Suzuki DR200SE, DR200SEV 2000, DR200SEV 2001, DR200SEV 2002, DR200W 1997, DR200W 1998, DR200W 1999, DR200X 2000, DR200X 2001, DR200X 2002 Service Manual
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FOREWORD
This manual contains an introductory description on
SUZUKI DR200SE and procedures for its inspection/service and overhaul of its main components.
Other information considered as generally known is not included.
Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAIN-
TENANCE and other sections to use as a guide for proper inspection and service.
This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service.
* This manual has been prepared on the basis of the latest specification at the time of publication.
If modification have been made since then, differences may exist between the content of this manual and the actual vehicle.
* Illustrations in this manual are used to show the basic principles of operation and work procedures.
They may not represent the actual vehicle exactly in detail.
* This manual is intended for those who have enough knowledge and skills for servicing
SUZUKI vehicles. Without such knowledge and skills, you should not attempt servicing by relying on this manual only.
Instead, please contact your nearby authorized SUZUKI motorcycle dealer.
IMPORTANT
All street-legal Suzuki motorcycles with engine displacement of 50 cc or greater are subject to Environmental Protection agency emission regulations.
These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific information required to properly inspect and service
DR200SE in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and Carburetion be thoroughly reviewed before any type of service work is performed.
Further information concerning the EPA emission regulations and U.S. Suzuki’s emission control program can be found in the U.S. SUZUKI EMISSION
CONTROL PROGRAM MANUAL/SERVICE BULLE-
TIN.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FUEL AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
EMISSION CONTROL
INFORMATION
c
COPYRIGHT SUZUKI MOTOR CORPORATION 1995
1
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3
4
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8
03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
SUPPLEMENTS
DR200SEV/W/X/Y/K1/K2/K3
(’97,'98,'99,'00,'01,'02,'03-MODELS)
9
DR200SEK4/K5 ('04, '05-MODELS)
10
DR200SEK6 ('06-MODEL)
11
DR200SEK7 /K8 ('07 &"08 -MODEL)
12
13
9
DR200SEK4 (’04-MODEL) 10-1
DR200SEK4/K5 (’04, ’05-MODELS)
This chapter describes service specifications and servicing procedurers which differ from those of the DR200SEK3 (’03-MODEL).
NOTE:
* Any differences between the DR200SEK3 (’03-MODEL) and DR200SEK4/K5 (’04, ’05-MOD-
ELS) in specifications are cleary indicated with an asterisk (*) mark.
* Please refer to the capters 1 through 9 for details which are not given in this chapter.
10
2
4
CONTENTS
SPECIFICATIONS ............................................................................. 10- 2
For E-03, 28, 33 ........................................................................ 10- 2
For E-06, 24 .............................................................................. 10- 3
SERVICE DATA ................................................................................ 10- 4
For E-03, 28, 33 ........................................................................ 10- 4
For E-06, 24 .............................................................................. 10-11
TIGHTENING TORQUE ..................................................................... 10-18
GENERATOR ROTOR NUT .............................................................. 10-19
6
10
10-2 DR200SEK4/K5 (’04, ’05-MODELS)
SPECIFICATIONS
For E-03, 28, 33
DIMENSIONS AND DRY MASS
Overall length ......................................................................................
2 150 mm (84.6 in)
Overall width .......................................................................................
805 mm (31.7 in)
Overall height ......................................................................................
1 185 mm (46.7 in)
Wheelbase ..........................................................................................
1 405 mm (55.3 in)
Ground clearance................................................................................
260 mm (10.2 in)
Seat height ..........................................................................................
810 mm (31.9 in)
Dry mass.............................................................................................
113 kg (249 lbs)
ENGINE
Type.....................................................................................................
Four-stroke, air-cooled, OHC
Number of cylinders ............................................................................
1
Bore ....................................................................................................
66.0 mm (2.60 in)
Stroke..................................................................................................
58.2 mm (2.29 in)
Displacement ......................................................................................
199 cm
3
(12.1 cu. in)
Compression ratio ...............................................................................
9.4 : 1
Carburetor ...........................................................................................
MIKUNI BST31SS, single
Air cleaner ...........................................................................................
Polyurethane foam element
Starter system.....................................................................................
Electric
Lubrication system ..............................................................................
Wet sump
Idle speed ...........................................................................................
1 500 ± 100 r/min
DRIVE TRAIN
Clutch ..................................................................................................
Wet multi-plate type
Transmission .......................................................................................
5 speed constant mesh
Gearshift pattern .................................................................................
1-down, 4-up
Primary reduction................................................................................
3.157 (60/19)
Final reduction ....................................................................................
3.000 (45/15)
Gear ratios, Low ..............................................................................
3.000 (33/11)
2nd ...............................................................................
1.933 (29/15)
3rd................................................................................
1.437 (23/16)
4th ................................................................................
1.095 (23/21)
Top ...............................................................................
0.913 (21/23)
Drive chain ..........................................................................................
D.I.D. 520VC.5, 112 links
CHASSIS
Front suspension.................................................................................
Telescopic, coil spring, oil damped
Rear suspension .................................................................................
Link type, coil spring, oil damped
Steering angle .....................................................................................
43° (right & left)
Caster .................................................................................................
29° 00’
Trail......................................................................................................
112 mm (4.4 in)
Turning radius .....................................................................................
2.3 m (7.5 ft)
Front brake ..........................................................................................
Disk brake
Rear brake ..........................................................................................
Drum brake
Front tire size ......................................................................................
70/100-21M/C 44P tube type
Rear tire size .......................................................................................
100/90-18M/C 56P tube type
ELECTRICAL
Ignition type.........................................................................................
Electronic ignition (Transistorized)
Ignition timing ......................................................................................
7° B.T.D.C. at 1 500 r/min
Spark plug ...........................................................................................
NGK DR8EA or DENSO X24ESR-U
Battery.................................................................................................
12V 21.6 kC (6 Ah/10 HR)
Generator ............................................................................................
Three-phase A.C. generator
Fuse ....................................................................................................
20A
Headlight .............................................................................................
12V 60/55W
Brake light/Taillight ..............................................................................
12V 21/5W
Turn signal light ...................................................................................
12V 21W
Speedometer light ...............................................................................
12V 3.4W
Neutral indicator light ..........................................................................
12V 3.4W
Turn signal indicator light ....................................................................
12V 3.4W
High beam indicator light ....................................................................
12V 1.7W
CAPACITIES
Fuel tank, including reserve ..............................................................
12.5 L (3.3/2.7 US/Imp gal) ….. E-33
13.0 L (3.4/2.9 US/Imp gal) ….. Others reserve ............................................................................
2.5 L (0.7/0.5 US/Imp gal)
Engine oil change.............................................................................
850 ml (0.9/0.7 US/Imp qt) with filter change .............................................................
950 ml (1.0/0.8 US/Imp qt) overhaul...........................................................................
1 100 ml (1.2/1.0 US/lmp qt)
DR200SEK4/K5 (’04, ’05-MODELS) 10-3
For E-06, 24
DIMENSIONS AND DRY MASS
Overall length .....................................................................................
2 220 mm (87.4 in)
Overall width.......................................................................................
805 mm (31.7 in) ..... E-06
940 mm (37.0 in) ..... E-24
Overall height .....................................................................................
1 185 mm (46.6 in)
Wheelbase .........................................................................................
1 405 mm (55.3 in)
Ground clearance ...............................................................................
260 mm (10.2 in)
Seat height .........................................................................................
850 mm (33.5 in)
Dry mass ............................................................................................
121 kg (266 lbs) ..... E-06
120 kg (264 lbs) ..... E-24
ENGINE
Type ....................................................................................................
Four-stroke, air-cooled, OHC
Number of cylinders ...........................................................................
1
Bore....................................................................................................
66.0 mm (2.598 in)
Stroke .................................................................................................
58.2 mm (2.291 in)
Displacement......................................................................................
199 cm
3
(12.1 cu. in)
Compression ratio ..............................................................................
9.4 : 1
Carburetor ..........................................................................................
MIKUNI BST31SS, single
Air cleaner ..........................................................................................
Polyurethane foam element
Starter system ....................................................................................
Electric and kick
Lubrication system .............................................................................
Wet sump
Idle speed ...........................................................................................
1 500 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................
Wet multi-plate type
Transmission.......................................................................................
5 speed constant mesh
Gearshift pattern.................................................................................
1-down, 4-up
Primary reduction ratio .......................................................................
3.157 (60/19)
Final reduction ratio ............................................................................
3.916 (47/12)
Gear ratios, Low..............................................................................
3.000 (33/11)
2nd ..............................................................................
1.933 (29/15)
3rd ...............................................................................
1.437 (23/16)
4th ...............................................................................
1.095 (23/21)
Top...............................................................................
0.913 (21/23)
Drive chain..........................................................................................
DID520V, 112 links
CHASSIS
Front suspension ................................................................................
Telescopic, coil spring, oil damped
Rear suspension ................................................................................
Link type, coil spring, oil damped
Front fork stroke..................................................................................
205 mm (8.1 in)
Rear wheel travel................................................................................
205 mm (8.1 in)
Steering angle ....................................................................................
43° (right & left)
Caster.................................................................................................
29°
Trail .....................................................................................................
112 mm (4.4 in)
Turning radius .....................................................................................
2.3 m (7.5 ft)
Front brake .........................................................................................
Disk brake
Rear brake..........................................................................................
Drum brake
Front tire size ......................................................................................
