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Suzuki DR 200 SE 2004 Factory Service Repair Manual Pdf Download
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🏷️ Basic Information Identification Make: Suzuki Model: DR200SE Year: 2004 Vehicle Type: Dual-Sport Motorcycle Generation Generation Designation: N/A Codes Chassis Code: DR200SEK4 👋 Introduction Market Position Vehicle Segment: Entry-level to...
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🏷️ Basic Information
Identification
Make:
Suzuki
Model:
DR200SE
Year:
2004
Vehicle Type:
Dual-Sport Motorcycle
Generation
Generation Designation:
N/A
Codes
Chassis Code:
DR200SEK4
👋 Introduction
Market Position
Vehicle Segment:
Entry-level to mid-range dual-sport motorcycle, popular for commuting, light trail riding, and general utility.
Competitive Analysis
Key Competitors:
Honda XR250L, Kawasaki KLX250S, Yamaha XT250.
Key Features
Engine Type:
Reliable, air-cooled, single-cylinder engine known for its longevity and ease of maintenance.
Drivetrain:
Chain drive, suitable for varied terrain.
Suspension Setup:
Versatile suspension capable of handling both pavement and off-road conditions.
Manual Value Proposition
Target Audience:
Owners seeking to perform their own maintenance and repairs, DIY enthusiasts, independent repair shops.
Dealership Equivalence:
Provides the same level of detail and accuracy as manuals used by official Suzuki dealerships.
📋 Manual Details
Coverage Areas
Primary Coverage:
2004 Suzuki DR200SE
Secondary Coverage:
Likely covers minor variations for adjacent model years (e.g., 2003, 2005) due to platform consistency.
Page Count
Estimated Page Count:
Approximately 250-350 pages (typical for comprehensive factory service manuals).
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed overhaul, internal components, combustion system, valve timing, cooling system (air-cooled).
Fuel And Lubrication:
Carburetor assembly, fuel delivery, oil pump, oil filter, oil capacities, lubrication points.
Chassis:
Frame, suspension (front forks, rear shock absorber), steering system, wheels, brakes (front disc, rear drum), final drive (chain).
Electrical System:
Ignition system, lighting, starting system, charging system (alternator, battery), wiring diagrams, component testing.
Emission Control:
Information on emission control systems as applicable to the 2004 model year, potential adjustments or checks.
Procedures Included
General Information:
Vehicle identification, safety precautions, basic tools, torque specifications, measurement units.
Periodic Maintenance:
Scheduled service intervals, oil changes, filter replacements, chain adjustment, brake inspection, valve clearance checks.
Engine Repair:
Engine disassembly, reassembly, piston, rings, cylinder, crankshaft, camshaft, timing chain replacement, cylinder head service.
Fuel System Repair:
Carburetor cleaning, adjustment, jetting, fuel line inspection, fuel tank maintenance.
Chassis Repair:
Front fork seal replacement, rear shock absorber servicing, steering bearing replacement, wheel bearing replacement, brake pad/shoe replacement, chain and sprocket replacement.
Electrical Troubleshooting:
Fault diagnosis using wiring diagrams, testing of ignition coil, stator, rectifier/regulator, battery, starter motor.
Technical Depth
Depth Of Coverage:
Comprehensive; covers all aspects from routine maintenance and minor adjustments to complete engine and chassis overhauls, including detailed diagnostics.
📊 Manual Specifications
File Format
Digital Format:
PDF
Accessibility Features:
Searchable text, zoom in/out capability.
Print Quality
Printability:
High-resolution digital scans, suitable for printing individual sections or the entire manual.
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Quality:
N/A (Digital format)
Software Requirements
Reader Software:
Adobe Acrobat Reader (or compatible PDF viewer)
Decompression Software:
WinZip (or compatible file archiving utility)
Compatibility
Operating Systems:
All Versions of Windows and Mac OS
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, OHC, air-cooled
Displacement:
199 cc
Bore X Stroke:
66.0 mm x 57.0 mm
Compression Ratio:
9.4:1
Carburetion:
Mikuni VM26 (or similar specification for 2004 model)
Performance
Horsepower:
Approximately 16-18 HP (estimated, as specific figures are often not published for this model).
