The Suzuki DR200SE is a versatile dual-sport motorcycle, produced for many years and representing a solid choice for riders seeking a reliable machine for both on-road commuting and light trail exploration. Known for its user-friendly nature, lightweight construction, and economical operation, this 1999 model embodies a heritage of building capable and accessible off-road and dual-purpose vehicles. Its durable 199cc four-stroke engine, coupled with a 5-speed manual transmission and a comfortable suspension system, makes it suitable for beginners and experienced riders alike who appreciate straightforward engineering and dependable performance. This comprehensive Factory Service Repair Manual provides detailed guidance for the maintenance and repair of your 1999 Suzuki DR200SE. It covers essential areas including the engine, fuel and lubrication systems, chassis components, and the electrical system. Within its pages, you will find step-by-step procedures for routine maintenance, in-depth repair instructions for engine and component overhauls, diagnostic information for troubleshooting common issues, and critical technical specifications such as torque values and fluid capacities. This manual is an invaluable resource for owners and technicians aiming to keep the DR200SE in optimal condition. 🏷️ Basic Information Identification Make: Suzuki Model: DR200SE Year: 1999 Model Code: DR200SE Codes Vin Code: Variable (refer to manual for specifics) 👋 Introduction Market Position Vehicle Type: Dual-sport motorcycle, known for its reliability and versatility for light trail riding and on-road use. Competitive Analysis Competitors: Honda CRF230F, Yamaha XT225, Kawasaki KLR250 (though slightly larger displacement) Key Features Features: Lightweight, user-friendly, economical, durable engine, suitable for beginners and experienced riders alike. Manual Value Proposition Value: Provides essential knowledge for DIY maintenance and repair, saving time and money compared to dealership services. Manual Target Audience Audience: Suzuki DR200SE owners, DIY mechanics, aspiring technicians. 📋 Manual Details Coverage Areas Engine: YES Fuel System: YES Lubrication System: YES Chassis: YES Electrical System: YES Periodic Maintenance: YES Servicing Information: YES Emission Control: YES Page Count Estimated Pages: Refer to actual manual file for exact count (typically 200-400 pages for this era) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Top-end (cylinder head, valves), bottom-end (crankshaft, connecting rod, piston), cylinder, cam timing, ignition system, starting system Fuel Lubrication: Carburetor operation and adjustment, fuel tank, fuel lines, oil pump, oil filter, oil passages Chassis Components: Frame, suspension (front fork, rear shock absorber), steering, brakes (front and rear), wheels and tires, swingarm, drive chain Electrical Systems: Wiring diagrams, lighting system, ignition system, battery, charging system (stator, rectifier/regulator), starter motor, fuses Procedures Included Maintenance: Oil changes, filter replacement, spark plug replacement, chain adjustment and lubrication, air filter cleaning/replacement, brake adjustments Repair: Engine rebuilds (top-end and bottom-end), carburetor overhaul, suspension servicing, brake system repair, electrical component replacement Diagnostics: Troubleshooting common problems, electrical system diagnostics, engine performance issues Technical Specifications: Torque values for all fasteners, fluid capacities, engine specifications, clearances, wear limits Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and component overhauls, including detailed electrical schematics) 📊 Manual Specifications File Format File Type: PDF Readability: High resolution, zoomable for detail Searchability: Likely text-searchable within PDF, enabling quick access to information Print Quality Printability: Printable from Adobe Reader, suitable for home or shop use Binding Type Binding: N/A (Digital download) Paper Type Paper: N/A (Digital download) Software Requirements Reader: Adobe PDF Reader Decompression: WinZip or equivalent for potential archive decompression ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, air-cooled Displacement: 199 cc Bore X Stroke: 66.0 mm x 57.0 mm Compression Ratio: 9.4:1 Valve Train: SOHC, 2 valves Performance Horsepower: Approx. 17-20 HP (factory specification may vary slightly by region) Torque: Approx. 15-17 Nm (factory specification may vary slightly by region) Fuel System Carburetor Type: Mikuni VM26 (single) Fuel Type: Unleaded gasoline Lubrication System Oil Type: SAE 10W-40 API SE or SF (as per general Suzuki recommendations for this era; refer to manual for exact spec) 🔧 Transmission Standard Transmission Type: 5-speed manual Clutch Type: Wet multi-plate Final Drive: Chain drive Features Gear Ratios: Refer to manual for specific gear ratios Transmission Oil: API GL-4 SAE 80W (typically, refer to manual for exact spec) 📐 Dimensions Exterior Length: Approx. 2095 mm (82.5 in) Width: Approx. 800 mm (31.5 in) Height: Approx. 1160 mm (45.7 in) Wheelbase: Approx. 1375 mm (54.1 in) Weights Dry Weight: Approx. 113 kg (249 lbs) Curb Weight: Approx. 120 kg (265 lbs) (with fluids) Fuel Tank Capacity: Approx. 6.5 L (1.7 US gal) Suspension Front Suspension Type: Telescopic, coil spring, oil damped Rear Suspension Type: Swingarm type, linkless mono-shock, spring pre-load adjustable Wheels Tires Front Tire Size: 80/90-21 48P Rear Tire Size: 100/90-18 56P Front Brake: Disc brake Rear Brake: Drum brake 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycles are not typically rated by standard automotive crash test agencies) Active Features Braking System: Hydraulic front disc and rear drum for...