70/100-21 44M tube type
Rear tire size ......................................................................................
90/100-18 54M tube type
ELECTRICAL
Ignition type ........................................................................................
Electronic ignition (C.D.I.)
Ignition timing .....................................................................................
7° B.T.D.C. at 1 500 rpm
Spark plug ..........................................................................................
NGK DR8EA or DENSO X24ESR-U
Battery ................................................................................................
12V 21.6 kC (6 Ah) 10 HR
Generator ...........................................................................................
Three-phase A.C. generator
Fuse ...................................................................................................
20A
Headlight ............................................................................................
12V 60/55W
Turn signal light ..................................................................................
12V 15W ..... E-06 only
Brake light/Taillight..............................................................................
12V 21/5W
Speedometer light ..............................................................................
12V 1.7W
Neutral indicator light..........................................................................
12V 2W
Turn signal indicator light....................................................................
12V 2W
High beam indicator light ....................................................................
12V 2W
CAPACITIES
Fuel tank, including reserve ..............................................................
13.0 L (3.4/2.9 US/Imp gal) reserve .............................................................................
2.5 L (0.7/0.5 US/Imp gal)
Engine oil, oil change .......................................................................
950 ml (1.0/0.8 US/Imp qt) with filter change.............................................................
1 050 ml (1.1/0.9 US/Imp qt) overhaul ..........................................................................
1 200 ml (1.3/1.1 US/Imp qt)
10-4 DR200SEK4/K5 (’04, ’05-MODELS)
SERVICE DATA
For E-03, 28, 33
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
INNER
OUTER
STANDARD
33
(1.3)
28
(1.1)
0.08 – 0.13
(0.003 – 0.005)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
—
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2146 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
—
—
—
0.9 – 1.1
(0.04 – 0.05)
—
—
—
7.1 – 9.2 kgf
(15.7 – 20.3 lbs) at length 32.5 mm (1.28 in)
17.3 – 21.3 kgf
(38.1 – 47.0 lbs) at length 36.0 mm (1.42 in)
Unit: mm (in)
LIMIT
—
—
—
—
—
0.35
(0.014)
—
—
—
0.05
(0.002)
0.5
(0.02)
2.6
(0.1)
—
0.03
(0.001)
35.1
(1.38)
40.6
(1.60)
—
—
DR200SEK4/K5 (’04, ’05-MODELS) 10-5
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
IN. & EX.
IN. & EX.
Camshaft runout
Rocker arm I.D.
IN. & EX.
IN. & EX.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
IN. & EX.
IN. & EX.
STANDARD
34.174 – 34.218
(1.3454 – 1.3472)
33.804 – 33.848
(1.3309 – 1.3326)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
—
12.000 – 12.018
(0.4724 – 0.4731)
11.977 – 11.995
(0.4715 – 0.4722)
—
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 400 kPa
(14 kgf/cm
2
, 199 psi)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
0.040 – 0.050
(0.0016 – 0.0020)
66.000 – 66.015
(2.5984 – 2.5990)
65.955 – 65.970
(2.5966 – 2.5972)
Measure at 15 mm (0.59 in) from the skirt end.
—
Piston ring free end gap
1st R Approx. 7.5 (0.30)
2nd R
Piston ring end gap
Piston ring to groove clearance
1st
2nd
1st
2nd
Approx. 9.4 (0.37)
0.10 – 0.25
(0.004 – 0.010)
0.10 – 0.25
(0.004 – 0.010)
—
—
Unit: mm (in)
LIMIT
33.870
(1.3335)
33.500
(1.3189)
0.150
(0.0059)
—
—
0.10
(0.004)
—
—
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
980 kPa
(9.8 kgf/cm
139 psi)
2 ,
0.120
(0.0047)
66.090
(2.6020)
65.880
(2.5937)
0.05
(0.002)
6.0
(0.24)
7.5
(0.30)
0.5
(0.02)
0.5
(0.02)
0.18
(0.007)
0.15
(0.006)
10-6 DR200SEK4/K5 (’04, ’05-MODELS)
ITEM
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
1st
2nd
Oil
1st
2nd
STANDARD
1.01 – 1.03
(0.040 – 0.041)
1.21 – 1.23
(0.047 – 0.048)
2.01 – 2.03
(0.079 – 0.080)
0.970 – 0.990
(0.038 – 0.039)
1.170 – 1.190
(0.046 – 0.047)
16.002 – 16.008
(0.6300 – 0.6302)
15.996 – 16.000
(0.6298 – 0.6299)
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
—
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.09 ± 0.004)
—
STANDARD
2.000 (30/15)
Above 15 kPa (0.15 kgf/cm 2 , 2.1 psi)
Below 35 kPa (0.35 kgf/cm 2 at 3 000 r/min
, 4.9 psi)
CLUTCH
ITEM
Clutch lever play
Clutch release screw
Clutch plate thickness
Driven plate distortion
Clutch spring free length
1 pc
5 pcs
STANDARD
10 – 15
(0.4 – 0.6)
1/4
!
turn back
2.9 – 3.1
(0.114 – 0.122)
2.95 – 3.15
(0.116 – 0.124)
—
—
LIMIT
—
—
Unit: mm (in)
LIMIT
—
—
2.6
(0.10)
0.10
(0.004)
31.0
(1.22)
LIMIT
—
—
—
—
—
16.030
(0.6311)
15.980
(0.6291)
Unit: mm (in)
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.00
(0.039)
—
—
0.08
(0.003)
DR200SEK4/K5 (’04, ’05-MODELS) 10-7
TRANSMISSTION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
No.1,2,3
No.1,2,3
Type
Links
20-pitch length
Drive chain slack
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Starter jet
Pilot screw
Throttle cable play
STANDARD
3.157 (60/19)
3.000 (45/15)
3.000 (33/11)
1.933 (29/15)
1.437 (23/16)
1.095 (23/21)
0.913 (21/23)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.20 – 0.21)
4.8 – 4.9
(0.18 – 0.19)
DID 520VC5
112 links
—
25 – 40
(1.0 – 1.6)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
—
—
—
—
319.4
(12.57)
—
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(G.S.)
(P.S.)
E-03, 28
MIKUNI BST31SS
SPECIFICATION
31 mm
42AC
1 500 ± 100 r/min
13.0 ± 1.0 mm (0.51 ± 0.04 in)
#
5D77
#125
#
#25
PRE-SET
2 – 4 mm (0.08 – 0.16 in)
E-33
←
←
42AE
←
←
←
←
←
←
←
←
←
←
10-8 DR200SEK4/K5 (’04, ’05-MODELS)
ELECTRICAL
Spark plug
ITEM
Spark performance
Signal coil resitance
Ignition coil resistance
Type
Gap
Primary
SPECIFICATION
DENSO: X24ESR-U
NGK: CR8EA
0.6 – 0.7
(0.024 – 0.028)
Over 8 mm (0.3) at 1 atm.
100 – 140
Ω
2 – 6
Ω
Generator coil resistance
Generator no-load voltage
Generator Max. output
Regulated voltage
Starter relay resistance
Battery Type designation
Capacity
Fuse size
Secondary 20 – 30 k
Ω
Charging 0.1 – 1.5
Ω
More than 60 V (AC) at 5 000 r/min
150 W at 5 000 r/min
13.0 – 16.0 V at 5 000 r/min
2 – 6
Ω
YTX7L-BS
12 V 21.6 kC (6 Ah)/10 HR
20 A
WATTAGE
ITEM
Headlight
Brake light/Taillight
Turn signal light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
HI
LO
SPECIFICATION
60
55
21/5
21
3.4
3.4
1.7
3.4
Unit: mm (in)
NOTE
G – Bl
Terminal –
Terminal
Plug cap –
Terminal
Unit: W
BRAKE + WHEEL
ITEM
Brake lever play
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Brake lining thickness
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Wheel rim runout
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
DR200SEK4/K5 (’04, ’05-MODELS) 10-9
Front
Axial
Radial
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Rear
Rear
Front
Front
Front
Front
Front
STANDARD
0.1 – 0.3
(0.004 – 0.010)
20 – 30
(0.8 – 1.2)
2.5
(0.10)
—
—
3.5 ± 0.2
(0.138 ± 0.008)
—
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
33.960 – 34.010
(1.3370 – 1.3390)
33.878 – 33.928
(1.3338 – 1.3357)
—
—
—
—
J21 × 1.60
J18 × 2.15
70/100-21 44P or 70/100-21 M/C 44P
100/90-18 56P or 100/90-18 M/C 56P
—
—
Unit: mm (in)
LIMIT
—
—
—
130.7
(5.15)
1.5
(0.06)
3.0
(0.12)
0.30
(0.012)
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
3.0
(0.12)
3.0
(0.12)
10-10 DR200SEK4/K5 (’04, ’05-MODELS)
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Rear shock absorber spring pre-set length
Rear wheel travel
Swingarm pivot shaft runout
STANDARD
205
(8.1)
—
179.5
(7.07)
231
(9.1)
205
(8.1)
—
LIMIT
—
561
(22.1)
—
—
—
0.6
(0.02)
Unit: mm (in)
NOTE
TIRE PRESSUER
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
FUEL + OIL
ITEM
Fuel type kPa
150
175
SOLO RIDING kgf/cm 2
1.50
1.75
psi
22
25 kPa
150
200
DUAL RIDING kgf/cm 2
1.50
2.00
psi
22
29
Fuel tank including
Engine oil type
Engine oil capacity reserve reserve
Front fork oil type
Front fork oil capacity (each leg)
Brake fluid type
SPECIFICATION
Use only unleaded gasoline of at least 87 pump octane (R/2+M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE
(Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
13.0 L
(3.4/2.9 US/lmp qt)
12.5 L
(3.3/2.7 US/lmp qt)
2.5 L
(0.7/0.5 US/lmp qt)
Change
SAE 10W-40, API SF or SG
850 ml
(0.90/0.75 US/lmp qt)
Filter change
Overhaul
950 ml
(1.00/0.84 US/lmp qt)
1 100 ml
(1.2/1.0 US/lmp qt)
Fork oil #10
309 ml
(10.4/10.9 US/lmp oz)
DOT 4
NOTE
E-03, 28
E-33
DR200SEK4/K5 (’04, ’05-MODELS) 10-11
For E-06, 24
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
INNER
OUTER
STANDARD
33
(1.3)
28
(1.1)
0.08 – 0.13
(0.003 – 0.005)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
—
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2146 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
—
—
—
0.9 – 1.1
(0.04 – 0.05)
—
—
—
7.1 – 9.2 kgf
(15.7 – 20.3 lbs) at length 32.5 mm (1.28 in)
17.3 – 21.3 kgf
(38.1 – 47.0 lbs) at length 36.0 mm (1.42 in)
Unit: mm (in)
LIMIT
—
—
—
—
—
0.35
(0.014)
—
—
—
0.05
(0.002)
0.5
(0.02)
2.6
(0.1)
—
0.03
(0.001)
35.1
(1.38)
40.6
(1.60)
—
—
10-12 DR200SEK4/K5 (’04, ’05-MODELS)
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
IN. & EX.
