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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类型: Motorcycle

斯库: 50699

标签: 2004 DR 200 SE DR Series Motorcycle Motorcycles Suzuki

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Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DR200SE

Year:

Vehicle Type:

Dual-Sport Motorcycle

Generation

Generation Designation:

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:

📖 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:

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:

Connectivity

Connectivity Options:

🔧 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).