1982-1985 Suzuki DR250 Service Manual

Suzuki DR250 troubleshooting and repair reference covering engine, chassis, electrical, and fuel systems. Includes diagnostic charts and specifications. PN 99500-42002-03E.

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Document Details

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Document Number / Seller:
29951 / Matthew Boyd
File Size:
58.15 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Jan 13, 2025

Models Covered & Key Technical Specifications

Thorough Workshop Wiring Manual: Suzuki DR250 1982-1985 - Essential Maintenance & Repair Reference Diagnostic-Reference Engineering-Base DR250 (99500-42002-03E) // Subsystem-Focus: Motorcycle / Engine Logic // Engineering-Base: repair-documentation. Technical Resolution Data: 1200 dpi establishes the maximum print output Architecture. Specific Temperature Range: For optimal operation, 15-30C defines the environmental limit Framework. Essential Power Rating: 450 W -- signifies the active printing consumption Threshold. Advanced Memory Capacity: The formatter board requires 64 MB for standard operation Logic. Core Speed Performance: Maximum throughput reaches 25 ppm Parameters. Standard Fill Levels: The engine requires 1.2 L of SAE 10W/40 oil for proper operation Topology.

Professional Workshop Service Manual & Technical Specifications

Thorough Workshop Wiring Manual: Suzuki DR250 1982-1985 - Essential Maintenance & Repair Reference Diagnostic-Reference

Engineering-Base DR250 (99500-42002-03E) // Subsystem-Focus: Motorcycle / Engine Logic // Engineering-Base: repair-documentation.

Specification Diagnostic-Logic Logic
Engine 249 cm³ Mikuni BS28SS
Clutch Wet multi-plate 5-speed constant mesh
Front Suspension Telescopic Pneumatic/coil spring
Rear Suspension Full-floating Oil dampened
Ignition PEI 10° BTDC
Front Brake Internal expanding Disc

Technical content addresses the following systems: GENERAL INFORMATION, PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES, SERVICING ENGINE, FUEL AND LUBRICATION SYSTEM, ELECTRICAL SYSTEM, CHASSIS, and SERVICING INFORMATION. This comprehensive document provides an in-depth look at the DR250's components and maintenance procedures.

GENERAL INFORMATION

This section details essential information including VIN and serial number locations, fuel and oil recommendations, and break-in procedures. It also covers special features like the starter de-compressor system and the ignition system.

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

This section outlines the recommended intervals for all required periodic service work to keep the motorcycle operating at peak performance. It includes maintenance charts for the engine and chassis, and detailed procedures for lubrication.

SERVICING ENGINE

This section covers engine-related tasks such as compression pressure and oil pressure checks, engine removal and remounting, and detailed procedures for the disassembly and reassembly of upper and lower end components.

FUEL AND LUBRICATION SYSTEM

This section focuses on the fuel and lubrication systems, detailing the construction and operation of the carburetor, fuel cock, and lubrication system diagrams.

ELECTRICAL SYSTEM

This section covers the motorcycle's electrical components, including the ignition system, lighting system, and switches. It provides inspection procedures and wiring diagrams.

Torque specifications are documented for engine and chassis components to ensure proper pivot-point integrity.

FAQ

What **essential** testing parameters are needed for the ignition system? keyboard_arrow_down

Resistance between lead wires for the ignitor should be approximately 1.5-3.0Ω when using a pocket tester (RX1kΩ range).

Check the **correct** diagnostic procedures for a slipping clutch. keyboard_arrow_down

115 N·m is the dry specification required for the clutch release sleeve hub nut to ensure proper adjustment and prevent slippage.

What does the **documented** fluid capacity requirements state for the front fork? keyboard_arrow_down

298 ml (10.1 US oz) is the specified capacity for each front fork leg, as detailed on page 17.

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Reviews (5)

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Rated 5 out of 5 stars
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I found this service manual incredibly helpful for keeping my DR250 in top shape. The download process was smooth, and the support team was quick to respond to my queries. A must-have for any owner!
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This manual has been a game changer for my bike repairs. The detailed instructions are easy to follow and helped me troubleshoot issues I didn't think I could handle. Highly recommend!
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How much Fork oil is in sp250 suzuki front fork?
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The Suzuki DR250 service manual is well-structured and informative. I had a question regarding the download link, and the support was very responsive and professional. This manual is a fantastic investment!