1988-1997 Suzuki DR750S / DR800S Service Manual

Covers DR750S and DR800S models, detailing engine, fuel, electrical, chassis, and more. Includes technical documentation and repair procedures for maintenance. Part No. 99500-47010-01E.

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Document Details

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Document Number / Seller:
24608 / William Thompson
File Size:
71.74 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Motorbike
Last updated / verified
Sep 19, 2025

Models Covered & Key Technical Specifications

Full-Coverage Instructional Shop Manual: Suzuki DR750S, DR800S (99500-47010-01E) manual, covers 1988-1997 Troubleshooting-Index Suzuki DR750S, DR800S (99500-47010-01E) | Suzuki Motor Corporation Compendium.

  • Published System Volume: 727 cm³ establishes the engine displacement data.
  • Specific Spacing Data: For engine clearance, 0.05 mm governs the maximum valve stem runout Precision.
  • Integral Wattage Specs: 12 V -- signifies the battery capacity Capacity.
  • Operational Cold Start Limits: The regulator/rectifier requires 15 A for proper function Stability.
  • Fundamental Form Factor: Maximum throughput reaches 1.5 kW Parameters.
  • Universal Liquid Volume: The fuel tank includes 29 L for reserve Logic.

Professional Workshop Service Manual & Technical Specifications

Full-Coverage Instructional Shop Manual: Suzuki DR750S, DR800S manual, covers 1988-1997 Troubleshooting-Index

Component-Focus: DR750S, DR800S // Model-Designation: Suzuki / Motorcycle Logic // Component-Focus: Repair Procedures.

TOP

Component Parameters Logic
Steering Stem Head Nut 60 – 100 N·m Bolt Torque
Front Fork Upper Clamp Bolt 15 – 25 N·m Bolt Torque
Front Brake Caliper Mounting Bolt 15 – 25 N·m Bolt Torque
Air Bleeder Valve 6 – 9 N·m Bolt Torque
Rear Axle Nut 55 – 88 N·m Bolt Torque
Drive Chain Slack 319.4 mm Chain Measurement

Factory procedures are documented for:

  • The engine section documents component inspection and servicing. We cover engine disassembly and reassembly.
  • The troubleshooting chapter addresses common issues like "Engine will not start" and "Noise seems to come from engine".
  • Cooling system maintenance is addressed in engine lubrication/cylinder head cooling system chart.
  • Testing requirements are specified for starter motor inspection, including brushes and commutator.
  • Clearance measurements are addressed for valve stem runout, ensuring proper operation and longevity.

This manual contains detailed information on all major systems, including engine, transmission, fuel system, electrical, chassis, and suspension. It outlines diagnostic procedures, component removal and installation, and routine maintenance schedules to keep your Suzuki DR750S/DR800S in peak condition. The manual documents torque specifications for critical engine components to ensure proper dynamic load distribution.

FAQ

What does the **exact** assembly sequence entail for the engine components? keyboard_arrow_down

115 N·m is the specified torque for the cylinder head nuts and bolts. Refer to page 90 for detailed assembly diagrams and sequences.

Reference the **specific** service interval parameters for the drive chain. keyboard_arrow_down

Clean and lubricate every 1000 km (600 miles). Drive chain slack should be maintained between 35 – 45 mm (1.4 – 1.8 in). Refer to page 24 for full details.

What are the **designated** system architecture specifications for the electrical system? keyboard_arrow_down

15 A is the maximum rating for the fuse. The charging system uses an AC generator with a regulator/rectifier. Refer to page 110 for complete electrical system schematics and component data.

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Reviews (3)

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Rated 4 out of 5 stars
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I had a few questions about the manual, and the support team was very helpful and responsive. The layout is clear, making repairs much easier!
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This manual is incredibly detailed and easy to follow. The download process was seamless, and I received my link almost instantly! Highly recommend!