The Suzuki DR200SE, produced in 2007, is a versatile dual-sport motorcycle renowned for its robust engineering and reliability. Part of Suzuki's esteemed DR series, this model offers a practical and enjoyable riding experience, suitable for both on-road commuting and light off-road adventures. Its 199 cc air-cooled, four-stroke engine, coupled with a 5-speed transmission, provides dependable performance, making it a popular choice for riders seeking a durable and user-friendly machine. The DR200SE's design emphasizes mechanical simplicity and ease of operation, reflecting Suzuki's long-standing heritage in producing quality motorcycles.
This comprehensive workshop service and repair manual provides detailed information for the Suzuki DR200SE DJ021 generation. It covers essential areas including periodic maintenance, diagnostics, troubleshooting, and component overhaul across all major systems, such as the engine, fuel, lubrication, chassis, and electrical systems. With over 300 pages of factory-level information, this English-language manual offers step-by-step repair procedures, diagnostic flowcharts, and technical specifications. It is an invaluable resource for owners, independent repair shops, and mechanics aiming to maintain, diagnose, and repair the DR200SE effectively, ensuring optimal performance and longevity.
Generation Designation:
DJ021
Target User:
Suzuki DR200SE 2007 owners, independent repair shops, mechanics
Comparison:
Provides factory-level information equivalent to official dealer service manuals
Ease Of Use:
Designed for simplicity with clear, step-by-step instructions and diagrams
Completeness:
Covers all aspects of the vehicle from basic maintenance to complex repairs
Primary Coverage:
Workshop Service and Repair
Secondary Coverage:
Periodic Maintenance, Diagnostics, Troubleshooting, Component Overhaul
Estimated Page Count:
300+
Type:
Factory Service Manual / Repair Manual
Engine System:
Complete engine overhaul, diagnostics, component replacement (pistons, rings, valves, camshaft, etc.)
Fuel System:
Carburetor tuning, cleaning, and rebuilding; fuel pump, fuel lines, fuel tank maintenance
Lubrication System:
Oil change procedures, oil filter replacement, oil pump inspection, lubrication points
Chassis System:
Frame inspection, suspension servicing (forks, rear shock), steering system maintenance, wheel and tire service
Electrical System:
Wiring diagrams, battery maintenance, ignition system testing, lighting system repair, charging system diagnosis
Emission Control:
Emission control system components and procedures
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, chain adjustment, brake pad replacement
Repair Procedures:
Step-by-step instructions for component removal, disassembly, repair, and reassembly
Troubleshooting:
Diagnostic charts and flowcharts for identifying and resolving common issues
Depth Level:
Comprehensive (from basic checks to complete engine rebuilds and electrical system diagnostics)
Readability:
Zoomable for clarity of diagrams and text
Compatibility:
Compatible with all Windows and Mac operating systems
Required Software:
Adobe PDF Reader, WinZip (for extraction)
Printability:
Printable pages for workshop use
Binding:
N/A (Digital Download)
Paper Quality:
N/A (Digital Download)
Engine Type:
Four-stroke, SOHC, single-cylinder
Bore X Stroke:
66.0 mm x 57.0 mm
Cooling System:
Air-cooled
Horsepower:
Approx. 19.5 HP @ 8,000 RPM (estimated, specific to model year variation)
Torque:
Approx. 12.0 lb-ft @ 7,000 RPM (estimated, specific to model year variation)
Fuel Delivery:
Mikuni VM28 carburetor
Fuel Type:
Unleaded gasoline
Oil Type Specification:
SAE 10W-40 API SE, SF, or SG (refer to manual for exact specification)
Oil Capacity:
Approx. 1.4 L (1.5 US qt) with filter change (refer to manual for exact capacity)
Type:
5-speed constant mesh
Clutch Type:
Wet, multi-plate
Overall Length:
2150 mm (84.6 in)
Overall Width:
805 mm (31.7 in)
Overall Height:
1140 mm (44.9 in)
Wheelbase:
1370 mm (53.9 in)
Curb Weight:
126 kg (277.7 lbs)
Safety Systems Overview:
Focus on mechanical integrity and rider control, no electronic safety aids typical of cars
Braking System Front:
Disc brake
Braking System Rear:
Drum brake
Frame Construction:
Steel pipe, semi-double cradle frame
Infotainment System:
N/A (Minimal electronics focus, basic instrumentation)
Rider Assistance:
N/A (No electronic rider aids)
Connectivity Features:
N/A
Oil Change Interval:
Every 3,000 km (1,800 miles) or 6 months (refer to manual for specific recommendation)
Air Filter Cleaning Interval:
Every 3,000 km (1,800 miles) or 6 months (refer to manual for specific recommendation)
Spark Plug Replacement Interval:
Every 6,000 km (3,600 miles) or 12 months (refer to manual for specific recommendation)
Valve Clearance Check Interval:
Every 6,000 km (3,600 miles) or 12 months (refer to manual for specific recommendation)
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for exact specification)
Coolant Type:
N/A (Air-cooled)
Common Wear Items:
Clutch plates, brake pads/shoes, tires, chain and sprockets, spark plug wear
Typical Maintenance Needs:
Regular carburetor cleaning and adjustment, chain lubrication and tensioning, suspension seal checks
Manufacturer Focus:
Suzuki has a long history in motorcycle manufacturing, known for robust and reliable off-road and dual-sport bikes.
Dr Series Legacy:
The DR200SE is part of Suzuki's popular line of dual-sport motorcycles, known for their versatility and ease of use.
Production Origin:
Likely manufactured in Japan or other global Suzuki facilities
Industry Standing:
Reputable for durability and ease of maintenance in the dual-sport segment.