IN. & EX.
Camshaft runout
Rocker arm I.D.
IN. & EX.
IN. & EX.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
IN. & EX.
IN. & EX.
STANDARD
34.174 – 34.218
(1.3454 – 1.3472)
33.804 – 33.848
(1.3309 – 1.3326)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
—
12.000 – 12.018
(0.4724 – 0.4731)
11.977 – 11.995
(0.4715 – 0.4722)
—
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 400 kPa
(14 kgf/cm
2
, 199 psi)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
0.040 – 0.050
(0.0016 – 0.0020)
66.000 – 66.015
(2.5984 – 2.5990)
65.955 – 65.970
(2.5966 – 2.5972)
Measure at 15 mm (0.59 in) from the skirt end.
—
Piston ring free end gap
1st R Approx. 7.5 (0.30)
2nd R
Piston ring end gap
Piston ring to groove clearance
1st
2nd
1st
2nd
Approx. 9.4 (0.37)
0.10 – 0.25
(0.004 – 0.010)
0.10 – 0.25
(0.004 – 0.010)
—
—
Unit: mm (in)
LIMIT
33.870
(1.3335)
33.500
(1.3189)
0.150
(0.0059)
—
—
0.10
(0.004)
—
—
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
980 kPa
(9.8 kgf/cm 2 ,
139 psi)
0.120
(0.0047)
66.090
(2.6020)
65.880
(2.5937)
0.05
(0.002)
6.0
(0.24)
7.5
(0.30)
0.5
(0.02)
0.5
(0.02)
0.18
(0.007)
0.15
(0.006)
ITEM
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
1st
2nd
Oil
1st
2nd
STANDARD
1.01 – 1.03
(0.040 – 0.041)
1.21 – 1.23
(0.047 – 0.048)
2.01 – 2.03
(0.079 – 0.080)
0.970 – 0.990
(0.038 – 0.039)
1.170 – 1.190
(0.046 – 0.047)
16.002 – 16.008
(0.6300 – 0.6302)
15.996 – 16.000
(0.6298 – 0.6299)
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
—
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.09 ± 0.004)
—
STANDARD
2.000 (30/15)
Above 15 kPa (0.15 kgf/cm 2
Below 35 kPa (0.35 kgf/cm at 3 000 r/min
2
, 2.1 psi)
, 4.9 psi)
CLUTCH
ITEM
Clutch lever play
Clutch release screw
Clutch plate thickness
Driven plate distortion
Clutch spring free length
1 pc
5 pcs
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turn back
2.9 – 3.1
(0.114 – 0.122)
2.95 – 3.15
(0.116 – 0.124)
—
—
DR200SEK4/K5 (’04, ’05-MODELS) 10-13
LIMIT
—
—
Unit: mm (in)
LIMIT
—
—
2.6
(0.10)
0.10
(0.004)
31.0
(1.22)
LIMIT
—
—
—
—
—
16.030
(0.6311)
15.980
(0.6291)
Unit: mm (in)
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.00
(0.039)
—
—
0.08
(0.003)
10-14 DR200SEK4/K5 (’04, ’05-MODELS)
TRANSMISSTION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
No.1,2,3
No.1,2,3
Type
Links
20-pitch length
Drive chain slack
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Main air jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Valve seat
Starter jet
Pilot screw
Throttle cable play
(M.J.)
(M.A.J)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(V.S.)
(G.S.)
(P.S.)
STANDARD
3.157 (60/19)
3.916 (47/12)
3.000 (33/11)
1.933 (29/15)
1.437 (23/16)
1.095 (23/21)
0.913 (21/23)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.20 – 0.21)
4.8 – 4.9
(0.18 – 0.19)
DID 520VC5
112 links, ENDLESS
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
—
—
—
—
319.4
(12.57)
25 – 40
(1.0 – 1.6)
—
SPECIFICATION
MIKUNI BST31SS
31 mm
42AA
1 500 ± 100 r/min
13.0 ± 1.0 mm (0.51 ± 0.04 in)
#122.5
0.8 mm
5D26-3rd
P-5
#125
#40
1.5 mm
#25
1 and 1/2 turns out
3 – 6 mm (0.1 – 0.2 in)
DR200SEK4/K5 (’04, ’05-MODELS) 10-15
ELECTRICAL
Ignition timing
Spark plug
ITEM
Spark performance
Signal coil resitance
Ignition coil resistance
Type
Gap
Primary
SPECIFICATION
7°B.T.D.C. Below at 1 500 r/min
DENSO: X24ESR-U
NGK: CR8EA
0.6 – 0.7
(0.024 – 0.028)
Over 8 mm (0.3) at 1 atm.
100 – 140
Ω
0.14 – 0.18
Ω
Secondary 15 – 18 k
Ω
Signal coil peak voltage
3.0 – 4.6 V
Ignition coil primary peak voltage
Generator coil resistance
Generator no-load voltage
Regulated voltage
Starter relay resistance
Battery Type designation
Capacity
Standard electrolyte S.G.
Fuse size
125 – 195 V
Charging 0.1 – 1.5
Ω
More than 70 V (AC) at 5 000 r/min
13.0 – 16.0 V at 5 000 r/min
2 – 6
Ω
YTX7L-BS
12 V 21.6 kC (6 Ah)/10 HR
1.32 at 20 °C (68 °F)
20 A
WATTAGE
ITEM
Headlight
HI
LO
Brake light/Taillight
Turn signal light
(For South Africa)
Speedometer light
Turn signal indicator light
(Fpr South Afriaca)
High beam indicator light
Neutral indicator light
SPECIFICATION
60
55
21/5
21
1.7
2
2
2
Unit: mm (in)
NOTE
G – Bl
Terminal –
Terminal
Plug cap –
Terminal
+
G/W –
-
Bl/Y
-
White –
+
Ground
—
Unit: W
10-16 DR200SEK4/K5 (’04, ’05-MODELS)
BRAKE + WHEEL
ITEM
Brake lever play
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Brake lining thickness
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Wheel rim runout
Wheel axle runout
Tire size
Tire tread depth
Front
Axial
Radial
Front
Rear
Front
Rear
Front
Rear
Rear
Rear
Front
Front
Front
Front
Front
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Rear shock absorber spring pre-set length
Rear wheel travel
Swingarm pivot shaft runout
STANDARD
205
(8.1)
—
179.5
(7.07)
231
(9.1)
205
(8.1)
—
STANDARD
0.1 – 0.3
(0.004 – 0.010)
20 – 30
(0.8 – 1.2)
2.5
(0.10)
—
—
3.5 ± 0.2
(0.138 ± 0.008)
—
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
33.960 – 34.010
(1.3370 – 1.3390)
33.878 – 33.928
(1.3338 – 1.3357)
—
—
—
—
70/100-21 44M
90/100-18 54M
—
—
LIMIT
—
561
(22.1)
—
—
—
0.6
(0.02)
Unit: mm (in)
LIMIT
—
—
—
130.7
(5.15)
1.5
(0.06)
3.0
(0.12)
0.30
(0.012)
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
40
(0.16)
4.0
(0.16)
Unit: mm (in)
NOTE
DR200SEK4/K5 (’04, ’05-MODELS) 10-17
TIRE PRESSUER
E-24
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
E-06
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
FUEL + OIL
ITEM
Fuel type
Fuel tank including
Engine oil type
Engine oil capacity reserve reserve
Front fork oil type
Front fork oil capacity (each leg)
Brake fluid type kPa
100
100
SOLO RIDING kgf/cm 2
1.0
1.0
psi
15
15 kPa
100
100
SOLO RIDING kgf/cm 2
1.0
1.0
psi
15
15 kPa
100
100
DUAL RIDING kgf/cm 2
1.0
1.0
psi
15
15
SPECIFICATION
Gasoline used should be graded 85 – 95 octane or higher. An unleaded gasoline is recommended.
