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1996-2013 Suzuki Dr200se Service Repair Manual & Owner ‘s Manual Ultimate Set – PDF Download
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1996-2013 Suzuki Dr200se Service Repair Manual & Owner ‘s Manual Ultimate Set
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Description
1996-2013 Suzuki Dr200se Service Repair Manual & Owner ‘s Manual Ultimate Set
FILE DETAILS:
1996-2013 Suzuki Dr200se Service Repair Manual & Owner ‘s Manual Ultimate Set
LANGUAGE:ENGLISH
PAGES:360+
DOWNLOADABLE:YES
FILE TYPE:PDF
1996-2013 SUZUKI DR200SE SERVICE REPAIR MANUAL & OWNER ‘S MANUAL ULTIMATE SET – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
1996-2013 Suzuki Dr200se Service Repair Manual & Owner ‘s Manual Ultimate Set
This manual contains an introductory description on SUZUKI DR200SE and procedures for its inspection/ service and overhaul of its main components. Other information considered as generally known is not included. Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTENANCE 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.
TABLE OF CONTENTS:
1996-2013 Suzuki Dr200se Service Repair Manual & Owner ‘s Manual Ultimate Set
FOREWORD................................................................. 1
HOW TO USE THIS MANUAL................................................... 4
TO LOCATE WHAT YOU ARE LOOKING FOR................................... 4
COMPONENT PARTS AND WORK TO BE DONE.................................. 4
SYMBOL............................................................... 5
01 GENERAL INFORMATION................................................... 7
WARNING/CAUTION/NOTE................................................. 8
GENERAL PRECAUTIONS.................................................. 8
SUZUKI DR200SET ('96-MODEL).......................................... 10
SERIAL NUMBER LOCATION............................................... 10
FUEL AND OIL RECOMMENDATIONS......................................... 10
FUEL............................................................. 10
ENGINE OIL....................................................... 11
BRAKE FLUID...................................................... 11
FRONT FORK OIL................................................... 11
BREAK-IN PROCEDURES.................................................. 11
INFORMATION LABELS................................................... 12
SPECIFICATIONS....................................................... 14
COUNTRY OR AREA...................................................... 16
02 PERIODIC MAINTENANCE.................................................. 17
PERIODIC MAINTENANCE SCHEDULE........................................ 18
PERIODIC MAINTENANCE CHART....................................... 18
LUBRICATION POINTS............................................... 19
MAINTENANCE AND TUNE-UP PROCEDURES................................... 20
EXHAUST PIPE NUTS................................................ 20
AIR CLEANER...................................................... 20
VALVE CLEARANCE.................................................. 21
SPARK PLUG....................................................... 22
FUEL LINE........................................................ 22
CARBURETOR....................................................... 23
CLUTCH........................................................... 23
ENGINE OIL AND OIL FILTER........................................ 24
DRIVE CHAIN...................................................... 25
BRAKE............................................................ 26
TIRE............................................................. 29
STEERING......................................................... 30
FRONT FORK....................................................... 30
REAR SUSPENSION.................................................. 30
CHASSIS BOLTS AND NUTS........................................... 31
COMPRESSION PRESSURE CHECK........................................... 33
OIL PRESSURE CHECK................................................... 34
03 ENGINE................................................................ 35
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE................. 36
ENGINE REMOVAL AND REINSTALLATION.................................... 37
ENGINE DISASSEMBLY................................................... 43
ENGINE COMPONENTS INSPECTON AND SERVICE.............................. 52
CYLINDER HEAD COVER.............................................. 52
ROCKER ARM....................................................... 52
CYLINDER HEAD.................................................... 53
VALVE............................................................ 54
CAMSHAFT......................................................... 60
CYLINDER......................................................... 61
PISTON........................................................... 61
PISTON RING...................................................... 62
CONROD........................................................... 63
CRANKSHAFT....................................................... 64
OIL FILTER....................................................... 64
CLUTCH........................................................... 65
STARTER CLUTCH................................................... 66
TRANSMISSION..................................................... 67
CRANKCASE BEARING................................................ 70
ENGINE REASSEMBLY.................................................... 71
CRANKCASE BEARING AND OIL SEAL................................... 71
CRANKSHAFT....................................................... 72
TRANSMISSION..................................................... 73
CRANKCASE........................................................ 75
GEARSHIFT........................................................ 76
OIL PUMP......................................................... 77
CLUTCH........................................................... 78
OIL SUMP FILTER.................................................. 81
STARTER GEARS AND GENERATOR...................................... 81
RING AND PISTON.................................................. 82
CYLINDER AND CYLINDER HEAD....................................... 84
CAMSHAFT......................................................... 85
CYLINDER HEAD COVER.............................................. 86
CAM DRIVE CHAIN TENSION ADJUSTER................................. 87
04 FUEL AND LUBRICATION SYSTEM........................................... 89
FUEL TANK AND FUEL VALVE............................................. 90
FUEL TANK REMOVAL................................................ 90
FUEL VALVE REMOVAL............................................... 90
FUEL FILTER CLEANING............................................. 90
FUEL HOSE INSPECTION............................................. 90
CARBURETOR........................................................... 91
CARBURETOR SPECIFICATIONS........................................ 92
I.D. NO. LOCATION................................................ 92
CARBURETOR REMOVAL............................................... 92
CARBURETOR DISASSEMBLY........................................... 92
CARBURETOR CLEANING.............................................. 94
CARBURETOR JET INSPECTION........................................ 96
NEEDLE VALVE INSPECTION.......................................... 96
FLOAT HEIGHT ADJUSTMENT.......................................... 96
REASSEMBLY AND REMOUNTING........................................ 96
LUBRICATION SYSTEM................................................... 97
ENGINE LUBRICATION SYSTEM CHART.................................. 97
OIL PRESSURE..................................................... 98
