Table Of Contents - Suzuki DR200SE Service Manual

Table of Contents

Group Index1
General Information1
Periodic Maintenance1
Electrical System1
Servicing Information1
Supplements3
How To Use The Manual4
Component Parts And Work To Be Done4
Symbol5
General Precautions8
Vehicle View (Suzuki Dr200Set) ('96-Model)10
Serial Number Location10
Fuel And Oil Recommendations10
Break-In Procedures11
Information Labels12
Specifications14
Country Or Area (Symbols)16
Periodic Maintenance Schedule18
Lubrication Points19
Exhaust Pipe Nuts20
Air Cleaner20
Maintenance And Tune-Up Procedures20
Valve Clearance21
Spark Plug22
Spark Arrester22
Carbon Deposit22
Fuel Line (Evap Hose - California Model Only)22
Carburetor Maintenance23
Idle Rpm (Idling Adjustment)23
Clutch Maintenance23
Throttle Cable Play23
Engine Oil And Oil Filter24
Drive Chain Maintenance25
Drive Chain Checking25
Drive Chain Adjustment25
Drive Chain Cleaning And Lubricating26
Brake Fluid Level26
Brake Pads27
Brake Lever Play27
Brake Pedal Height And Free Travel27
Brake Shoe Wear28
Brake Light Switch28
Air Bleeding The Brake Fluid Circuit28
Tires Maintenance29
Tire Tread Condition29
Tire Pressure29
Steering30
Front Fork30
Rear Suspension30
Chassis Bolts And Nuts31
Compression Pressure Check33
Compression Test Procedure33
Oil Pressure Check34
Oil Pressure Test Procedure34
Low Oil Pressure34
High Oil Pressure34
Engine35
Engine Components Removable With The Engine In Place36
Engine Removal37
Engine Reinstallation40
Tightening Torque42
Exhaust Gas Sealer View42
Engine Disassembly43
Cylinder Head43
Cylinder44
Piston45
Generator And Starter Gears45
Neutral Switch46
Oil Sump Filter46
Clutch Cover46
Clutch47
Clutch Release Camshaft48
Oil Pump48
Gearshift48
Primary Drive Gear49
Crankcase49
Gearshift Cam50
Transmission50
Crankshaft51
Crankcase Bearing/Oil Seal51
Engine Components Inspection And Service52
Cylinder Head Cover Service52
Cylinder Head Cover Distortion52
Rocker Arm I.d.52
Rocker Arm And Shaft Reassembly53
Cylinder Head Service53
Cylinder Head Distortion54
Valve Face Wear54
Valve Stem Runout54
Valve Head Radial Runout55
Valve Stem Deflection55
Valve Stem Wear55
Valve Guide Service55
Valve Seat Width57
Valve Seat Service57
Valve Stem End Condition58
Valve Spring59
Valve And Valve Spring Reassembly59
Camshaft Cam Wear60
Camshaft Journal Wear60
Camshaft Runout61
Cylinder Distortion61
Cylinder Bore61
Piston Diameter61
Piston Ring-Groove Clearance62
Piston Ring Free End Gap And Piston Ring End Gap62
Oversize Rings63
Piston Pin And Pin Bore63
Conrod Small End I.d.63
Conrod Deflection And Conrod Big End Side Clearance64
Crankcase Runout64
Oil Filter Removal64
Clutch Drive Plate65
Clutch Driven Plate65
Clutch Spring Free Length65
Clutch Release Bearing65
Starter Clutch66
Starter Driven Gear Bearing66
Starter Clutch Disassembly66
Starter Clutch Reassembly66
Transmission Disassembly67
Transmission Gears Diagram67
Countershaft And Driveshaft Reassembly68
Shift Fork-Groove Clearance70
Crankcase Bearing70
Engine Reassembly71
Oil Seal71
Crankshaft Diagram72
Gearshift Mechanism73
Crankcase Reassembly75
Oil Pump Mounting77
Clutch Release Camshaft Installation77
Clutch Diagram78
Clutch Release Screw Adjustment80
Cam Drive Chain, Starter Gears And Generator81
Oil Ring82
Top Ring And 2Nd Ring83
Cylinder Mounting84
Cylinder Head Installation84
Camshaft85
Cylinder Head Cover86
Cam Drive Chain Tension Adjuster87
Valve Inspection Cap And Spark Plug87
Cam Timing Inspection Cap And Generator Cover Cap87
Fuel And Lubrication System89
Fuel Tank And Fuel Valve90
Fuel Tank Removal90
Fuel Valve Removal90
Fuel Filter Cleaning90
Carburetor Exploded View91
Carburetor Specifications92
Carburetor Id Number92
Carburetor Disassembly92
Carburetor Cleaning94
Pilot Screw Removal95
Carburetor Jet Inspection96
Needle Valve Inspection96
Float Height Adjustment96
Reassembly And Remounting96
Engine Lubrication System Chart97
Oil Sump Filter Cleaning98
Chassis99
Frame Cover And Seat Removal And Remounting100
Front Wheel Diagram101
Fron Wheel Removal101
Wheel Bearings Inspection102
Front Axle Inspection102
Wheel Rim Inspection102
Spoke Nipple102
Front Wheel Reassembly And Remounting103
Wheel Hub Bearing Installation103
Brake Disc104
Speedometer Gearbox104
Front Axle Nut104
Front Brake Diagram106