13.0 L
(3.4/2.9 US/lmp qt)
Change
2.5 L
(0.7/0.5 US/lmp qt)
SAE 10W-40, API SF or SG
Filter change
950 ml
(1.0/0.8 US/lmp qt)
1 050 ml
(1.1/0.9 US/lmp qt)
Overhaul
1 200 ml
(1.3/1.1 US/lmp qt)
Fork oil #10
309 ml
(10.4/10.9 US/lmp oz)
DOT 4
NOTE
10-18 DR200SEK4/K5 (’04, ’05-MODELS)
TIGHTENING TORQUE
ENGINE
Cylinder head cover bolt
ITEM
Camshaft sprocket bolt
Cylinder head nut 8 mm Diam.
Cylinder head nut 6 mm Diam.
Cylinder base nut
Starter clutch securing bolt
Cam drive chain tension adjuster bolt
Generator rotor nut
Crankcase bolt
Primary drive gear nut
Clutch cover bolt and generator cover bolt
Starter motor lead wire connecting bolt
Starter motor mounting bolt
Clutch sleeve hub nut
Gearshift arm stopper
Engine oil drain plug
Oil filter cap nut and oil pump filter cap bolt
Engine sprocket bolt
Engine mounting bolt (Top side)
Engine mounting bolt (Front side)
Engine mounting bolt (Rear side)
Engine mounting bracket bolt
Exhaust pipe nut
Muffler connection bolt
Muffler mounting bolt (Front side)
Muffler mounting bolt (Rear side)
88
10
41
23
28
7
25
41
23
23
44
25
10
50
19
*80
11
50
10
10
10
25
7
N·m
10
11
27
2.0
5.0
18.0
29.5
63.5
7.0
29.5
16.5
16.5
16.5
32.0
58
8.0
36.0
7.0
1.8
7.0
36.0
13.5
lb-ft
7.0
8.0
19.5
7.0
7.0
18.0
5.0
8.8
1.0
4.1
2.3
2.8
0.7
2.5
4.1
2.3
2.3
4.4
8.0
1.1
5.0
1.0
0.25
1.0
5.0
1.9
kgf-m
1.0
1.1
2.7
1.0
1.0
2.5
0.7
GENERATOR ROTOR NUT
REASSEMBLY
• Hold the generator rotor using the special tool, and tighten the generator rotor nut to the specified torque.
"
09930-44511: Rotor holder
#
Generator rotor nut
A
: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
DR200SEK4/K5 (’04, ’05-MODELS) 10-19
DR200SEK6 (’06-MODEL)
DR200SEK4 (’04-MODEL) 10-1
This chapter describes service specifications and servicing procedurers which differ from those of the DR200SEK4/K5 (’04, ’05-MODELS).
NOTE:
* Any differences between the DR200SEK4/K5 (’04, ’05-MODELS) and DR200SEK6 (’06-
MODEL) in specifications are cleary indicated with an asterisk (*) mark.
* Please refer to the capters 1 through 10 for details which are not given in this chapter.
2
11
4
CONTENTS
SPECIFICATIONS ............................................................................. 11- 2
For E-03, 28, 33 ........................................................................ 11- 2
For E-06, 24 .............................................................................. 11- 3
SERVICE DATA ................................................................................ 11- 4
For E-03, 28, 33 ........................................................................ 11- 4
For E-06, 24 .............................................................................. 11-11
6
11
11-2 DR200SEK6 (’06-MODEL)
SPECIFICATIONS
For E-03, 28, 33
DIMENSIONS AND DRY MASS
Overall length ......................................................................................
2 150 mm (84.6 in)
Overall width .......................................................................................
805 mm (31.7 in)
Overall height ......................................................................................
1 185 mm (46.7 in)
Wheelbase ..........................................................................................
1 405 mm (55.3 in)
Ground clearance................................................................................
260 mm (10.2 in)
Seat height ..........................................................................................
810 mm (31.9 in)
Dry mass.............................................................................................
113 kg (249 lbs)
ENGINE
Type.....................................................................................................
Four-stroke, air-cooled, OHC
Number of cylinders ............................................................................
1
Bore ....................................................................................................
66.0 mm (2.60 in)
Stroke..................................................................................................
58.2 mm (2.29 in)
Displacement ......................................................................................
199 cm
3
(12.1 cu. in)
Compression ratio ...............................................................................
9.4 : 1
Carburetor ...........................................................................................
MIKUNI BST31SS, single
Air cleaner ...........................................................................................
Polyurethane foam element
Starter system.....................................................................................
Electric
Lubrication system ..............................................................................
Wet sump
Idle speed ...........................................................................................
1 500 ± 100 r/min
DRIVE TRAIN
Clutch ..................................................................................................
Wet multi-plate type
Transmission .......................................................................................
5 speed constant mesh
Gearshift pattern .................................................................................
1-down, 4-up
Primary reduction................................................................................
3.157 (60/19)
Final reduction ....................................................................................
3.000 (45/15)
Gear ratios, Low ..............................................................................
3.000 (33/11)
2nd ...............................................................................
1.933 (29/15)
3rd................................................................................
1.437 (23/16)
4th ................................................................................
1.095 (23/21)
Top ...............................................................................
0.913 (21/23)
Drive chain ..........................................................................................
D.I.D. 520VC.5, 112 links
CHASSIS
Front suspension.................................................................................
Telescopic, coil spring, oil damped
Rear suspension .................................................................................
Link type, coil spring, oil damped
Steering angle .....................................................................................
43° (right & left)
Caster .................................................................................................
29° 00’
Trail......................................................................................................
112 mm (4.4 in)
Turning radius .....................................................................................
2.3 m (7.5 ft)
Front brake ..........................................................................................
Disc brake
Rear brake ..........................................................................................
Drum brake
Front tire size ......................................................................................
70/100-21M/C 44P tube type
Rear tire size .......................................................................................
100/90-18M/C 56P tube type
ELECTRICAL
Ignition type.........................................................................................
Electronic ignition (Transistorized)
Ignition timing ......................................................................................
7° B.T.D.C. at 1 500 r/min
Spark plug ...........................................................................................
NGK DR8EA or DENSO X24ESR-U
Battery.................................................................................................
12 V 21.6 kC (6 Ah/10 HR)
Generator ............................................................................................
Three-phase A.C. generator
Fuse ....................................................................................................
20 A
Headlight .............................................................................................
12 V 60/55 W
Brake light/Taillight ..............................................................................
12 V 21/5 W
Turn signal light ...................................................................................
12 V 21 W
Speedometer light ...............................................................................
12 V 3.4 W
Neutral indicator light ..........................................................................
12 V 3.4 W
Turn signal indicator light ....................................................................
12 V 3.4 W
High beam indicator light ....................................................................
12 V 1.7 W
CAPACITIES
Fuel tank, including reserve ............................................................
12.5 L (3.3/2.7 US/Imp gal)....... E-33
13.0 L (3.4/2.9 US/Imp gal)....... Others reserve............................................................................
2.5 L (0.7/0.5 US/Imp gal)
Engine oil change ............................................................................
850 ml (0.9/0.7 US/Imp qt) with filter change.............................................................
950 ml (1.0/0.8 US/Imp qt) overhaul ..........................................................................
1 100 ml (1.2/1.0 US/lmp qt)
For E-06, 24
DIMENSIONS AND DRY MASS
Overall length .....................................................................................
2 220 mm (87.4 in)
Overall width.......................................................................................
805 mm (31.7 in) ...... E-06
940 mm (37.0 in) ...... E-24
Overall height .....................................................................................
1 185 mm (46.6 in)
Wheelbase .........................................................................................
1 405 mm (55.3 in)
Ground clearance ...............................................................................
260 mm (10.2 in)
Seat height .........................................................................................
850 mm (33.5 in)
Dry mass ............................................................................................
121 kg (266 lbs) ....... E-06
120 kg (264 lbs) ....... E-24
ENGINE
Type ....................................................................................................
Four-stroke, air-cooled, OHC
Number of cylinders ...........................................................................
1
Bore....................................................................................................
66.0 mm (2.598 in)
Stroke .................................................................................................
58.2 mm (2.291 in)
Displacement......................................................................................
199 cm 3 (12.1 cu. in)
Compression ratio ..............................................................................
9.4 : 1
Carburetor ..........................................................................................
MIKUNI BST31SS, single
Air cleaner ..........................................................................................
Polyurethane foam element
Starter system ....................................................................................
Electric and kick
Lubrication system .............................................................................
Wet sump
Idle speed ...........................................................................................
1 500 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................
Wet multi-plate type
Transmission.......................................................................................
5 speed constant mesh
Gearshift pattern.................................................................................
1-down, 4-up
Primary reduction ratio .......................................................................
3.157 (60/19)
Final reduction ratio ............................................................................
3.916 (47/12)
Gear ratios, Low..............................................................................
3.000 (33/11)
2nd ..............................................................................
1.933 (29/15)
3rd ...............................................................................
1.437 (23/16)
4th ...............................................................................
1.095 (23/21)
Top...............................................................................
0.913 (21/23)
Drive chain..........................................................................................
DID520V, 112 links
CHASSIS
Front suspension ................................................................................
Telescopic, coil spring, oil damped
Rear suspension ................................................................................
Link type, coil spring, oil damped
Front fork stroke..................................................................................
