1996-2009 Suzuki DR200SE Service Manual (P/N 99500-41141-03E)
262 Pages • 22.66 MB • Instant, Printable PDF
Suzuki Models Covered & Key Technical Specifications
Models: Suzuki DR200SE
Sub-models / Variants: DR200SEV, DR200SEW, DR200SEX, DR200SEY, DR200SEK1, DR200SEK2, DR200SEK3, DR200SEK4, DR200SEK5, DR200SEK6, DR200SEK7, DR200SEK8, DR200SEK9, US Model, Canadian Model, California Model, Singapore Model
Model Years: 1996–2009
Technical Data:
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Engine: Four-stroke, air-cooled, OHC, 199 cm3 displacement
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Compression ratio: 9.4:1
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Transmission: 5-speed constant mesh, wet multi-plate clutch
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Ignition: Electronic ignition (fully transistorized)
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Spark plug: DR8EA or X24ESR-U
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Valve clearance (cold): 0.08–0.13 mm (0.003–0.005 in)
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Engine oil capacity: 850 ml (change), 950 ml (with filter), 1300 ml (overhaul)
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Tire pressure (solo): Front 150 kPa (1.50 kg/cm2), Rear 175 kPa (1.75 kg/cm2)
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Drive chain: DID520VC5, 112 links
Suzuki Manual Features & Content Preview
- Covers all 1996–2009 Suzuki DR200SE models, including the 1995 base manual (P/N 99500-41141-03E) and all K1 through K9 supplements
- Over 75 exploded-view component diagrams featuring exact factory torque values in N·m, kg-m, and lb-ft
Technical Scope and Coverage
This official 262-page Suzuki publication delivers a comprehensive breakdown of the four-stroke, air-cooled OHC engine and chassis. It provides the exact technical baseline required for professional shop work and serious DIY maintenance. Chapters dive deep into the inspection, service, and complete overhaul of the top end, transmission, crankcase, and fuel delivery systems. Because working on motorcycles involves inherent risks to both the technician and the rider, always review the factory safety guidelines and torque sequences outlined in these chapters before tearing down critical components.
Specification Highlights
You get precise tolerance charts right at your fingertips. For example, cold intake and exhaust valve clearances are specified at 0.08–0.13 mm. Need fastener specs? The manual lists safety-critical tightening limits like the 90 N·m steering stem head nut and 65 N·m rear axle nut. It also maps out the fully transistorized ignition system, 12V 21W turn signal specs, and fuel system variations across US, California, and Canadian emission standards. Plus, because this is an instant download, you can pull up these exact OEM specifications on your tablet or shop computer the second a bike rolls onto the lift.
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