 24 DIMENSIONS AND DRY MASS Overall length ..................2 220 mm (87.4 in) Overall width..................805 mm (31.7 in) ..E-06 940 mm (37.0 in) ..E-24 Overall height ..................1 185 mm (46.6 in) Wheelbase ..................
  • Page 236 11-4 DR200SEK6 (’06-MODEL) SERVICE DATA For E-03, 28, 33 VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.3) — (1.1) Valve clearance (when cold) 0.08 – 0.13 IN. & EX. — (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 237 DR200SEK6 (’06-MODEL) 11-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 34.174 – 34.218 33.870 (1.3454 – 1.3472) (1.3335) 33.804 – 33.848 33.500 (1.3309 – 1.3326) (1.3189) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 238 11-6 DR200SEK6 (’06-MODEL) ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 (0.040 – 0.041) 1.21 – 1.23 (0.047 – 0.048) 2.01 – 2.03 (0.079 – 0.080) Piston ring thickness 0.970 – 0.990 — (0.038 – 0.039) 1.170 – 1.190 —...
  • Page 239 DR200SEK6 (’06-MODEL) 11-7 TRANSMISSTION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.157 (60/19) — Final reduction ratio 3.000 (45/15) — Gear ratios 3.000 (33/11) — 1.933 (29/15) — 1.437 (23/16) — 1.095 (23/21) —...
  • Page 240 11-8 DR200SEK6 (’06-MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug DENSO: X24ESR-U Type NGK: CR8EA 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 mm (0.3) at 1 atm. 100 – 140 Ω Signal coil resitance G – Bl Ignition coil resistance Terminal –...
  • Page 241 DR200SEK6 (’06-MODEL) 11-9 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Brake lever play 0.1 – 0.3 — (0.004 – 0.010) Rear brake pedal free travel 20 – 30 — (0.8 – 1.2) Rear brake pedal height — (0.10) Brake drum I.D.
  • Page 242 11-10 DR200SEK6 (’06-MODEL) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (8.1) Front fork spring free length — (22.1) Front fork oil level 179.5 — (7.07) Rear shock absorber spring — pre-set length (9.1) Rear wheel travel —...
  • Page 243 DR200SEK6 (’06-MODEL) 11-11 For E-06, 24 VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.3) — (1.1) Valve clearance (when cold) 0.08 – 0.13 IN. & EX. — (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 244 11-12 DR200SEK6 (’06-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 34.174 – 34.218 33.870 (1.3454 – 1.3472) (1.3335) 33.804 – 33.848 33.500 (1.3309 – 1.3326) (1.3189) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 245 DR200SEK6 (’06-MODEL) 11-13 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 (0.040 – 0.041) 1.21 – 1.23 (0.047 – 0.048) 2.01 – 2.03 (0.079 – 0.080) Piston ring thickness 0.970 – 0.990 — (0.038 – 0.039) 1.170 – 1.190 —...
  • Page 246 11-14 DR200SEK6 (’06-MODEL) TRANSMISSTION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.157 (60/19) — Final reduction ratio 3.916 (47/12) — Gear ratios 3.000 (33/11) — 1.933 (29/15) — 1.437 (23/16) — 1.095 (23/21) —...
  • Page 247 DR200SEK6 (’06-MODEL) 11-15 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 7°B.T.D.C. Below at 1 500 r/min Spark plug DENSO: X24ESR-U Type NGK: CR8EA 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 mm (0.3) at 1 atm. 100 –...
  • Page 248 11-16 DR200SEK6 (’06-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Brake lever play 0.1 – 0.3 — (0.004 – 0.010) Rear brake pedal free travel 20 – 30 — (0.8 – 1.2) Rear brake pedal height — (0.10) Brake drum I.D.
  • Page 249 DR200SEK6 (’06-MODEL) 11-17 TIRE PRESSUER E-24 SOLO RIDING COLD INFLATION TIRE PRESSURE kgf/cm FRONT REAR E-06 SOLO RIDING DUAL RIDING COLD INFLATION TIRE PRESSURE kgf/cm kgf/cm FRONT REAR FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 85 – 95 octane or higher.
  • Page 250  ...
  • Page 251 DR200SEK4 (’04-MODEL) 10-1 DR200SEK7/K8 ('07&’08-MODELS) NOTE: * Any differences between the DR200SEK6 ('06-MODEL) and DR200SEK ('07-MODEL) in specifications are cleary indicated with an asterisk (*) mark. * Please refer to the capters 1 through 11 for details which are not given in this chapter. For E-06, 24 service data are same as K6 MODEL.
  • Page 252 12- 2 DR200SEK7/K8 (’07&’08-MODEL) SPECIFICATIONS For E-03, 28, 33 DIMENSIONS AND DRY MASS Overall length ..................2 150 mm (84.6 in) Overall width..................805 mm (31.7 in) Overall height ..................1 185 mm (46.7 in) Wheelbase ..................1 405 mm (55.3 in) Ground clearance................
  • Page 253 DR200SEK7/K8 (’07&’08-MODEL) 12- 3 SERVICE DATA For E-03, 28, 33 VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.3) — (1.1) Valve clearance (when cold) 0.08 – 0.13 IN. & EX. — (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 254 12- 4 DR200SEK7/K8 (’07&’08-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 34.174 – 34.218 33.870 (1.3454 – 1.3472) (1.3335) 33.804 – 33.848 33.500 (1.3309 – 1.3326) (1.3189) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN.
  • Page 255 DR200SEK7/K8 (’07&’08-MODEL) 12- 5 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 (0.040 – 0.041) 1.21 – 1.23 (0.047 – 0.048) 2.01 – 2.03 (0.079 – 0.080) Piston ring thickness 0.970 – 0.990 — (0.038 – 0.039) 1.170 – 1.190 —...
  • Page 256 12- 6 DR200SEK7/K8 (’07&’08-MODEL) TRANSMISSTION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.157 (60/19) — Final reduction ratio 3.000 (45/15) — Gear ratios 3.000 (33/11) — 1.933 (29/15) — 1.437 (23/16) — 1.095 (23/21) —...
  • Page 257 DR200SEK7/K8 (’07&’08-MODEL) 12- 7 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug DENSO: X24ESR-U Type NGK: CR8EA 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 mm (0.3) at 1 atm. 100 – 140 Ω Signal coil resitance G –...
  • Page 258 12- 8 DR200SEK7/K8 (’07&’08-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Brake lever play 0.1 – 0.3 — (0.004 – 0.010) Rear brake pedal free travel 20 – 30 — (0.8 – 1.2) Rear brake pedal height — (0.10) Brake drum I.D.
  • Page 259: Dr200Sek7/K8 Suspension

    DR200SEK7/K8 (’07&’08-MODEL) 12- 9 SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (8.1) Front fork spring free length — (22.1) Front fork oil level 179.5 — (7.07) Rear shock absorber spring — pre-set length (9.1) Rear wheel travel —...
  • Page 260  ...
  • Page 261 DR200SEK9 (’09-MODEL) 13-1 DR200SEK9 (’09-MODEL) 52'%+(+%#6+105   NOTE: * Differences between K9-MODEL and K8-MODEL specifications are indicated as an aster- isk mark (*). * The service data are the same as the K8-MODEL.
  • Page 262 13-2 DR200SEK9 (’09-MODEL) SPECIFICATIONS (E-03, 28, 33) DIMENSIONS AND CURB MASS Overall length ..................2 150 mm (84.6 in) Overall width..................805 mm (31.7 in) Overall height ..................1 185 mm (46.7 in) Wheelbase ..................1 405 mm (55.3 in) Ground clearance................

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