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Suzuki D Service Manual

Manual is about: SUZUKI DR200SE

Summary of D

  • Page 1

    Foreword this manual contains an introductory description on suzuki dr200se and procedures for its inspec- tion/service and overhaul of its main components. Other information considered as generally known is not included. Read general information section to famil- iarize yourself with outline of the...

  • Page 2

    03 engine.Book page 105 tuesday, february 28, 2006 3:03 pm.

  • Page 3: Supplements

    Supplements dr200sev/w/x/y/k1/k2/k3 (’97,'98,'99,'00,'01,'02,'03-models) dr200sek4/k5 ('04, '05-models) dr200sek6 ('06-model) dr200sek7 /k8 ('07 &"08 -model) 9 10 11 12 13 13 dr200sek9 ('09-model).

  • Page 203

    9.

  • Page 213

    2 4 6 dr200sek4 (’04-model) 10-1 contents dr200sek4/k5 (’04, ’05-models) 10 this chapter describes service specifications and servicing procedurers which differ from those of the dr200sek3 (’03-model). Note: * any differences between the dr200sek3 (’03-model) and dr200sek4/k5 (’04, ’05-mod- els) in ...

  • Page 214: Specifications

    10-2 dr200sek4/k5 (’04, ’05-models) specifications for e-03, 28, 33 dimensions and dry mass overall length ...................................................................................... 2 150 mm (84.6 in) overall width ............................................................................

  • Page 215

    Dr200sek4/k5 (’04, ’05-models) 10-3 for e-06, 24 dimensions and dry mass overall length ..................................................................................... 2 220 mm (87.4 in) overall width....................................................................................... 805 mm...

  • Page 216: Service Data

    10-4 dr200sek4/k5 (’04, ’05-models) service data for e-03, 28, 33 valve + guide unit: mm (in) item standard limit valve diam. In. 33 (1.3) — ex. 28 (1.1) — valve clearance (when cold) in. & ex. 0.08 – 0.13 (0.003 – 0.005) — valve guide to valve stem clearance in. 0.010 – 0.037 (0.0004 – 0.0015) — ex...

  • Page 217

    Dr200sek4/k5 (’04, ’05-models) 10-5 camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 34.174 – 34.218 (1.3454 – 1.3472) 33.870 (1.3335) ex. 33.804 – 33.848 (1.3309 – 1.3326) 33.500 (1.3189) camshaft journal oil clearance in. & ex....

  • Page 218

    10-6 dr200sek4/k5 (’04, ’05-models) conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit piston ring groove width 1st 1.01 – 1.03 (0.040 – 0.041) — 2nd 1.21 – 1.23 (0.047 – 0.048) — oil 2.01 – 2.03 (0.079 – 0.080) — piston ring thickness 1st 0.970 – 0.990 (0.038 – 0.03...

  • Page 219

    Dr200sek4/k5 (’04, ’05-models) 10-7 transmisstion + drive chain unit: mm (in) except ratio carburetor item standard limit primary reduction ratio 3.157 (60/19) — final reduction ratio 3.000 (45/15) — gear ratios low 3.000 (33/11) — 2nd 1.933 (29/15) — 3rd 1.437 (23/16) — 4th 1.095 (23/21) — top 0.91...

  • Page 220

    10-8 dr200sek4/k5 (’04, ’05-models) electrical unit: mm (in) wattage unit: w item specification note spark plug type denso: x24esr-u ngk: cr8ea gap 0.6 – 0.7 (0.024 – 0.028) spark performance over 8 mm (0.3) at 1 atm. Signal coil resitance 100 – 140 Ω g – bl ignition coil resistance primary 2 – 6 Ω ...

  • Page 221

    Dr200sek4/k5 (’04, ’05-models) 10-9 brake + wheel unit: mm (in) item standard limit brake lever play 0.1 – 0.3 (0.004 – 0.010) — rear brake pedal free travel 20 – 30 (0.8 – 1.2) — rear brake pedal height 2.5 (0.10) — brake drum i.D. Rear — 130.7 (5.15) brake lining thickness rear — 1.5 (0.06) brake ...

  • Page 222

    10-10 dr200sek4/k5 (’04, ’05-models) suspension unit: mm (in) tire pressuer fuel + oil item standard limit note front fork stroke 205 (8.1) — front fork spring free length — 561 (22.1) front fork oil level 179.5 (7.07) — rear shock absorber spring pre-set length 231 (9.1) — rear wheel travel 205 (8....