205 mm (8.1 in)
Rear wheel travel................................................................................
205 mm (8.1 in)
Steering angle ....................................................................................
43° (right & left)
Caster.................................................................................................
29°
Trail .....................................................................................................
112 mm (4.4 in)
Turning radius .....................................................................................
2.3 m (7.5 ft)
Front brake .........................................................................................
Disc brake
Rear brake..........................................................................................
Drum brake
Front tire size ......................................................................................
70/100-21 44M tube type
Rear tire size ......................................................................................
90/100-18 54M tube type
ELECTRICAL
Ignition type ........................................................................................
Electronic ignition (C.D.I.)
Ignition timing .....................................................................................
7° B.T.D.C. at 1 500 rpm
Spark plug ..........................................................................................
NGK DR8EA or DENSO X24ESR-U
Battery ................................................................................................
12 V 21.6 kC (6 Ah) 10 HR
Generator ...........................................................................................
Three-phase A.C. generator
Fuse ...................................................................................................
20 A
Headlight ............................................................................................
12V 60/55 W
Turn signal light ..................................................................................
12 V 15 W ......E-06 only
Brake light/Taillight..............................................................................
12 V 21/5 W
Speedometer light ..............................................................................
12 V 1.7 W
Neutral indicator light..........................................................................
12 V 2 W
Turn signal indicator light....................................................................
12 V 2 W
High beam indicator light ....................................................................
12 V 2 W
CAPACITIES
Fuel tank, including reserve............................................................
13.0 L (3.4/2.9 US/Imp gal) reserve ...........................................................................
2.5 L (0.7/0.5 US/Imp gal)
Engine oil, oil change.......................................................................
950 ml (1.0/0.8 US/Imp qt) with filter change 1 050 ml (1.1/0.9 US/Imp qt) overhaul 1 200 ml (1.3/1.1 US/Imp qt)
DR200SEK6 (’06-MODEL) 11-3
11-4 DR200SEK6 (’06-MODEL)
SERVICE DATA
For E-03, 28, 33
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
INNER
OUTER
STANDARD
33
(1.3)
28
(1.1)
0.08 – 0.13
(0.003 – 0.005)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
—
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2146 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
—
—
—
0.9 – 1.1
(0.04 – 0.05)
—
—
—
70 – 90 N
(7.1 – 9.2 kgf, 15.7 – 20.3 lbs) at length 32.5 mm (1.28 in)
170 – 209 N
(17.3 – 21.3 kgf, 38.1 – 47.0 lbs) at length 36.0 mm (1.42 in)
Unit: mm (in)
LIMIT
—
—
—
—
—
0.35
(0.014)
—
—
—
0.05
(0.002)
0.5
(0.02)
2.6
(0.1)
—
0.03
(0.001)
35.1
(1.38)
40.6
(1.60)
—
—
DR200SEK6 (’06-MODEL) 11-5
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
IN. & EX.
IN. & EX.
Camshaft runout
Rocker arm I.D.
IN. & EX.
IN. & EX.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
IN. & EX.
IN. & EX.
STANDARD
34.174 – 34.218
(1.3454 – 1.3472)
33.804 – 33.848
(1.3309 – 1.3326)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
—
12.000 – 12.018
(0.4724 – 0.4731)
11.977 – 11.995
(0.4715 – 0.4722)
—
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 400 kPa
(14 kgf/cm 2 , 199 psi)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
0.040 – 0.050
(0.0016 – 0.0020)
66.000 – 66.015
(2.5984 – 2.5990)
65.955 – 65.970
(2.5966 – 2.5972)
Measure at 15 mm (0.59 in) from the skirt end.
—
Piston ring free end gap
1st R Approx. 7.5 (0.30)
Piston ring end gap
Piston ring to groove clearance
2nd R
1st
2nd
1st
2nd
Approx. 9.4 (0.37)
0.10 – 0.25
(0.004 – 0.010)
0.10 – 0.25
(0.004 – 0.010)
—
—
Unit: mm (in)
LIMIT
33.870
(1.3335)
33.500
(1.3189)
0.150
(0.0059)
—
—
0.10
(0.004)
—
—
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
980 kPa
(9.8 kgf/cm
2
,
139 psi)
0.120
(0.0047)
66.090
(2.6020)
65.880
(2.5937)
0.05
(0.002)
6.0
(0.24)
7.5
(0.30)
0.5
(0.02)
0.5
(0.02)
0.18
(0.007)
0.15
(0.006)
11-6 DR200SEK6 (’06-MODEL)
ITEM
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
1st
2nd
Oil
1st
2nd
STANDARD
1.01 – 1.03
(0.040 – 0.041)
1.21 – 1.23
(0.047 – 0.048)
2.01 – 2.03
(0.079 – 0.080)
0.970 – 0.990
(0.038 – 0.039)
1.170 – 1.190
(0.046 – 0.047)
16.002 – 16.008
(0.6300 – 0.6302)
15.996 – 16.000
(0.6298 – 0.6299)
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
—
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.09 ± 0.004)
—
STANDARD
2.000 (30/15)
Above 15 kPa (0.15 kgf/cm 2 , 2.1 psi)
Below 35 kPa (0.35 kgf/cm
2
, 4.9 psi) at 3 000 r/min
CLUTCH
ITEM
Clutch lever play
Clutch release screw
Clutch plate thickness
Driven plate distortion
Clutch spring free length
1 pc.
5 pcs.
STANDARD
10 – 15
(0.4 – 0.6)
1/4
!
turn back
2.9 – 3.1
(0.114 – 0.122)
2.95 – 3.15
(0.116 – 0.124)
—
—
LIMIT
LIMIT
—
—
Unit: mm (in)
LIMIT
—
—
2.6
(0.10)
0.10
(0.004)
31.0
(1.22)
—
—
16.030
(0.6311)
15.980
(0.6291)
Unit: mm (in)
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.00
(0.039)
—
—
0.08
(0.003)
DR200SEK6 (’06-MODEL) 11-7
TRANSMISSTION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
No.1, 2, 3
No.1, 2, 3
Type
Links
20-pitch length
Drive chain slack
STANDARD
3.157 (60/19)
3.000 (45/15)
3.000 (33/11)
1.933 (29/15)
1.437 (23/16)
1.095 (23/21)
0.913 (21/23)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.20 – 0.21)
4.8 – 4.9
(0.18 – 0.19)
D.I.D. 520VC5
112 links
—
25 – 40
(1.0 – 1.6)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
—
—
—
—
319.4
(12.57)
—
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Starter jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(G.S.)
(P.S.)
E-03, 28
MIKUNI BST31SS
31 mm
SPECIFICATION
42AC
1 500 ± 100 r/min
13.0 ± 1.0 mm (0.51 ± 0.04 in)
#
5D77
#125
#
#25
PRE-SET
2 – 4 mm (0.08 – 0.16 in)
E-33
←
←
42AE
←
←
←
←
←
←
←
←
←
←
11-8 DR200SEK6 (’06-MODEL)
ELECTRICAL
Spark plug
ITEM
Spark performance
Signal coil resitance
Ignition coil resistance
Type
Gap
Primary
SPECIFICATION
DENSO: X24ESR-U
NGK: CR8EA
0.6 – 0.7
(0.024 – 0.028)
Over 8 mm (0.3) at 1 atm.
100 – 140
Ω
2 – 6
Ω
Generator coil resistance
Generator no-load voltage
Generator Max. output
Regulated voltage
Starter relay resistance
Battery Type designation
Capacity
Fuse size
Secondary 20 – 30 k
Ω
Charging 0.1 – 1.5
Ω
More than 60 V (AC) at 5 000 r/min
150 W at 5 000 r/min
13.0 – 16.0 V at 5 000 r/min
2 – 6
Ω
YTX7L-BS
12 V 21.6 kC (6 Ah)/10 HR
20 A
WATTAGE
ITEM
Headlight
Brake light/Taillight
Turn signal light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
HI
LO
SPECIFICATION
60
55
21/5
21
3.4
3.4
1.7
3.4
Unit: mm (in)
NOTE
G – Bl
Terminal –
Terminal
Plug cap –
Terminal
Unit: W
BRAKE + WHEEL
ITEM
Brake lever play
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Brake lining thickness
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Wheel rim runout
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
Front
Axial
Radial
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Rear
Rear
Front
Front
Front
Front
Front
STANDARD
0.1 – 0.3
(0.004 – 0.010)
20 – 30
(0.8 – 1.2)
2.5
(0.10)
—
—
3.5 ± 0.2
(0.138 ± 0.008)
—
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
33.960 – 34.010
(1.3370 – 1.3390)
33.878 – 33.928
(1.3338 – 1.3357)
—
—
—
—
J21 × 1.60
J18 × 2.15
70/100-21 M/C 44P
100/90-18 M/C 56P
—
—
DR200SEK6 (’06-MODEL) 11-9
Unit: mm (in)
LIMIT
—
—
—
130.7
(5.15)
1.5
(0.06)
3.0
(0.12)
0.30
(0.012)
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
3.0
(0.12)
3.0
(0.12)
11-10 DR200SEK6 (’06-MODEL)
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Rear shock absorber spring pre-set length
Rear wheel travel
Swingarm pivot shaft runout
STANDARD
205
(8.1)
—
179.5
(7.07)
231
(9.1)
205
(8.1)
—
LIMIT
—
561
(22.1)
—
—
—
0.6
(0.02)
Unit: mm (in)
NOTE
TIRE PRESSUER
COLD INFLATION
TIRE PRESSURE
FRONT
REAR kPa
150
175
SOLO RIDING kgf/cm
2
1.50
1.75
psi
22
25 kPa
150
200
DUAL RIDING kgf/cm
2
1.50
2.00
psi
22
29
FUEL + OIL
Fuel type
ITEM
Fuel tank capacity
Engine oil type
Engine oil capacity
Front fork oil type
Brake fluid type including reserve reserve
Front fork oil capacity (each leg)
SPECIFICATION
Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE
(Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
13.0 L
(3.4/2.9 US/lmp qt)
12.5 L
(3.3/2.7 US/lmp qt)
2.5 L
(0.7/0.5 US/lmp qt)
* SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Change
850 ml
(0.90/0.75 US/lmp qt)
Filter change
Overhaul
950 ml
(1.00/0.84 US/lmp qt)
1 100 ml
(1.2/1.0 US/lmp qt)
Fork oil #10
309 ml
(10.4/10.9 US/lmp oz)
DOT 4
NOTE
E-03, 28
E-33
DR200SEK6 (’06-MODEL) 11-11
For E-06, 24
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
INNER
OUTER
STANDARD
33
(1.3)
28
(1.1)
0.08 – 0.13
(0.003 – 0.005)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
—
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2146 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
—
—
—
0.9 – 1.1
(0.04 – 0.05)
—
—
—
70 – 90 N
(7.1 – 9.2 kgf, 15.7 – 20.3 lbs) at length 32.5 mm (1.28 in)
170 – 209 N
(17.3 – 21.3 kgf, 38.1 – 47.0 lbs) at length 36.0 mm (1.42 in)
Unit: mm (in)
LIMIT
—
—
—
—
—
0.35
(0.014)
—
—
—
0.05
(0.002)
0.5
(0.02)
2.6
(0.1)
—
0.03
(0.001)
35.1
(1.38)
40.6
(1.60)
—
—
11-12 DR200SEK6 (’06-MODEL)
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
IN. & EX.