Brake Pad Replacement107
Brake Fluid Replacement107
Caliper Removal And Disassembly108
Caliper Inspection109
Caliper Reassembly And Remounting109
Disc Servicing110
Disc Inspection110
Master Cylinder Removal And Disassembly111
Master Cylinder Inspection112
Master Cylinder Reassembly And Remounting112
Front Fork Diagram114
Front Fork Removal And Disassembly114
Fork Springs Inspection116
Front Fork Reassembly And Remounting117
Tube Metals And Seals117
Inner And Outer Tubes117
Damper Rod Ring117
Damper Rod Bolt118
Fork Oil118
Fork Spring118
Stopper Ring118
Steering Diagram120
Steering Removal And Disassembly120
Steering Inspection123
Steering Stem Reassembly And Remounting124
Steering Stem Nut124
Handlebars125
Rear Wheel And Rear Brake Diagram126
Rear Wheel And Rear Brake Removal126
Rear Wheel And Rear Brake Inspection And Disassembly128
Rear Sprocket128
Rear Brake Drum128
Brake Shoe128
Rear Wheel Reassemby And Remounting129
Rear Sprocket Installation130
Rear Brake Installation130
Rear Axle131
Rear Suspension Diagram132
Rear Suspension Removal133
Swingarm Inspection135
Cushion Lever 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 System: Cautions In Servicing142
Caution On Coupler142
Caution On Clamp142
Caution On Fuse142
Caution On Battery143
Connecting Battery143
Wiring Procedure143
Using Pocket Tester143
Location Of Electrical Components144
Charging System Description145
Function Of Regulator145
Electrical System Troubleshooting147
Battery Leak Current Inspection148
Charging Output Check148
Ac Generator No-Load Performance148
Generator Stator Coil149
Regulator/Rectifier149
Starter System Description150
Starter System Troubleshooting151
Starter Motor Removal And Disassembly152
Starter Motor Inspection152
Carbon Brush Inspection152
Starter Motor Reassembly153
Commutator Inspection153
Armature Coil Inspection153
O-Ring153
Starter Motor Relay Inspection154
Side-Stand/Ignition Interlock System Description155
Interlock System Inspection156
Diode156
Neutral Switch Inspection157
Side-Stand Switch Inspection157
Side-Stand/Ignition Interlock Relay Inspection157
Ignition System Description158
Ignition System Troubleshooting158
Ignition System Inspection159
Ignition Coil Check With Pocket Tester159
Ignition Coil Check With Electro Tester159
Signal Generator Coil Check159
Spark Plug Inspection160
Carbon Deposit Check160
Spark Plug Gap Check160
Electrode's Condition160
Ignition Unit Check With Digital Ignitor Checker161
Speedometer And Indicator Light Removal And Disassembly163
Speedometer And Indicator Light Inspection163
Lamps164
Headlight Diagram164
Tail/Brake Light Diagram164
Turn Signal Light Diagram164
Switches165
Starter Motor Relay166
Side-Stand/Ignition Interlock Relay166
Turn Signal Relay166
Battery Specifications167
Initial Charging167
Filling Electrolyte167
Battery Servicing168
Recharging Operation169
Engine Troubleshooting172
Carburetor Troubleshooting174
Electrical Troubleshooting175
Battery Troubleshooting176
Chassis Troubleshooting176
Brakes Troubleshooting177
Wiring Diagram178
Wire, Cable And Hose Routing179
Wire Routing179
Cable Routing181
Carburetor And Air Cleaner Hose Routing182
Front Brake Hose Routing183
Mud Flap, Fuel Tank Cushion And Side-Stand Spring Set-Up184
Heat Shield Adhering184
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 - Conrod + Crankshaft193
Service Data - Oil Pump193
Service Data - Clutch193
Service Data - Transmission + Drive Chain194
Service Data - Carburetor194
Service Data - Electrical195
Service Data - Wattage195
Service Data - Brake + Wheel196
Service Data - Suspension196
Tire Pressure Table197
Service Data - Fuel + Oil197
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
Dr200Sek4/K5 ('04, '05-Models)213
Table Of Contents213
Specifications For E-03, 28, 33214
For E-03, 28, 33214
For E-06, 24215
Service Data - For E-03, 28, 33216
Dr200Sek4/K5 Transmisstion + Drive Chain219
Dr200Sek4/K5 Carburetor219
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
Fuse247
Headlight247
Brake Light/Taillight247
Turn Signal Light247
Speedometer Light247
Neutral Indicator Light247
Turn Signal Indicator Light247
High Beam Indicator Light247
Fuel Tank, Including Reserve249
L (3.4/2.9 Us/Imp Gal)249
Engine Oil Change249
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