Torque:
Approximately 11-13 lb-ft (estimated).
Fuel System
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approximately 3.4 US gallons (13 Liters)
Lubrication
Oil Type:
SAE 10W-40 API SE, SF, SG or higher (specific recommendations in manual)
Oil Capacity With Filter Change:
Approximately 1.6 US quarts (1.5 Liters)
Ignition
Ignition System:
Electronic ignition (CDI)
🔧 Transmission
Standard
Transmission Type:
5-speed manual transmission
Clutch Type:
Wet multi-plate clutch
Features
Gear Ratios:
Detailed gear ratios provided in the manual.
Final Drive:
Chain drive
Transmission Oil Type:
API GL-4 SAE 80W (or specific grade recommended in manual)
Transmission Oil Capacity:
Approximately 0.8 US quarts (0.75 Liters)
📐 Dimensions
Exterior
Overall Length:
Approximately 80.5 inches (2045 mm)
Overall Width:
Approximately 32.1 inches (815 mm)
Overall Height:
Approximately 44.3 inches (1125 mm)
Wheelbase:
Approximately 53.0 inches (1345 mm)
Ground Clearance:
Approximately 10.4 inches (265 mm)
Weights
Dry Weight:
Approximately 256 lbs (116 kg)
Wet Weight:
Approximately 276 lbs (125 kg) (estimated with fluids)
Wheels And Tires
Front Tire Size:
80/100-21 51P
Rear Tire Size:
100/90-17 55P
Front Brake:
Disc brake
Rear Brake:
Drum brake
Suspension
Front Suspension Type:
Telescopic, coil spring, oil damped
Rear Suspension Type:
Swingarm type, coil spring, oil damped (linkage type often on larger models)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycles are not typically subjected to automotive crash test ratings).
Active Features
Braking System:
Front disc and rear drum brakes provide adequate stopping power for intended use.
Passive Features
Lighting:
Headlight, taillight, brake light, turn signals for visibility.
💡 Technology Features
Infotainment
Infotainment Features:
N/A (Basic dual-sport motorcycle with focus on function over electronics).
Driver Assistance
Rider Assistance Systems:
N/A
Connectivity
Connectivity Options:
N/A
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Typically every 2,000-3,000 miles or 6 months, refer to manual for precise interval.
Air Filter Cleaning Interval:
Frequent checks recommended, cleaning/replacement every 4,000-6,000 miles or as needed based on riding conditions.
Spark Plug Replacement Interval:
Typically every 6,000-10,000 miles, refer to manual for specific spark plug type and gap.
Chain Lubrication And Adjustment:
Recommended every 500-1,000 miles or after riding in wet conditions.
Fluid Specifications
Engine Oil Specification:
SAE 10W-40 API SE, SF, SG or higher (refer to manual for exact API service classification and viscosity grade).
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid (refer to manual for specific type and replacement interval).
Known Issues
Common Wear Items:
Chain and sprockets, brake pads/shoes, tires, clutch plates, fork seals.
Carburetor Cleaning:
Carburetors can sometimes become gummed up if the motorcycle sits for extended periods without fuel stabilizer, requiring cleaning and re-jetting.
Electrical Connections:
Corrosion in electrical connectors can lead to intermittent issues, particularly in humid or salty environments.
Troubleshooting Guidance
Manual Diagnostic Assistance:
The manual provides step-by-step troubleshooting guides for common starting, running, and electrical problems.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation, a globally recognized Japanese manufacturer with a long history in motorcycles and automobiles.
Model Evolution
Dr Series Lineage:
The DR series has a lineage of versatile dual-sport motorcycles, with the DR200SE representing an evolution of smaller-displacement models focused on reliability and user-friendliness.
Production
Manufacturing Location:
Likely manufactured in Japan or other Suzuki global production facilities.
🏆 Awards & Recognition
Recognitions
Industry Awards:
N/A (While the DR200SE is a respected model, specific industry awards for this particular model year are not commonly documented).