IN. & EX.
Camshaft runout
Rocker arm I.D.
IN. & EX.
IN. & EX.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
IN. & EX.
IN. & EX.
STANDARD
34.174 – 34.218
(1.3454 – 1.3472)
33.804 – 33.848
(1.3309 – 1.3326)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
—
12.000 – 12.018
(0.4724 – 0.4731)
11.977 – 11.995
(0.4715 – 0.4722)
—
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 400 kPa
(14 kgf/cm 2 , 199 psi)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
0.040 – 0.050
(0.0016 – 0.0020)
66.000 – 66.015
(2.5984 – 2.5990)
65.955 – 65.970
(2.5966 – 2.5972)
Measure at 15 mm (0.59 in) from the skirt end.
—
Piston ring free end gap
1st R Approx. 7.5 (0.30)
Piston ring end gap
Piston ring to groove clearance
2nd R
1st
2nd
1st
2nd
Approx. 9.4 (0.37)
0.10 – 0.25
(0.004 – 0.010)
0.10 – 0.25
(0.004 – 0.010)
—
—
Unit: mm (in)
LIMIT
33.870
(1.3335)
33.500
(1.3189)
0.150
(0.0059)
—
—
0.10
(0.004)
—
—
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
980 kPa
(9.8 kgf/cm
2
,
139 psi)
0.120
(0.0047)
66.090
(2.6020)
65.880
(2.5937)
0.05
(0.002)
6.0
(0.24)
7.5
(0.30)
0.5
(0.02)
0.5
(0.02)
0.18
(0.007)
0.15
(0.006)
ITEM
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
1st
2nd
Oil
1st
2nd
STANDARD
1.01 – 1.03
(0.040 – 0.041)
1.21 – 1.23
(0.047 – 0.048)
2.01 – 2.03
(0.079 – 0.080)
0.970 – 0.990
(0.038 – 0.039)
1.170 – 1.190
(0.046 – 0.047)
16.002 – 16.008
(0.6300 – 0.6302)
15.996 – 16.000
(0.6298 – 0.6299)
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
—
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.09 ± 0.004)
—
STANDARD
2.000 (30/15)
Above 15 kPa (0.15 kgf/cm 2 , 2.1 psi)
Below 35 kPa (0.35 kgf/cm
2
, 4.9 psi) at 3 000 r/min
CLUTCH
ITEM
Clutch lever play
Clutch release screw
Clutch plate thickness
Driven plate distortion
Clutch spring free length
1 pc.
5 pcs.
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turn back
2.9 – 3.1
(0.114 – 0.122)
2.95 – 3.15
(0.116 – 0.124)
—
—
DR200SEK6 (’06-MODEL) 11-13
LIMIT
LIMIT
—
—
Unit: mm (in)
LIMIT
—
—
2.6
(0.10)
0.10
(0.004)
31.0
(1.22)
—
—
16.030
(0.6311)
15.980
(0.6291)
Unit: mm (in)
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.00
(0.039)
—
—
0.08
(0.003)
11-14 DR200SEK6 (’06-MODEL)
TRANSMISSTION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
No.1, 2, 3
No.1, 2, 3
Type
Links
20-pitch length
Drive chain slack
CARBURETOR
Carburetor type
ITEM
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Main air jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Valve seat
Starter jet
Pilot screw
Throttle cable play
(M.J.)
(M.A.J)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(V.S.)
(G.S.)
(P.S.)
STANDARD
3.157 (60/19)
3.916 (47/12)
3.000 (33/11)
1.933 (29/15)
1.437 (23/16)
1.095 (23/21)
0.913 (21/23)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.20 – 0.21)
4.8 – 4.9
(0.18 – 0.19)
D.I.D. 520VC5
112 links, ENDLESS
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
—
—
—
—
319.4
(12.57)
25 – 40
(1.0 – 1.6)
—
SPECIFICATION
MIKUNI BST31SS
31 mm
42AA
1 500 ± 100 r/min
13.0 ± 1.0 mm (0.51 ± 0.04 in)
#122.5
0.8 mm
5D26-3rd
P-5
#125
#40
1.5 mm
#25
1 and 1/2 turns out
2 – 4 mm (0.08 – 0.16 in)
ELECTRICAL
Ignition timing
Spark plug
ITEM
Spark performance
Signal coil resitance
Ignition coil resistance
Type
Gap
Primary
SPECIFICATION
7°B.T.D.C. Below at 1 500 r/min
DENSO: X24ESR-U
NGK: CR8EA
0.6 – 0.7
(0.024 – 0.028)
Over 8 mm (0.3) at 1 atm.
100 – 140
Ω
0.14 – 0.18
Ω
Secondary 15 – 18 k
Ω
Signal coil peak voltage
3.0 – 4.6 V
Ignition coil primary peak voltage
Generator coil resistance
Generator no-load voltage
Regulated voltage
Starter relay resistance
Battery Type designation
Capacity
Standard electrolyte S.G.
Fuse size
125 – 195 V
Charging 0.1 – 1.5
Ω
More than 70 V (AC) at 5 000 r/min
13.0 – 16.0 V at 5 000 r/min
2 – 6
Ω
YTX7L-BS
12 V 21.6 kC (6 Ah)/10 HR
1.32 at 20 °C (68 °F)
20 A
WATTAGE
ITEM
Headlight
HI
LO
Brake light/Taillight
Turn signal light
(For South Africa)
Speedometer light
Turn signal indicator light
(Fpr South Afriaca)
High beam indicator light
Neutral indicator light
SPECIFICATION
60
55
21/5
21
1.7
2
2
2
DR200SEK6 (’06-MODEL) 11-15
Unit: mm (in)
NOTE
G – Bl
Terminal –
Terminal
Plug cap –
Terminal
+
G/W –
-
Bl/Y
-
White –
+
Ground
—
Unit: W
11-16 DR200SEK6 (’06-MODEL)
BRAKE + WHEEL
ITEM
Brake lever play
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Brake lining thickness
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Wheel rim runout
Wheel axle runout
Tire size
Tire tread depth
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Rear shock absorber spring pre-set length
Rear wheel travel
Swingarm pivot shaft runout
Front
Axial
Radial
Front
Rear
Front
Rear
Front
Rear
Rear
Rear
Front
Front
Front
Front
Front
STANDARD
205
(8.1)
—
179.5
(7.07)
231
(9.1)
205
(8.1)
—
STANDARD
0.1 – 0.3
(0.004 – 0.010)
20 – 30
(0.8 – 1.2)
2.5
(0.10)
—
—
3.5 ± 0.2
(0.138 ± 0.008)
—
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
33.960 – 34.010
(1.3370 – 1.3390)
33.878 – 33.928
(1.3338 – 1.3357)
—
—
—
—
70/100-21 44M
90/100-18 54M
—
—
LIMIT
—
561
(22.1)
—
—
—
0.6
(0.02)
Unit: mm (in)
LIMIT
—
—
—
130.7
(5.15)
1.5
(0.06)
3.0
(0.12)
0.30
(0.012)
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
40
(0.16)
4.0
(0.16)
Unit: mm (in)
NOTE
DR200SEK6 (’06-MODEL) 11-17
TIRE PRESSUER
E-24
COLD INFLATION
TIRE PRESSURE
FRONT
REAR kPa
100
100
SOLO RIDING kgf/cm 2
1.0
1.0
psi
15
15
E-06
COLD INFLATION
TIRE PRESSURE
FRONT
REAR kPa
100
100
SOLO RIDING kgf/cm 2
1.0
1.0
psi
15
15 kPa
100
100
DUAL RIDING kgf/cm 2
1.0
1.0
psi
15
15
FUEL + OIL
Fuel type
ITEM
Fuel tank capacity
Engine oil type
Engine oil capacity
Front fork oil type
Brake fluid type including reserve reserve
Front fork oil capacity (each leg)
SPECIFICATION
Gasoline used should be graded 85 – 95 octane or higher. An unleaded gasoline is recommended.
