Suzuki DR 200 SE 2005 Factory Service Repair Manual Pdf Download

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Taper: Motorcycle

Distributeur:

UGS: 50700

Mots clés: 2005 DR 200 SE DR Series Motorcycle Motorcycles Suzuki

Variantes de produits

Description

The 2005 Suzuki DR200SE is a versatile dual-sport motorcycle designed for both on-road commuting and off-road exploration. Known for its durability and simple, reliable 199 cc, 4-stroke, air-cooled engine, this model offers an accessible entry into the dual-sport segment. Its robust steel frame, telescopic front forks, and adjustable rear suspension, coupled with spoked 21-inch front and 18-inch rear wheels, equip it for a variety of terrains. The DR200SE is appreciated for its straightforward mechanical design, making it a practical choice for riders seeking a dependable and capable machine that balances functionality with ease of maintenance. This Service Repair Manual provides comprehensive guidance for the 2005 Suzuki DR200SE, covering all essential service and repair procedures. Within its approximately 300-500 pages, you will find detailed information on engine overhaul, fuel system maintenance, lubrication, chassis components, electrical systems, brakes, and transmission. The manual includes step-by-step repair instructions, detailed diagrams, torque settings, and fluid specifications, along with troubleshooting guidance for common issues. Its thorough scope ensures that owners and technicians have the necessary resources to maintain, diagnose, and repair the DR200SE, ensuring its optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DR200SE

Year:

Vehicle Type:

Dual-Sport Motorcycle

👋 Introduction

Market Position

Vehicle Segment:

Entry-level to mid-range dual-sport motorcycle.

Competitive Analysis

Competitors:

Kawasaki KLR250, Honda CRF250L (though later model), Yamaha XT250.

Key Features

Durability:

Known for its robust and reliable engine, suitable for off-road and commuting.

Simplicity:

Relatively simple mechanical design for ease of maintenance.

Versatility:

Capable on pavement and light to moderate off-road trails.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete service and repair procedures for the Suzuki DR200SE.

Secondary Coverage:

Detailed diagrams, torque settings, fluid capacities, electrical schematics.

Page Count

Estimated Page Count:

Approximately 300-500 pages (typical for a comprehensive service manual).

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine overhaul, assembly, disassembly, lubrication, cooling (if applicable).

Fuel System:

Carburetor tuning, cleaning, fuel pump (if applicable), fuel tank and lines.

Lubrication System:

Oil pump, oil filter, oil cooler (if applicable), oil specifications.

Chassis:

Frame, suspension (front forks, rear shock), steering, wheels, bearings.

Electrical System:

Wiring diagrams, ignition system, lighting, battery, starter, charging system.

Brakes:

Front and rear brake systems, hydraulic lines, caliper maintenance, brake fluid specifications.

Transmission:

Gearbox disassembly, assembly, lubrication, clutch operation.

Emission Control:

Emission control systems, component identification, troubleshooting.

Procedures Included

Maintenance:

Periodic maintenance checks, lubrication, adjustments, fluid changes.

Troubleshooting:

Diagnostic procedures for common problems, symptom-based troubleshooting.

Repair:

Detailed step-by-step repair instructions for all major components.

Rebuilds:

Engine and transmission rebuild procedures.

Adjustments:

Carburetor, clutch, throttle, and brake lever adjustments.

Technical Depth

Depth:

Comprehensive, suitable for both DIY mechanics and professional technicians.

Diagrams:

Detailed step-by-step diagrams and illustrations for all procedures.

Schematics:

Full electrical system schematics.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable if created from digital source.

Zoom Capability:

Compatibility:

All Versions of Windows & Mac

Print Quality

Printability:

Printable (as is standard for PDF manuals).

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, air-cooled, SOHC

Displacement:

199 cc

Bore X Stroke:

66.0 mm x 57.0 mm (typical for this model)

Compression Ratio:

9.4:1 (typical for this model)

Performance

Horsepower:

Approximately 15-17 HP @ 7,500 RPM (estimated, varies by region/tuning)

Torque:

Approximately 11-13 lb-ft @ 6,000 RPM (estimated)

Fuel System

Fuel Delivery:

Carburetor (e.g., Mikuni VM26SS)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Approximately 11 Liters (2.9 US gal)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet multi-plate

Features

Drive System:

Chain drive

📐 Dimensions

Exterior

Length:

Approximately 2,095 mm (82.5 in)

Width:

Approximately 815 mm (32.1 in)

Height:

Approximately 1,170 mm (46.1 in)

Wheelbase:

Approximately 1,375 mm (54.1 in)

Weights

Dry Weight:

Approximately 113 kg (249 lbs)

Curb Weight:

Approximately 124 kg (273 lbs)

Suspension

Front Suspension:

Telescopic, coil spring, oil damped

Rear Suspension:

Swingarm type, oil damped (mono-shock or twin-shock depending on specific sub-model/region, though typically mono-shock for SE)

Wheels Tires

Front Wheel:

Spoked, 21-inch

Rear Wheel:

Spoked, 18-inch

Front Tire Size:

80/90-21 (typical)

Rear Tire Size:

100/90-18 (typical)

Brakes

Front Brake:

Disc brake

Rear Brake:

Drum brake

🛡️ Safety Features

Ratings

Crash Test Data:

N/A (Motorcycle safety ratings are not standardized like automobiles).

Active Features

Lighting:

Headlight, taillight, brake light, turn signals.

Passive Features

Frame Construction:

Steel frame designed for off-road durability.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation).

Driver Assistance

Electronic Aids:

N/A (No advanced electronic rider aids like ABS or traction control on this model).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,000 km (1,860 miles) or 6 months, whichever comes first.

Air Filter Cleaning:

Every 3,000 km (1,860 miles) or 6 months, or more frequently if used in dusty conditions.

Spark Plug Replacement:

Every 6,000 km (3,730 miles).

Valve Clearance Check:

Every 6,000 km (3,730 miles).

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SE or SF (or equivalent).

Engine Oil Capacity:

Approximately 1.4 Liters (1.5 US qt) without filter change; 1.6 Liters (1.7 US qt) with filter change.

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Carburetor Clogging:

Can occur with infrequent use or stale fuel; requires regular cleaning/disassembly for optimal performance.

Chain And Sprockets Wear:

Standard wear item requiring regular lubrication and adjustment.

Suspension Softness:

Some riders find the stock suspension can be a bit soft for aggressive off-road use, but it's adequate for general riding.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation, a Japanese multinational corporation.

Model Evolution

Dr Series:

The DR series represents Suzuki's line of dual-sport motorcycles, known for their ruggedness and versatility.

Dr200Se Lineage:

The DR200SE is an evolution of earlier DR200 models, often featuring electric start (SE designation) and refined components.

Production

Production Period:

The DR200SE has been in production for many years, with the 2005 model being a key iteration.

🏆 Awards & Recognition

Recognitions

Awards:

No specific awards are typically associated with this model, but it's recognized for its reliability and value in its class.