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• 1987 Suzuki Dr 200 Manual Free Download

The Cyclepedia Press LLC Suzuki DR200 SE online motorcycle service manual features detailed full-color photographs and color wiring diagrams, complete specifications with step-by-step procedures performed and written by a veteran Suzuki dealer trained motorcycle technician. This manual covers 1996 – 2013 Suzuki DR200SE Dual Sport motorcycles.

. 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. 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).

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. 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. 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. 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. — (0.003 – 0.005) Valve guide to valve stem 0.010 –. 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. 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 –. 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) —. 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 –.

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. 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 —. 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. — (0.003 – 0.005) Valve guide to valve stem 0.010 –.

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. 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 –. 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) —. 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.

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. 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. 10-18 DR200SEK4/K5 (’04, ’05-MODELS) TIGHTENING TORQUE ENGINE ITEM Nm 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. 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. ' 1: Rotor holder # Generator rotor nut A: 80 Nm (8.0 kgf-m, 58.0 lb-ft).

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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. 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.

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. 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.

— (0.003 – 0.005) Valve guide to valve stem 0.010 –. Applied technology test study guide. 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. 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 —. 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) —.

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 –.

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. 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 —. 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. — (0.003 – 0.005) Valve guide to valve stem 0.010 –.

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. 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 —. 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) —. 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. 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.

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. 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.

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. 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. — (0.003 – 0.005) Valve guide to valve stem 0.010 –. 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. 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 —. 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) —.

1987 Suzuki Dr 200 Manual Free Download

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 –. 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. 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 —. 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. 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.