13.0 L
(3.4/2.9 US/lmp qt)
2.5 L
(0.7/0.5 US/lmp qt)
* SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Change
950 ml
(1.0/0.8 US/lmp qt)
Filter change
Overhaul
1 050 ml
(1.1/0.9 US/lmp qt)
1 200 ml
(1.3/1.1 US/lmp qt)
Fork oil #10
309 ml
(10.4/10.9 US/lmp oz)
DOT 4
NOTE
DR200SEK4 (’04-MODEL) 10-1
DR200SEK7 /K8 ('07 &’08 -MODEL S )
NOTE:
* Any differences between the DR200SEK6 ('06-MODEL) and DR200SEK ('07-MODEL) in specifications are cleary indicated with an asterisk (*) mark.
* Please refer to the capters 1 through 11 for details which are not given in this chapter.
For E-06, 24 service data are same as K6 MODEL.
2
12
4
CONTENTS
SPECIFICATIONS ............................................................................. 12- 2
For E-03, 28, 33 ........................................................................ 12- 2
SERVICE DATA ................................................................................ 12- 3
For E-03, 28, 33 ........................................................................ 12- 3
6
11
12- 2 DR200SEK7
/K8
(’07
&’08
-MODEL)
SPECIFICATIONS
For E-03, 28, 33
DIMENSIONS AND DRY MASS
Overall length ......................................................................................
2 150 mm (84.6 in)
Overall width........................................................................................
805 mm (31.7 in)
Overall height ......................................................................................
1 185 mm (46.7 in)
Wheelbase ..........................................................................................
1 405 mm (55.3 in)
Ground clearance................................................................................
260 mm (10.2 in)
Seat height ..........................................................................................
810 mm (31.9 in)
Dry mass .............................................................................................
113 kg (249 lbs)
ENGINE
Type.....................................................................................................
Four-stroke, air-cooled, OHC
Number of cylinders ............................................................................
1
Bore.....................................................................................................
66.0 mm (2.60 in)
Stroke ..................................................................................................
58.2 mm (2.29 in)
Displacement ......................................................................................
199 cm 3 (12.1 cu. in)
Compression ratio ...............................................................................
9.4 : 1
Carburetor ...........................................................................................
MIKUNI BST31SS, single
Air cleaner ...........................................................................................
Polyurethane foam element
Starter system .....................................................................................
Electric
Lubrication system ..............................................................................
Wet sump
Idle speed............................................................................................
1 500 ± 100 r/min
DRIVE TRAIN
Clutch ..................................................................................................
Wet multi-plate type
Transmission .......................................................................................
5 speed constant mesh
Gearshift pattern .................................................................................
1-down, 4-up
Primary reduction ................................................................................
3.157 (60/19)
Final reduction.....................................................................................
3.000 (45/15)
Gear ratios, Low...............................................................................
3.000 (33/11)
2nd ...............................................................................
1.933 (29/15)
3rd ................................................................................
1.437 (23/16)
4th ................................................................................
1.095 (23/21)
Top ...............................................................................
0.913 (21/23)
Drive chain ..........................................................................................* D.I.D. 520V, 112 links
CHASSIS
Front suspension .................................................................................
Telescopic, coil spring, oil damped
Rear suspension .................................................................................
Link type, coil spring, oil damped
Steering angle .....................................................................................
43° (right & left)
Caster..................................................................................................
29° 00’
Trail......................................................................................................
112 mm (4.4 in)
Turning radius......................................................................................
2.3 m (7.5 ft)
Front brake ..........................................................................................
Disc brake
Rear brake...........................................................................................
Drum brake
Front tire size.......................................................................................
70/100-21M/C 44P tube type
Rear tire size .......................................................................................
100/90-18M/C 56P tube type
ELECTRICAL
Ignition type .........................................................................................
Electronic ignition (Transistorized)
Ignition timing ......................................................................................
7° B.T.D.C. at 1 500 r/min
Spark plug ...........................................................................................
NGK DR8EA or DENSO X24ESR-U
Battery.................................................................................................
12 V 21.6 kC (6 Ah/10 HR)
Generator ............................................................................................
Three-phase A.C. generator
Fuse ....................................................................................................
20 A
Headlight .............................................................................................
12 V 60/55 W
Brake light/Taillight ..............................................................................
12 V 21/5 W
Turn signal light ...................................................................................
12 V 21 W
Speedometer light ...............................................................................
12 V 3.4 W
Neutral indicator light...........................................................................
12 V 3.4 W
Turn signal indicator light.....................................................................
12 V 3.4 W
High beam indicator light.....................................................................
12 V 1.7 W
CAPACITIES
Fuel tank, including reserve ..............................................................
12.5 L (3.3/2.7 US/Imp gal)....... E-33
13.0 L (3.4/2.9 US/Imp gal)....... Others reserve .............................................................................
2.5 L (0.7/0.5 US/Imp gal)
Engine oil change .............................................................................
850 ml (0.9/0.7 US/Imp qt) with filter change ..............................................................
950 ml (1.0/0.8 US/Imp qt) overhaul............................................................................
1 100 ml (1.2/1.0 US/lmp qt)
– 2 –
DR200SEK7
/K8
(’07
&’08
-MODEL) 12- 3
SERVICE DATA
For E-03, 28, 33
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
INNER
OUTER
STANDARD
33
(1.3)
28
(1.1)
0.08 – 0.13
(0.003 – 0.005)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
—
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2146 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
—
—
—
0.9 – 1.1
(0.04 – 0.05)
—
—
—
70 – 90 N
(7.1 – 9.2 kgf, 15.7 – 20.3 lbs) at length 32.5 mm (1.28 in)
170 – 209 N
(17.3 – 21.3 kgf, 38.1 – 47.0 lbs) at length 36.0 mm (1.42 in)
Unit: mm (in)
LIMIT
—
—
—
—
—
0.35
(0.014)
—
—
—
0.05
(0.002)
0.5
(0.02)
2.6
(0.1)
—
0.03
(0.001)
35.1
(1.38)
40.6
(1.60)
—
—
– 3 –
12- 4 DR200SEK7
/K8
(’07
&’08
-MODEL)
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
IN. & EX.
IN. & EX.
Camshaft runout
Rocker arm I.D.
IN. & EX.
IN. & EX.
IN. & EX.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
IN. & EX.
STANDARD
34.174 – 34.218
(1.3454 – 1.3472)
33.804 – 33.848
(1.3309 – 1.3326)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
—
12.000 – 12.018
(0.4724 – 0.4731)
11.977 – 11.995
(0.4715 – 0.4722)
—
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 400 kPa
(14 kgf/cm 2 , 199 psi)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
0.040 – 0.050
(0.0016 – 0.0020)
66.000 – 66.015
(2.5984 – 2.5990)
65.955 – 65.970
(2.5966 – 2.5972)
Measure at 15 mm (0.59 in) from the skirt end.
—
Piston ring free end gap
1st R Approx. 7.5 (0.30)
Piston ring end gap
Piston ring to groove clearance
2nd R
1st
2nd
1st
2nd
Approx. 9.4 (0.37)
0.10 – 0.25
(0.004 – 0.010)
0.10 – 0.25
(0.004 – 0.010)
—
—
—
0.10
(0.004)
—
—
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
33.870
(1.3335)
33.500
(1.3189)
0.150
(0.0059)
—
Unit: mm (in)
LIMIT
980 kPa
(9.8 kgf/cm
2
,
139 psi)
0.120
(0.0047)
66.090
(2.6020)
65.880
(2.5937)
0.05
(0.002)
6.0
(0.24)
7.5
(0.30)
0.5
(0.02)
0.5
(0.02)
0.18
(0.007)
0.15
(0.006)
– 4 –
ITEM
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
1st
2nd
Oil
1st
2nd
STANDARD
DR200SEK7
/K8
(’07
&’08
-MODEL) 12- 5
LIMIT
1.01 – 1.03
(0.040 – 0.041)
1.21 – 1.23
(0.047 – 0.048)
2.01 – 2.03
(0.079 – 0.080)
0.970 – 0.990
(0.038 – 0.039)
1.170 – 1.190
(0.046 – 0.047)
16.002 – 16.008
(0.6300 – 0.6302)
15.996 – 16.000
(0.6298 – 0.6299)
—
—
16.030
(0.6311)
15.980
(0.6291)
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
—
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.09 ± 0.004)
—
Unit: mm (in)
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.00
(0.039)
—
—
0.08
(0.003)
STANDARD
2.000 (30/15)
Above 15 kPa (0.15 kgf/cm 2
Below 35 kPa (0.35 kgf/cm at 3 000 r/min
2
, 2.1 psi)
, 4.9 psi)
LIMIT
—
—
CLUTCH
ITEM
Clutch lever play
Clutch release screw
Clutch plate thickness
Driven plate distortion
Clutch spring free length
1 pc.
5 pcs.
