Target Audience:
Mechanics and DIY enthusiasts seeking comprehensive repair information.
Value Proposition:
Provides detailed, step-by-step procedures with diagrams for effective and accurate repairs, saving time and money.
Instructional Clarity:
Prepared with simple explanations, allowing even new personnel to perform satisfactory service.
Completeness:
100% complete and intact, no missing or corrupt pages/sections.
Applicable Models:
Suzuki DR750, Suzuki DR800
Applicable Years:
1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997
Type:
Workshop Service Repair Manual
Delivery Method:
Instant Download
Engine Mechanical:
Full coverage including disassembly, assembly, inspection, and overhaul of engine components.
Fuel System:
Carburetor (Mikuni BS36 for DR750, potentially BST40 for DR800 variations), fuel pump, fuel lines, tank, and petcock.
Ignition System:
CDI ignition, spark plugs, coils, and related wiring.
Transmission:
Gearbox components, clutch operation and servicing, gear shift mechanism.
Drivetrain:
Final drive system (chain and sprockets), swingarm, and rear suspension linkage.
Suspension:
Front telescopic forks (including oil type and level), rear monoshock absorber, linkage, and adjustment procedures.
Brakes:
Front and rear disc brake systems, hydraulic components, caliper servicing, pad replacement, fluid specifications.
Electrical System:
Wiring diagrams, lighting, starting system, charging system (stator, regulator/rectifier), battery maintenance, fuse box.
Cooling System:
Oil cooling system (oil cooler, lines, oil filter), engine oil specifications and capacities.
Frame And Bodywork:
Frame inspection, body panel removal and installation, fairings, seat, fuel tank mounting.
Maintenance:
Routine maintenance tasks, periodic service schedules, lubrication points, filter replacements.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting charts.
Repair:
Detailed step-by-step repair instructions for all major vehicle systems and components.
Disassembly Assembly:
Comprehensive instructions for taking apart and putting back together various assemblies.
Adjustments:
Carburetor synchronization, valve clearance adjustments, chain tension, brake lever free play, clutch adjustment.
Installation Removal:
Proper methods for removing and installing components and accessories.
Diagnostic Information:
Includes specific diagnostic procedures and checks for electrical and mechanical issues.
Special Tools:
References to specific service tools required for certain procedures, with illustrations.
Specifications:
Includes service data, factory specifications, allowable limits, and torque values.
Pictorial Diagrams:
Detailed illustrations, exploded diagrams, drawings, and photos to guide repair procedures.
Engine Type:
Four-stroke, air-cooled, single-cylinder (DR750), or larger displacement single (DR800).
Engine Displacement:
DR750: 729 cc; DR800: typically 779 cc (specific variants may exist).
Bore X Stroke:
DR750: 89.0 x 58.6 mm; DR800: typically 85.0 x 69.0 mm (check specific model details).
Compression Ratio:
Typically around 9.5:1 (check specific model details).
Carburetor Model:
DR750: Mikuni BS36; DR800: Mikuni BST40 or similar (dual carb setup less common for these models).
Oil Capacity:
Approximately 2.0 - 2.5 liters (including oil filter, check manual for exact specification).
Valve Clearance Intake:
e.g., 0.08-0.12 mm (cold, check manual for exact specification).
Valve Clearance Exhaust:
e.g., 0.10-0.14 mm (cold, check manual for exact specification).
Oil Change Interval:
Recommended every 3,000-5,000 km or annually (refer to manual for precise intervals).
Valve Adjustment Interval:
Recommended every 6,000-10,000 km or as per manual.
Engine Oil Specification:
API SE, SF, SG or equivalent; SAE 10W-40 or 20W-50 motorcycle oil.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (check specific recommendations).
Fork Oil Type And Level:
Specific grade motorcycle fork oil, level typically 100-150 mm from top of inner tube (check manual).
Common Wear Items:
Cam chain tensioner, clutch plates, swingarm bearings, and fork seals can be common wear points.
Electrical Gremlins:
Older wiring can sometimes develop issues; periodic inspection and maintenance of connectors is advised.
Suzuki Offroad Legacy:
Suzuki has a strong heritage in off-road and dual-sport motorcycles, building on models like the DR series.
Dr750 To Dr800 Transition:
The DR800 was an evolution of the DR750, primarily featuring an increase in engine displacement for more power and torque.
Production Era:
These models were part of Suzuki's 'Big Big Enduro' line, popular for adventure touring and off-road capabilities.