  • Page 223

    Dr200sek4/k5 (’04, ’05-models) 10-11 for e-06, 24 valve + guide unit: mm (in) item standard limit valve diam. In. 33 (1.3) — ex. 28 (1.1) — valve clearance (when cold) in. & ex. 0.08 – 0.13 (0.003 – 0.005) — valve guide to valve stem clearance in. 0.010 – 0.037 (0.0004 – 0.0015) — ex. 0.030 – 0.057 ...

  • Page 224

    10-12 dr200sek4/k5 (’04, ’05-models) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 34.174 – 34.218 (1.3454 – 1.3472) 33.870 (1.3335) ex. 33.804 – 33.848 (1.3309 – 1.3326) 33.500 (1.3189) camshaft journal oil clearance in. & ex...

  • Page 225

    Dr200sek4/k5 (’04, ’05-models) 10-13 conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit piston ring groove width 1st 1.01 – 1.03 (0.040 – 0.041) — 2nd 1.21 – 1.23 (0.047 – 0.048) — oil 2.01 – 2.03 (0.079 – 0.080) — piston ring thickness 1st 0.970 – 0.990 (0.038 – 0.0...

  • Page 226

    10-14 dr200sek4/k5 (’04, ’05-models) transmisstion + drive chain unit: mm (in) except ratio carburetor item standard limit primary reduction ratio 3.157 (60/19) — final reduction ratio 3.916 (47/12) — gear ratios low 3.000 (33/11) — 2nd 1.933 (29/15) — 3rd 1.437 (23/16) — 4th 1.095 (23/21) — top 0.9...

  • Page 227

    Dr200sek4/k5 (’04, ’05-models) 10-15 electrical unit: mm (in) wattage unit: w item specification note ignition timing 7°b.T.D.C. Below at 1 500 r/min spark plug type denso: x24esr-u ngk: cr8ea gap 0.6 – 0.7 (0.024 – 0.028) spark performance over 8 mm (0.3) at 1 atm. Signal coil resitance 100 – 140 Ω...

  • Page 228

    10-16 dr200sek4/k5 (’04, ’05-models) brake + wheel unit: mm (in) suspension unit: mm (in) item standard limit brake lever play 0.1 – 0.3 (0.004 – 0.010) — rear brake pedal free travel 20 – 30 (0.8 – 1.2) — rear brake pedal height 2.5 (0.10) — brake drum i.D. Rear — 130.7 (5.15) brake lining thicknes...

  • Page 229

    Dr200sek4/k5 (’04, ’05-models) 10-17 tire pressuer e-24 e-06 fuel + oil cold inflation tire pressure solo riding kpa kgf/cm 2 psi front 100 1.0 15 rear 100 1.0 15 cold inflation tire pressure solo riding dual riding kpa kgf/cm 2 psi kpa kgf/cm 2 psi front 100 1.0 15 100 1.0 15 rear 100 1.0 15 100 1....

  • Page 230: Tightening Torque

    10-18 dr200sek4/k5 (’04, ’05-models) tightening torque engine item n·m kgf-m lb-ft cylinder head cover bolt 10 1.0 7.0 camshaft sprocket bolt 11 1.1 8.0 cylinder head nut 8 mm diam. 27 2.7 19.5 cylinder head nut 6 mm diam. 10 1.0 7.0 cylinder base nut 10 1.0 7.0 starter clutch securing bolt 25 2.5 1...

  • Page 231: Generator Rotor Nut

    Dr200sek4/k5 (’04, ’05-models) 10-19 generator rotor nut reassembly • hold the generator rotor using the special tool, and tighten the generator rotor nut to the specified torque. " 09930-44511: rotor holder # generator rotor nut a : 80 n·m (8.0 kgf-m, 58.0 lb-ft).

  • Page 233: Dr200Sek6 (’06-Model)

    2 4 6 dr200sek4 (’04-model) 10-1 contents dr200sek6 (’06-model) 11 this chapter describes service specifications and servicing procedurers which differ from those of the dr200sek4/k5 (’04, ’05-models). Note: * any differences between the dr200sek4/k5 (’04, ’05-models) and dr200sek6 (’06- model) in s...

  • Page 234: Specifications

    11-2 dr200sek6 (’06-model) specifications for e-03, 28, 33 dimensions and dry mass overall length ...................................................................................... 2 150 mm (84.6 in) overall width .....................................................................................

  • Page 235

    Dr200sek6 (’06-model) 11-3 for e-06, 24 dimensions and dry mass overall length ..................................................................................... 2 220 mm (87.4 in) overall width....................................................................................... 805 mm (31.7 in...

  • Page 236: Service Data

    11-4 dr200sek6 (’06-model) service data for e-03, 28, 33 valve + guide unit: mm (in) item standard limit valve diam. In. 33 (1.3) — ex. 28 (1.1) — valve clearance (when cold) in. & ex. 0.08 – 0.13 (0.003 – 0.005) — valve guide to valve stem clearance in. 0.010 – 0.037 (0.0004 – 0.0015) — ex. 0.030 –...