OIL FILTER....................................................... 98
OIL SUMP FILTER.................................................. 98
05 CHASSIS............................................................... 99
FRAME COVER AND SEAT.................................................100
REMOVAL AND REMOUNTING...........................................100
FRONT WHEEL..........................................................101
REMOVAL..........................................................101
INSPECTION AND DISASSEMBLY.......................................102
REASSEMBLY AND REMOUNTING........................................103
FRONT BRAKE..........................................................106
BRAKE PAD REPLACEMENT............................................107
BRAKE FLUID REPLACEMENT..........................................107
CALIPER REMOVAL AND DISASSEMBLY..................................108
CALIPER INSPECTION...............................................109
CALIPER REASSEMBLY AND REMOUNTING................................109
DISC SERVICING...................................................110
DISC INSPECTION..................................................110
MASTER CYLINDER REMOVAL AND DISASSEMBLY..........................111
MASTER CYLINDER INSPECTION.......................................112
MASTER CYLINDER REASSEMBLY AND REMOUNTING........................112
FRONT FORK...........................................................114
REMOVAL AND DISASSEMBLY..........................................114
INSPECTION.......................................................116
REASSEMBLY AND REMOUNTING........................................117
STEERING.............................................................120
REMOVAL AND DISASSEMBLY..........................................120
INSPECTION.......................................................123
REASSEMBLY AND REMOUNTING........................................124
REAR WHEEL AND REAR BRAKE............................................126
REMOVAL..........................................................126
INSPECTION AND DISASSEMBLY.......................................128
REASSEMBLY AND REMOUNTING........................................129
REAR SUSPENSION......................................................132
REMOVAL..........................................................133
INSPECTION AND DISASSEMBLY.......................................135
REASSEMBLY AND REMOUNTING........................................137
FINAL INSPECTION AND ADJUSTMENT..................................139
06 ELECTRICAL SYSTEMS....................................................141
CAUTIONS IN SERVICING................................................142
LOCATION OF ELECTRICAL COMPONENTS....................................144
CHARGING SYSTEM......................................................145
DESCRIPTION......................................................145
TROUBLESHOOTING..................................................147
INSPECTION.......................................................148
STARTER SYSTEM.......................................................150
DESCRIPTION......................................................150
TROUBLESHOOTING..................................................151
STARTER MOTOR REMOVAL AND DISASSEMBLY............................152
STARTER MOTOR INSPECTION.........................................152
STARTER MOTOR REASSEMBLY.........................................153
STARTER MOTOR RELAY INSPECTION...................................154
SIDE-STAND/IGNITION INTERLOCK SYSTEM.................................155
DESCRIPTION......................................................155
INSPECTION.......................................................156
IGNITION SYSTEM......................................................158
DESCRIPTION......................................................158
TROUBLESHOOTING..................................................158
INSPECTION.......................................................159
SPEEDOMETER AND INDICATOR LIGHT......................................163
REMOVAL AND DISASSEMBLY..........................................163
INSPECTION.......................................................163
LAMPS................................................................164
SWITCHES.............................................................165
RELAY................................................................166
BATTERY..............................................................167
SPECIFICATIONS...................................................167
INITIAL CHARGING.................................................167
SERVICING........................................................168
RECHARGING OPERATION.............................................169
07 SERVICING INFORMATION.................................................171
TROUBLESHOOTING......................................................172
WIRING DIAGRAM.......................................................178
WIRE, CABLE AND HOSE ROUTING.........................................179
WIRE ROUTING.....................................................179
CABLE ROUTING....................................................181
CARBURETOR AND AIR CLEANER HOSE ROUTING..........................182
FRONT BRAKE HOSE ROUTING.........................................183
MUD FLAP, FUEL TANK CUSHION AND SIDE-STAND SPRING SET-UP.............184
HEAT SHIELD ADHERING.................................................184
SPECIAL TOOL.........................................................185
TIGHTENING TORQUE....................................................188
SERVICE DATA.........................................................191
08 EMISSION CONTROL INFORMATION..........................................199
EMISSION CONTROL CARBURETOR COMPONENTS...............................200
EVAPORATIVE EMISSION CONTROL SYSTEM..................................201
CANISTER HOSE ROUTING................................................202
09 DR200SEV/W/X/Y/K1/K2/K3 ('97, '98, '99, '00, '01, '02, '03-MODELS)....203
SPECIFICATIONS.......................................................204
SERVICE DATA.........................................................206
10 DR200SEK4/K5 ('04, '05-MODELS)........................................213
SPECIFICATIONS.......................................................214
For E-03, 28, 33.................................................214
For E-06, 24.....................................................215
SERVICE DATA.........................................................216
For E-03, 28, 33.................................................216
For E-06, 24.....................................................223
TIGHTENING TORQUE....................................................230
GENERATOR ROTOR NUT..................................................231
11 DR200SEK6 ('06-MODEL).................................................233
SPECIFICATIONS.......................................................234
For E-03, 28, 33.................................................234
For E-06, 24.....................................................235
SERVICE DATA.........................................................236
For E-03, 28, 33.................................................236
For E-06, 24.....................................................243
12 DR200SEK7/K8 ('07&’08-MODELS).........................................251
SPECIFICATIONS.......................................................252
SERVICE DATA.........................................................253
13 DR200SEK9 (’09-MODEL) ................................................261
SPECIFICATIONS.......................................................262
(E-03, 28, 33)...................................................262
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
