1996-2009 Suzuki DR200SE Service Manual

1996-2009 DR200SE service documentation with detailed procedures for engine, chassis, and electrical systems. Publication 99500-41141-03E covers all models.

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Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

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
Build Years: 1996–2009
Technical Data:

  • Engine: Four-stroke, air-cooled, OHC, 199 cm3 displacement
  • Compression ratio: 9.4:1
  • Transmission: 5-speed constant mesh, wet multi-plate clutch
  • Ignition: Electronic ignition (fully transistorized)
  • Spark plug: DR8EA or X24ESR-U
  • Valve clearance (cold): 0.08–0.13 mm (0.003–0.005 in)
  • Engine oil capacity: 850 ml (change), 950 ml (with filter), 1300 ml (overhaul)
  • Tire pressure (solo): Front 150 kPa (1.50 kg/cm2), Rear 175 kPa (1.75 kg/cm2)
  • Drive chain: DID520VC5, 112 links
Technical Specifications
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Document Number / Seller:
26596 / Walter Williams
File Size:
22.66 MB
File Type:
PDF
Language:
`English`
Pages:
262
Printable:
Yes
Category:
Motorbike
Last updated / verified
Dec 4, 2025

Suzuki Manual Features & Content Preview

Suzuki DR200SE 1996–2009 Workshop Manual Overview

  • Covers 1996–2009 Suzuki DR200SE motorcycles, documenting all major engine, chassis, and electrical system service requirements
  • Official Suzuki Motor Corporation publication P/N 99500-41141-03E, dated 1995
  • Includes over 75 exploded-view component diagrams with torque values in N·m, kg-m, and lb-ft
  • File delivers the moment payment clears, with no shipping wait time for access
  • Laid out for standard letter and A4 printing for shop-floor utility
  • Document features an OCR text layer for quick lookup of part numbers and specifications
  • This 1995 original is the base manual for the entire 1996–2009 DR200SE production cycle, including specific supplements for K1 through K9 model years

Technical Scope and Coverage

The 1996–2009 Suzuki DR200SE service manual provides a comprehensive technical overview of the four-stroke, air-cooled OHC engine and associated chassis components. Chapters detail the inspection, service, and overhaul of the top end, transmission, crankcase, and fuel delivery systems. Sections on periodic maintenance outline the interval-based checks for valve clearances, spark plug condition, drive chain tension, and brake fluid integrity essential for optimal performance.

Specification Highlights

Data sections document key tolerance charts, including intake and exhaust valve clearances specified at 0.08–0.13 mm when cold. The manual lists specific tightening torque for safety-critical fasteners, such as 90 N·m for the steering stem head nut and 65 N·m for the rear axle nut. Electrical references include a fully transistorized ignition system and 12V 21W turn signal light specifications. The 1996–2009 Suzuki DR200SE fuel system is documented for various market emissions standards, including specific requirements for the US, California, and Canadian configurations. An official 262-page Suzuki OEM workshop manual covering the 1996–2009 Suzuki DR200SE, documenting engine, chassis, electrical, and fuel-injection specifications for the full production run.

Manual FAQ, Purchase & Download Details

Are tightening specification tables for engine and chassis components included in the document? keyboard_arrow_down

Manual includes specification sections that detail torque ranges for various fasteners throughout the machine. These tables provide technical reference data for hardware categories without outlining specific procedural instructions.

Does the manual contain exploded view diagrams to illustrate component assembly? keyboard_arrow_down

Document contains exploded view illustrations for various systems, such as the starter motor, to show how parts are positioned relative to one another.

Can I find electrical system information like connector pinouts and harness references in this PDF? keyboard_arrow_down

Electrical system chapter lists technical reference values and includes diagrams for the machine circuitry. These references provide data on component arrangements and electrical specifications to assist with understanding the system layout.

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