STANDARD
10 – 15
(0.4 – 0.6)
1/4
turn back
2.9 – 3.1
(0.114 – 0.122)
2.95 – 3.15
(0.116 – 0.124)
—
—
Unit: mm (in)
LIMIT
—
—
2.6
(0.10)
0.10
(0.004)
31.0
(1.22)
– 5 –
12- 6 DR200SEK7
/K8
(’07
&’08
-MODEL)
TRANSMISSTION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
No.1, 2, 3
No.1, 2, 3
Type
Links
20-pitch length
Drive chain slack
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Starter jet
Pilot screw
Throttle cable play
STANDARD
3.157 (60/19)
3.000 (45/15)
3.000 (33/11)
1.933 (29/15)
1.437 (23/16)
1.095 (23/21)
0.913 (21/23)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.20 – 0.21)
4.8 – 4.9
(0.18 – 0.19)
* D.I.D. 520V5
112 links
—
25 – 40
(1.0 – 1.6)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
—
—
—
—
319.4
(12.57)
—
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(G.S.)
(P.S.)
E-03, 28
MIKUNI BST31SS
31 mm
SPECIFICATION
42AC
1 500 ± 100 r/min
13.0 ± 1.0 mm (0.51 ± 0.04 in)
#
5D77
#125
#
#25
PRE-SET
2 – 4 mm (0.08 – 0.16 in)
E-33
←
←
←
←
←
←
←
←
42AE
←
←
←
←
– 6 –
DR200SEK7
/K8
(’07
&’08
-MODEL) 12- 7
ELECTRICAL
Spark plug
ITEM
Spark performance
Signal coil resitance
Ignition coil resistance
Type
Gap
Primary
SPECIFICATION
DENSO: X24ESR-U
NGK: CR8EA
0.6 – 0.7
(0.024 – 0.028)
Over 8 mm (0.3) at 1 atm.
100 – 140
Ω
2 – 6
Ω
Generator coil resistance
Generator no-load voltage
Generator Max. output
Regulated voltage
Starter relay resistance
Battery Type designation
Capacity
Fuse size
Secondary 20 – 30 k
Ω
Charging 0.1 – 1.5
Ω
More than 60 V (AC) at 5 000 r/min
150 W at 5 000 r/min
13.0 – 16.0 V at 5 000 r/min
2 – 6
Ω
YTX7L-BS
12 V 21.6 kC (6 Ah)/10 HR
20 A
Unit: mm (in)
NOTE
G – Bl
Terminal –
Terminal
Plug cap –
Terminal
WATTAGE
ITEM
Headlight
Brake light/Taillight
Turn signal light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
HI
LO
SPECIFICATION
60
55
21/5
21
3.4
3.4
1.7
3.4
Unit: W
– 7 –
12- 8 DR200SEK7
/K8
(’07
&’08
-MODEL)
BRAKE + WHEEL
ITEM
Brake lever play
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Brake lining thickness
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Wheel rim runout
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
Front
Front
Front
Front
Rear
Rear
Front
Front
Axial
Radial
Front
Rear
Front
Rear
Front
Rear
Front
Rear
STANDARD
0.1 – 0.3
(0.004 – 0.010)
20 – 30
(0.8 – 1.2)
2.5
(0.10)
—
—
3.5 ± 0.2
(0.138 ± 0.008)
—
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
33.960 – 34.010
(1.3370 – 1.3390)
33.878 – 33.928
(1.3338 – 1.3357)
—
—
—
—
J21 × 1.60
J18 × 2.15
70/100-21 M/C 44P
100/90-18 M/C 56P
—
—
Unit: mm (in)
LIMIT
—
—
—
130.7
(5.15)
1.5
(0.06)
3.0
(0.12)
0.30
(0.012)
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
3.0
(0.12)
3.0
(0.12)
– 8 –
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Rear shock absorber spring pre-set length
Rear wheel travel
STANDARD
205
(8.1)
—
179.5
(7.07)
231
(9.1)
205
(8.1)
—
DR200SEK7
/K8
(’07
&’08
-MODEL) 12- 9
Unit: mm (in)
NOTE LIMIT
—
561
(22.1)
—
—
Swingarm pivot shaft runout
—
0.6
(0.02)
TIRE PRESSUER
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
FUEL + OIL
ITEM
Fuel type kPa
150
175
SOLO RIDING kgf/cm 2
1.50
1.75
psi
22
25 kPa
150
200
DUAL RIDING kgf/cm 2
1.50
2.00
Fuel tank capacity
Engine oil type
Engine oil capacity
Front fork oil type
Brake fluid type including reserve reserve
Front fork oil capacity (each leg)
SPECIFICATION
Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE
(Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
13.0 L
(3.4/2.9 US/lmp qt)
12.5 L
(3.3/2.7 US/lmp qt)
2.5 L
(0.7/0.5 US/lmp qt)
SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Change
850 ml
(0.90/0.75 US/lmp qt)
Filter change
Overhaul
950 ml
(1.00/0.84 US/lmp qt)
1 100 ml
(1.2/1.0 US/lmp qt)
Fork oil #10
309 ml
(10.4/10.9 US/lmp oz)
DOT 4 psi
22
29
NOTE
E-03, 28
E-33
– 9 –
DR200SEK 9 (’0 9 -MODEL)
DR200SEK9 (’09-MODEL) 13-1
#/.4%.43
0!'%
52'%+(+%#6+105
%
NOTE:
* Differences between K9-MODEL and K8-MODEL specifications are indicated as an asterisk mark (*).
* The service data are the same as the K8-MODEL.
13
13-2 DR200SEK9 (’09-MODEL)
SPECIFICATIONS
(E-03, 28, 33)
DIMENSIONS AND CURB MASS
Overall length ......................................................................................
2 150 mm (84.6 in)
Overall width........................................................................................
805 mm (31.7 in)
Overall height ......................................................................................
1 185 mm (46.7 in)
Wheelbase ..........................................................................................
1 405 mm (55.3 in)
Ground clearance................................................................................
260 mm (10.2 in)
Seat height ..........................................................................................
810 mm (31.9 in)
* Curb mass ........................................................................................
126 kg (278 lbs)
ENGINE
Type.....................................................................................................
Four-stroke, air-cooled, OHC
Number of cylinders ............................................................................
1
Bore.....................................................................................................
66.0 mm (2.60 in)
Stroke ..................................................................................................
58.2 mm (2.29 in)
Displacement ......................................................................................
199 cm 3 (12.1 cu. in)
Compression ratio ...............................................................................
9.4 : 1
Carburetor ...........................................................................................
MIKUNI BST31SS, single
Air cleaner ...........................................................................................
Polyurethane foam element
Starter system .....................................................................................
Electric
Lubrication system ..............................................................................
Wet sump
Idle speed............................................................................................
1 500 ± 100 r/min
DRIVE TRAIN
Clutch ..................................................................................................
Wet multi-plate type
Transmission .......................................................................................
5 speed constant mesh
Gearshift pattern .................................................................................
1-down, 4-up
Primary reduction ................................................................................
3.157 (60/19)
Final reduction.....................................................................................
3.000 (45/15)
Gear ratios, Low...............................................................................
3.000 (33/11)
2nd ...............................................................................
1.933 (29/15)
3rd ................................................................................
1.437 (23/16)
4th ................................................................................
1.095 (23/21)
Top ...............................................................................
0.913 (21/23)
Drive chain ..........................................................................................
DID 520V, 112 links
CHASSIS
Front suspension .................................................................................
Telescopic, coil spring, oil damped
Rear suspension .................................................................................
Link type, coil spring, oil damped
Front fork stroke ..................................................................................
205 mm (8.1 in)
Rear wheel travel ................................................................................
205 mm (8.1 in)
Caster..................................................................................................
29°
Trail......................................................................................................
112 mm (4.4 in)
Steering angle .....................................................................................
43° (right & left)
Turning radius......................................................................................
2.3 m (7.5 ft)
Front brake ..........................................................................................
Disc brake
Rear brake...........................................................................................
Drum brake
Front tire ..............................................................................................
70/100-21M/C 44P, tube type
Rear tire ..............................................................................................
100/90-18M/C 56P, tube type
ELECTRICAL
Ignition type .........................................................................................
Electronic ignition (Transistorized)
Ignition timing ......................................................................................
7° B.T.D.C. at 1 500 r/min
Spark plug ...........................................................................................
NGK DR8EA or DENSO X24ESR-U
Battery.................................................................................................
12 V 21.6 kC (6 Ah)/10 HR
Generator ............................................................................................
Three-phase A.C. generator
Fuse ....................................................................................................
20 A
Headlight .............................................................................................
12 V 60/55 W
Brake light/Taillight ..............................................................................
12 V 21/5 W
Turn signal light ...................................................................................
12 V 21 W
Speedometer light ...............................................................................
12 V 3.4 W
Neutral indicator light...........................................................................
12 V 3.4 W
Turn signal indicator light.....................................................................
12 V 3.4 W
High beam indicator light.....................................................................
12 V 1.7 W
CAPACITIES
Fuel tank, including reserve ..............................................................
12.5 L (3.3/2.7 US/Imp gal)..... E-33
13.0 L (3.4/2.9 US/Imp gal)..... Others reserve .............................................................................
2.5 L (0.7/0.5 US/Imp gal)
Engine oil change .............................................................................
850 ml (0.9/0.7 US/Imp qt) with filter change ..............................................................
950 ml (1.0/0.8 US/Imp qt) overhaul............................................................................
1 100 ml (1.2/1.0 US/lmp qt)
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