Market Position:
The Suzuki DR200SE is a lightweight, versatile dual-sport motorcycle renowned for its reliability, ease of use, and affordability. It caters to riders seeking a capable machine for light trail riding, commuting, and general recreational use.
Competitive Analysis:
In its segment, the DR200SE competes with other entry-level dual-sport motorcycles from manufacturers like Honda (e.g., XR200/CRF230F variants), Yamaha (e.g., XT200/TW200), and Kawasaki (e.g., KLR250 variants, though often larger displacement).
Key Features:
Robust four-stroke engine, approachable power delivery, durable chassis, electric start (on SE models), modest seat height for accessibility, and capability for both on-road and off-road excursions.
Manual Value Proposition:
This comprehensive service manual is an invaluable resource for owners and mechanics, providing the necessary technical data, procedures, and diagrams to maintain, troubleshoot, and repair the DR200SE effectively, ensuring its longevity and optimal performance.
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Manual Type:
Factory Repair Manual / Service Manual
Format:
PDF (Downloadable)
Engine Mechanical:
Complete engine tear-down and rebuild, including cylinder head, piston, crankshaft, connecting rod, camshaft, valves, timing, lubrication system, and more.
Fuel System:
Carburetor (Mikuni VM series likely), fuel tank, fuel lines, fuel filter, mixture screw, pilot jet, main jet, slow jet.
Ignition System:
CDI (Capacitor Discharge Ignition), stator, ignition coil, spark plug, timing, troubleshooting ignition system issues.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox disassembly and reassembly, primary reduction gear, final drive (chain).
Suspension Steering:
Front forks (oil change, seal replacement, internal components), rear shock absorber, swingarm, steering head bearings, triple trees.
Brakes:
Front and rear brake systems (likely drum or disc depending on exact configuration for some years, though DR200SE typically has drum front/rear for this era), brake pads/shoes, fluid, bleeding procedures.
Electrical System:
Wiring diagrams, battery, charging system (rectifier/regulator, magneto), lights (headlight, taillight, turn signals), switches, fuses.
Bodywork Chassis:
Plastics, fenders, seat, fuel tank, frame, handlebars, footpegs, exhaust system.
Maintenance:
Regular service intervals, oil changes, filter replacement, chain lubrication and adjustment, spark plug inspection and replacement, valve clearance checks and adjustments.
Troubleshooting:
Comprehensive troubleshooting guides for common problems such as starting issues, poor performance, electrical faults, and more.
Rebuilds:
Detailed procedures for complete engine rebuilds, transmission overhauls, and suspension component refurbishment.
Diagnostics:
Diagnostic procedures for identifying issues within various systems.
Depth:
Comprehensive, covering everything from basic maintenance and fluid changes to complete engine and transmission overhauls, electrical system diagnostics, and chassis component repair.
Visual Aids:
Includes pictures and part diagrams to aid in repair and identification.
Data Tables:
Provides torque specifications for critical fasteners, viscosity charts for oils, and other essential technical data.
Engine Type:
Four-stroke, air-cooled, SOHC
Displacement:
199cc (approximately)
Bore X Stroke:
Typically around 66.0 mm x 57.0 mm (specifics may vary slightly by year, but this is common for the 200cc class Suzuki engines of this era).
Compression Ratio:
Approximately 9.4:1 (typical for this engine type)
Horsepower:
Estimated around 15-18 HP (specific figures often not officially published for this class of bike, but this is a general range).
Torque:
Estimated around 12-14 lb-ft (general estimate).
Fuel Delivery:
Carburetor (likely Mikuni VM28 or similar size)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approximately 3.3 US gallons (12.5 Liters)
Oil Type:
SAE 10W-40 API SE, SF or SG classification motorcycle oil is typically recommended. The manual will specify exact viscosity and API rating.
Oil Capacity:
Approximately 1.7 US quarts (1.6 Liters) with filter change.
Overall Length:
Approximately 84.1 inches (2135 mm)
Overall Width:
Approximately 32.1 inches (815 mm)
Overall Height:
Approximately 45.1 inches (1145 mm)
Wheelbase:
Approximately 54.1 inches (1375 mm)
Ground Clearance:
Approximately 10.2 inches (260 mm)
Dry Weight:
Approximately 258 lbs (117 kg)
Curb Weight:
Approximately 278 lbs (126 kg) (with all fluids)
Seat Height:
Approximately 31.3 inches (795 mm)
Oil Change Interval:
Typically every 3,000-4,000 miles (4,800-6,400 km) or 6-12 months, whichever comes first. The manual will detail the exact recommended interval.
Air Filter Cleaning:
Regular cleaning/replacement recommended, especially if ridden in dusty conditions. Intervals often around 3,000 miles.
Spark Plug Inspection:
Typically inspected at 3,000-6,000 mile intervals and replaced as needed. The manual will list the correct spark plug type and gap.
Valve Clearance Check:
Usually recommended every 6,000-10,000 miles. This is a critical maintenance item for engine longevity and performance.
Engine Oil Viscosity:
SAE 10W-40 is a common recommendation, conforming to API SE, SF, or SG standards. Refer to manual for precise specification.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify.
Common Issues:
General wear and tear items like brake shoes/pads, clutch plates, and chain/sprockets are common. Some units may experience carburetor gumming if fuel is left sitting for extended periods without stabilization. Electrical connections can sometimes corrode if exposed to moisture.
Troubleshooting Focus:
The manual's troubleshooting section is crucial for addressing common maladies like starting difficulties, intermittent power loss, or electrical system quirks.
Brand Heritage:
Suzuki boasts a long and storied history in motorcycle manufacturing, with a reputation for building reliable and performance-oriented machines across various categories, from street bikes to off-road and sportbikes.
Model Evolution:
The DR series has been a cornerstone of Suzuki's dual-sport offerings for decades. The DR200SE represents an evolution of earlier 200cc dual-sport models, refined for improved reliability, usability, and often featuring electric start for convenience, particularly in the SE (Special Edition) variants.
Production Period:
The DR200SE was produced for a significant period, with the specified manual covering models from 1996 through 2009, indicating a consistent and popular model run.
