1982-1985 Suzuki DR250 Service Manual

Suzuki DR250 1982–1985 Service Manual

• Covers 1982–1985 Suzuki DR250 and SP250 models, including D, E, F, and Z variants with 4-stroke TSCC engine technology.
• Official Suzuki publication 99500-42002-03E, printed October 1990.
• Documents complete engine rebuild procedures with torque specifications for 35–40 Nm cylinder head nuts and 95–100 Nm magneto rotor nuts.
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• Stored against your account so you can retrieve it after a hard-drive loss.
• Suitable for printing individual sections for shop-floor use.
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• This edition provides technical reference for the specific Suzuki TSCC combustion chamber and Full-Floating suspension system featured on the 1982–1985 DR250 and SP250 series.

Engine and Chassis Documentation

The 1982–1985 Suzuki DR250 service manual details engine removal, lower-end disassembly, and top-end servicing for the single-cylinder TSCC engine. Technical sections cover the transmission gear shifts, balancer assembly, and the primary drive system components. Lubrication and fuel system chapters outline maintenance for the Mikuni VM28SS carburetor and proper oil pump operation. Chassis coverage spans the front and rear brake adjustments, drive chain tensioning, and the Full-Floating suspension system settings. Periodic maintenance schedules are included to assist with engine oil changes, valve clearance settings, and spark plug intervals.

Technical Specification Highlights

Standard torque values for critical fasteners are provided, such as the 37–45 Nm for engine mounting bolts and 9–12 Nm for exhaust pipe bolts. Valve clearance for the intake is listed at 0.03–0.08 mm in the cylinder head specification table. Engine oil capacity for the 1982–1985 Suzuki DR250 is documented at 1.2 liters. The manual also contains extensive exploded-view diagrams of the cylinder head, clutch assembly, and gearbox, making it a valuable tool for understanding factory assembly standards. For those interested in how factory workshop documentation is structured, this publication serves as a technical record.

Reference only — always consult a certified technician before performing service on this equipment.

An official 304-page Suzuki OEM workshop manual covering the 1982–1985 DR250 and SP250, documenting engine, chassis, electrical, and fuel-system specifications for this 4-stroke machine.