  • Page 237

    Dr200sek6 (’06-model) 11-5 camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 34.174 – 34.218 (1.3454 – 1.3472) 33.870 (1.3335) ex. 33.804 – 33.848 (1.3309 – 1.3326) 33.500 (1.3189) camshaft journal oil clearance in. & ex. 0.032 – ...

  • Page 238

    11-6 dr200sek6 (’06-model) conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit piston ring groove width 1st 1.01 – 1.03 (0.040 – 0.041) 2nd 1.21 – 1.23 (0.047 – 0.048) oil 2.01 – 2.03 (0.079 – 0.080) piston ring thickness 1st 0.970 – 0.990 (0.038 – 0.039) — 2nd 1.170 ...

  • Page 239

    Dr200sek6 (’06-model) 11-7 transmisstion + drive chain unit: mm (in) except ratio carburetor item standard limit primary reduction ratio 3.157 (60/19) — final reduction ratio 3.000 (45/15) — gear ratios low 3.000 (33/11) — 2nd 1.933 (29/15) — 3rd 1.437 (23/16) — 4th 1.095 (23/21) — top 0.913 (21/23)...

  • Page 240

    11-8 dr200sek6 (’06-model) electrical unit: mm (in) wattage unit: w item specification note spark plug type denso: x24esr-u ngk: cr8ea gap 0.6 – 0.7 (0.024 – 0.028) spark performance over 8 mm (0.3) at 1 atm. Signal coil resitance 100 – 140 Ω g – bl ignition coil resistance primary 2 – 6 Ω terminal ...

  • Page 241

    Dr200sek6 (’06-model) 11-9 brake + wheel unit: mm (in) item standard limit brake lever play 0.1 – 0.3 (0.004 – 0.010) — rear brake pedal free travel 20 – 30 (0.8 – 1.2) — rear brake pedal height 2.5 (0.10) — brake drum i.D. Rear — 130.7 (5.15) brake lining thickness rear — 1.5 (0.06) brake disc thic...

  • Page 242

    11-10 dr200sek6 (’06-model) suspension unit: mm (in) tire pressuer fuel + oil item standard limit note front fork stroke 205 (8.1) — front fork spring free length — 561 (22.1) front fork oil level 179.5 (7.07) — rear shock absorber spring pre-set length 231 (9.1) — rear wheel travel 205 (8.1) — swin...

  • Page 243

    Dr200sek6 (’06-model) 11-11 for e-06, 24 valve + guide unit: mm (in) item standard limit valve diam. In. 33 (1.3) — ex. 28 (1.1) — valve clearance (when cold) in. & ex. 0.08 – 0.13 (0.003 – 0.005) — valve guide to valve stem clearance in. 0.010 – 0.037 (0.0004 – 0.0015) — ex. 0.030 – 0.057 (0.0012 –...

  • Page 244

    11-12 dr200sek6 (’06-model) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 34.174 – 34.218 (1.3454 – 1.3472) 33.870 (1.3335) ex. 33.804 – 33.848 (1.3309 – 1.3326) 33.500 (1.3189) camshaft journal oil clearance in. & ex. 0.032 –...

  • Page 245

    Dr200sek6 (’06-model) 11-13 conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit piston ring groove width 1st 1.01 – 1.03 (0.040 – 0.041) 2nd 1.21 – 1.23 (0.047 – 0.048) oil 2.01 – 2.03 (0.079 – 0.080) piston ring thickness 1st 0.970 – 0.990 (0.038 – 0.039) — 2nd 1.170...

  • Page 246

    11-14 dr200sek6 (’06-model) transmisstion + drive chain unit: mm (in) except ratio carburetor item standard limit primary reduction ratio 3.157 (60/19) — final reduction ratio 3.916 (47/12) — gear ratios low 3.000 (33/11) — 2nd 1.933 (29/15) — 3rd 1.437 (23/16) — 4th 1.095 (23/21) — top 0.913 (21/23...

  • Page 247

    Dr200sek6 (’06-model) 11-15 electrical unit: mm (in) wattage unit: w item specification note ignition timing 7°b.T.D.C. Below at 1 500 r/min spark plug type denso: x24esr-u ngk: cr8ea gap 0.6 – 0.7 (0.024 – 0.028) spark performance over 8 mm (0.3) at 1 atm. Signal coil resitance 100 – 140 Ω g – bl i...

