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Suzuki DR 200 SE 1996 Factory Service Repair Manual Pdf Download
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Basic Information Identification Make: Suzuki Model: DR200SE Year: 1996 Vehicle Type: Dual-sport Motorcycle Product Type: Factory Service Repair Manual Introduction Market Position Market Position: Entry-level to mid-range dual-sport motorcycle, appealing...
Type: Motorcycles
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Sku: 50691
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| Basic Information | |
| Identification | |
| Make: | Suzuki |
| Model: | DR200SE |
| Year: | 1996 |
| Vehicle Type: | Dual-sport Motorcycle |
| Product Type: | Factory Service Repair Manual |
| Introduction | |
| Market Position | |
| Market Position: | Entry-level to mid-range dual-sport motorcycle, appealing to riders for light trail use, commuting, and general off-road adventure. |
| Competitive Analysis | |
| Competitive Analysis: | Competes with other lightweight dual-sport offerings from manufacturers like Kawasaki (KLR250), Honda (XR250L), and Yamaha (XT225) in the mid-1990s market, emphasizing affordability and ease of use. |
| Key Features | |
| Key Features: | Compact and lightweight design, user-friendly engine, reliable performance, suitable for both on-road and off-road riding, robust build quality characteristic of Suzuki's DR series. |
| Manual Details | |
| Coverage | |
| Coverage Areas: | Engine, Fuel System, Lubrication System, Chassis, Electrical System, Servicing Information, Emission Control Information, Periodic Maintenance, General Information |
| Page Count | |
| Page Count: | Not Specified (Comprehensive) |
| Manual Type | |
| Manual Type: | Service and Repair Manual |
| Dealer Equivalence: | Same as available in official dealer workshops. |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine Systems: | Engine disassembly, assembly, internal components, troubleshooting, torque specifications, specifications |
| Fuel And Lubrication Systems: | Carburetor, fuel tank, fuel lines, oil pump, oil filter, lubrication passages, oil capacities |
| Chassis Systems: | Frame, suspension (front fork, rear shock), steering, wheels, brakes (front and rear), chain drive |
| Electrical System: | Ignition system, charging system (stator, regulator/rectifier), lighting, battery, wiring diagrams, fuses |
| Emission Control: | Information related to emission control systems and regulations. |
| Procedures Included | |
| Maintenance Procedures: | Oil changes, filter replacements, spark plug service, chain adjustment, brake pad inspection/replacement, air filter cleaning/replacement |
| Repair Procedures: | Engine rebuilds, carburetor tuning, suspension overhauls, brake system repairs, electrical component replacement |
| Troubleshooting: | Diagnostic charts for common problems, step-by-step troubleshooting guides |
| Torque Settings: | Comprehensive listing of all critical torque specifications for engine, chassis, and drivetrain components. |
| Technical Depth | |
| Technical Depth: | Comprehensive (from basic maintenance to complete engine and chassis overhauls) |
| Diagnostic Charts: | Yes, includes detailed troubleshooting charts for various systems. |
| Illustrations Diagrams: | Step-by-step diagrams and illustrations for all workshop procedures. |
| Manual Specifications | |
| File Characteristics | |
| File Format: | |
| Searchable Text: | Yes (implied by PDF format, though explicit confirmation not provided) |
| Zoom Capability: | Yes |
| Compatibility: | All Versions of Windows & Mac |
| Additional Requirements: | Adobe PDF Reader & WinZip |
| Print Quality | |
| Print Quality: | High Resolution (suitable for printing) |
| Binding Type | |
| Binding Type: | Digital (Downloadable File) |
| Paper Type | |
| Paper Type: | N/A (Digital) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Four-stroke, air-cooled, SOHC |
| Displacement: | 199 cc |
| Bore X Stroke: | 66.0 mm x 57.6 mm |
| Compression Ratio: | 9.4:1 |
| Performance | |
| Horsepower: | Approximately 16-18 HP (estimated, varies by region and tuning) |
| Torque: | Not specified, but typical for its class. |
| Fuel System | |
| Fuel Delivery: | Carburetor (Mikuni VM26) |
| Fuel Type: | Unleaded gasoline |
| Fuel Tank Capacity: | Approximately 7.0 liters (1.8 gallons) |
| Lubrication System | |
| Lubrication Type: | Wet sump |
| Oil Capacity: | Approximately 1.4 liters (1.5 US qt) with filter change |
| Oil Type: | API SE, SF or SG classification, SAE 10W-30 or 10W-40 (check manual for exact specification) |
| Transmission | |
| Standard | |
| Transmission Type: | 5-speed manual |
| Features | |
| Clutch Type: | Wet multi-plate |
| Final Drive: | O-ring sealed chain |
| Dimensions | |
| Exterior | |
| Overall Length: | Approximately 2145 mm (84.4 in) |
| Overall Width: | Approximately 805 mm (31.7 in) |
| Overall Height: | Approximately 1155 mm (45.5 in) |
| Wheelbase: | Approximately 1370 mm (53.9 in) |
| Ground Clearance: | Approximately 265 mm (10.4 in) |
| Seat Height: | Approximately 840 mm (33.1 in) |
| Weights | |
| Dry Weight: | Approximately 113 kg (249 lbs) |
| Wet Weight: | Not specified (typically around 120-125 kg with fluids) |
| Safety Features | |
| Ratings | |
| Safety Ratings: | N/A (Motorcycle safety ratings are typically not standardized like automobiles) |
| Active Features | |
| Braking System Front: | Disc brake |
| Braking System Rear: | Drum brake |
| Passive Features | |
| Lighting: | Headlight, taillight, brake lights, turn signals |
| Technology Features | |
| Infotainment | |
| Infotainment Features: | N/A (Basic motorcycle instrumentation) |
| Driver Assistance | |
| Driver Assistance Features: | N/A |
| Connectivity | |
| Connectivity Features: | N/A |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 3,000 km (1,800 miles) or 6 months (refer to manual for exact recommendation) |
| Spark Plug Service: | Inspect every 3,000 km (1,800 miles), replace as needed |
| Air Filter Cleaning: | Clean every 3,000 km (1,800 miles) or more frequently in dusty conditions |
| Chain Adjustment: | Check and adjust slack every 1,000 km (600 miles) |
| Fluid Specifications | |
| Brake Fluid Type: | DOT 3 or DOT 4 (check manual) |
| Known Issues | |
| Known Issues: | Carburetor gumming if not ridden regularly, occasional electrical connector corrosion, wear on chain and sprockets, fork seal leaks with heavy off-road use. |
| Vehicle History | |
| Brand Heritage | |
| Brand Heritage: | Suzuki has a long and successful history in motorcycle manufacturing, particularly in dual-sport and off-road segments, with the DR series being a hallmark of their rugged and reliable offerings. |
| Model Evolution | |
| Model Evolution: | The DR200SE is part of Suzuki's lineage of dual-sport motorcycles, evolving from earlier DR models. It focused on providing an accessible and versatile platform for a wide range of riders. |
| Production | |
| Production Period: | The DR200SE was produced through the late 1990s and into the early 2000s, with minor updates. |
| Manufacturing Location: | Primarily Japan |
| Awards & Recognition | |
| Recognitions | |
| Recognitions: | While the DR200SE itself may not have specific documented awards, the DR series is generally recognized for its reliability and value in the dual-sport market. |