Positioning:
This manual is positioned as the definitive factory-authorized guide for servicing the Suzuki DR200 and SP200 models from 1986-1988, offering the same information used by authorized dealerships.
User Experience:
Features a clickable menu, keyword searchability, and bookmarks for efficient navigation. High resolution ensures clarity of diagrams and text.
Cost Savings:
Enables do-it-yourself mechanics to perform maintenance and repairs, potentially saving significant dealer labor costs ($70+ per hour).
Market Segment:
Competed in the lightweight dual-sport market against models from Honda (e.g., XR250L), Yamaha (e.g., XT225), and Kawasaki (e.g., KLR250).
Navigation Features:
Clickable table of contents and bookmarks provide intuitive navigation, making it easy to find specific sections.
Engine Systems:
General Information, Periodic Maintenance, Fuel System, Cooling System, Engine Top End, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Crankcase
Drivetrain And Chassis:
Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame
Electrical And Troubleshooting:
Electrical System, Troubleshooting
Body And Frame:
Frame inspection, bodywork removal/installation, seat, fuel tank, fenders.
Ignition System:
Details on the CDI ignition system, including component testing and troubleshooting.
Lighting And Instruments:
Coverage of headlights, taillights, brake lights, turn signals, and instrument cluster functions.
Cooling System:
Although air-cooled, the manual covers any components related to heat dissipation, such as cylinder head fins and engine casing design.
Diagnostic And Repair:
Diagnostics, step-by-step repair instructions, detailed procedures for all covered systems
Maintenance And Adjustment:
Periodic maintenance, adjustments, fluid checks and changes, component inspections
Wiring Diagrams:
Comprehensive electrical wiring diagrams are included, essential for diagnosing and repairing electrical faults.
Valve Adjustment:
Step-by-step instructions for checking and adjusting valve clearances, a critical periodic maintenance task.
Wheel Bearing Service:
Instructions for removing, cleaning, lubricating, and replacing wheel bearings for safe and smooth operation.
Depth Of Information:
Comprehensive factory-level detail, suitable for dealership technicians and experienced DIY mechanics, including exploded views and detailed illustrations.
Illustrations And Diagrams:
Extensive use of detailed illustrations, photos, and exploded views to clarify complex procedures and component relationships.
Troubleshooting Charts:
Diagnostic flowcharts and symptom-based troubleshooting guides to help identify and resolve common problems.
Torque Specifications:
Crucial torque values for all fasteners are provided, ensuring proper assembly and preventing damage or component failure.
Compatibility:
All PC-based Windows operating systems and Mac OS
Digital Storage:
Can be saved to hard drive or burned to CD-ROM.
Printability:
Fully printable, high-resolution pages
Searchability:
Keyword searchable PDF allows for quick access to specific topics, terms, or part names.
Recommended Binding:
3-ring binder (suggested by seller for ease of use and replacing greasy pages)
Physical Format Notes:
Digital PDF format allows for selective printing of individual pages or entire chapters.
Engine Type:
Air-cooled, 4-stroke, SOHC, single-cylinder (typical for this era and displacement)
Displacement:
Approximately 199cc (based on model name DR200)
Bore X Stroke:
Specific bore and stroke dimensions are detailed in the manual, contributing to the 199cc displacement.
Horsepower And Torque:
Approximate power output is in the range of 15-20 HP, with torque figures suited for manageable acceleration. Precise specifications are in the manual.
Fuel Delivery:
Carburetor (specific model and jetting details would be in the manual)
Dry Weight:
Approximate dry weight typically around 115-125 kg for this class of dual-sport motorcycle (specific figures available in manual).
Curb Weight:
Curb weight would include all necessary fluids and a full tank of fuel. Specifics detailed in manual.
Wheelbase:
Wheelbase specifications are crucial for handling characteristics and are detailed in the manual.
Ground Clearance:
Ground clearance is important for dual-sport capability and will be specified in the manual.
Oil Change Interval:
Typically every 3,000-5,000 km or annually. Manual will provide exact factory recommendations.
Spark Plug Replacement:
Intervals vary, but typically around 6,000-10,000 km. Manual will list specifications and replacement procedures.
Air Filter Cleaning:
Regular cleaning and eventual replacement of the air filter are critical for engine longevity. Intervals detailed in manual.
Chain Lubrication And Adjustment:
Guidance on proper chain maintenance, including lubrication frequency and adjustment procedures to prolong drivetrain life.
Engine Oil Type:
API SE or SF, SAE 20W-40 or 10W-40 motorcycle-specific oil. Manual confirms exact viscosity and API classification.
Brake Fluid Type:
DOT 3 or DOT 4 (for front disc brake, if equipped). Manual will specify. Rear drum brake typically does not use hydraulic fluid.
Fork Oil Type And Level:
Specific type and quantity of fork oil are critical for proper suspension performance. Manual provides these details.
Gearbox Oil Type:
Specific recommendations for gearbox oil viscosity and type are critical for transmission longevity. Manual will provide this information.
Common Wear Items:
Potential wear on clutch plates, brake pads, and suspension bushings due to age and use. Carburetor cleaning/rebuilding may be required on well-used examples.
Electrical System Notes:
Age-related degradation of wiring insulation and connectors can occur. Manual's electrical section and troubleshooting guide are crucial.
Carburetor Issues:
Carburetors can be prone to clogging from stale fuel or debris. Manual provides cleaning and rebuilding procedures.
Suspension Wear:
Over time, fork seals can leak and rear shock absorbers may lose damping. Manual details seal replacement and shock absorber maintenance.
Suzuki Motorcycles:
Suzuki has a long history of producing reliable and capable motorcycles, from small-displacement commuters to high-performance sportbikes and off-road machines.
Dr Series:
The DR series represents Suzuki's commitment to dual-sport motorcycles, offering versatility for on-road and light off-road use. The DR200/SP200 are entry-level models in this popular line.
Sp200 Designation:
The 'SP' designation often indicated a model with specific features or a slight variation, though typically very similar to the standard DR model in this case.
Manufacturing Location:
Likely manufactured in Japan or potentially other Suzuki global production facilities for these model years.