  • Page 248

    11-16 dr200sek6 (’06-model) brake + wheel unit: mm (in) suspension unit: mm (in) item standard limit brake lever play 0.1 – 0.3 (0.004 – 0.010) — rear brake pedal free travel 20 – 30 (0.8 – 1.2) — rear brake pedal height 2.5 (0.10) — brake drum i.D. Rear — 130.7 (5.15) brake lining thickness rear — ...

  • Page 249

    Dr200sek6 (’06-model) 11-17 tire pressuer e-24 e-06 fuel + oil cold inflation tire pressure solo riding kpa kgf/cm 2 psi front 100 1.0 15 rear 100 1.0 15 cold inflation tire pressure solo riding dual riding kpa kgf/cm 2 psi kpa kgf/cm 2 psi front 100 1.0 15 100 1.0 15 rear 100 1.0 15 100 1.0 15 item...

  • Page 251: Dr200Sek7

    2 4 6 dr200sek4 (’04-model) 10-1 contents 11 note: dr200sek7 /k8 ('07 &’08 -model s ) in specifications are cleary indicated with an asterisk (*) mark. * please refer to the capters 1 through 11 for details which are not given in this chapter. 12 specifications .........................................

  • Page 252: Specifications

    – 2 – specifications for e-03, 28, 33 dimensions and dry mass overall length ...................................................................................... 2 150 mm (84.6 in) overall width........................................................................................ 805 mm (31.7 in...

  • Page 253: Service Data

    – 3 – service data for e-03, 28, 33 valve + guide unit: mm (in) item standard limit valve diam. In. 33 (1.3) — ex. 28 (1.1) — valve clearance (when cold) in. & ex. 0.08 – 0.13 (0.003 – 0.005) — valve guide to valve stem clearance in. 0.010 – 0.037 (0.0004 – 0.0015) — ex. 0.030 – 0.057 (0.0012 – 0.00...

  • Page 254

    – 4 – camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 34.174 – 34.218 (1.3454 – 1.3472) 33.870 (1.3335) ex. 33.804 – 33.848 (1.3309 – 1.3326) 33.500 (1.3189) camshaft journal oil clearance in. & ex. 0.032 – 0.066 (0.0013 – 0.002...

  • Page 255

    – 5 – conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit piston ring groove width 1st 1.01 – 1.03 (0.040 – 0.041) 2nd 1.21 – 1.23 (0.047 – 0.048) oil 2.01 – 2.03 (0.079 – 0.080) piston ring thickness 1st 0.970 – 0.990 (0.038 – 0.039) — 2nd 1.170 – 1.190 (0.046 – 0.04...

  • Page 256

    – 6 – transmisstion + drive chain unit: mm (in) except ratio carburetor item standard limit primary reduction ratio 3.157 (60/19) — final reduction ratio 3.000 (45/15) — gear ratios low 3.000 (33/11) — 2nd 1.933 (29/15) — 3rd 1.437 (23/16) — 4th 1.095 (23/21) — top 0.913 (21/23) — shift fork to groo...

  • Page 257

    – 7 – electrical unit: mm (in) wattage unit: w item specification note spark plug type denso: x24esr-u ngk: cr8ea gap 0.6 – 0.7 (0.024 – 0.028) spark performance over 8 mm (0.3) at 1 atm. Signal coil resitance 100 – 140 Ω g – bl ignition coil resistance primary 2 – 6 Ω terminal – terminal secondary ...

  • Page 258

    – 8 – brake + wheel unit: mm (in) item standard limit brake lever play 0.1 – 0.3 (0.004 – 0.010) — rear brake pedal free travel 20 – 30 (0.8 – 1.2) — rear brake pedal height 2.5 (0.10) — brake drum i.D. Rear — 130.7 (5.15) brake lining thickness rear — 1.5 (0.06) brake disc thickness front 3.5 ± 0.2...

  • Page 259

    – 9 – suspension unit: mm (in) tire pressuer fuel + oil item standard limit note front fork stroke 205 (8.1) — front fork spring free length — 561 (22.1) front fork oil level 179.5 (7.07) — rear shock absorber spring pre-set length 231 (9.1) — rear wheel travel 205 (8.1) — swingarm pivot shaft runou...

  • Page 261: Dr200Sek

    #/.4%.43 0!'% 52'%+(+%#6+105 % note: * differences between k9-model and k8-model specifications are indicated as an aster- isk mark (*). * the service data are the same as the k8-model. 13 dr200sek 9 (’0 9 -model) dr200sek9 (’09-model) 13-1.

  • Page 262: Specifications

    Specifications (e-03, 28, 33) dimensions and curb mass overall length ...................................................................................... 2 150 mm (84.6 in) overall width........................................................................................ 805 mm (31.7 in) overa...