1998 Suzuki DR200SE

Suzuki DR200 SAE Torque Specs

Rear Axle Nut 47 ft/lbs (DR-200-Owners-Manual)

Other Specifications SAE

Chain Slack 1" - 1.6" (DR-200-Owners-Manual)

Tightening the Chain

Measure the total movement up and down of the chain. It should only move 1" - 1.6" ,this is the total movement of the chain from top to bottom.

Required Parts

Take out old cotter pin and loosten the axle of the bike.

Take out the old cotter pin located on the left axle bolt of the bike.

After the cotter pin is out loosten the left axle bolt of the bike.

Jack up the bike

Leave the bike on its kickstand and slide the jack underneath the mid section of the bike from the right side.

Mark a spot on the chain

Wipe off the spot that is to be marked with a paper towel to remove any dirt or grease. Then mark the spot with a paint marker. This spot is so you have a reference point to measure the chain travel. Make sure to mark the chain in 3 different spots roughly 25" apart. This will help ensure that no spot in the chain is overly tight or loose.

Move the rear tire backward

Move the rear tire backward until the chain feels reasonably tight. Make sure to keep the spacing the same on each side.

Measure the tightness of the chain

Hold a tape measure against the floor and measure the total movement of the chain. The chain should only move an 1 1/2". Make sure to measure the chain in 3 different spots to asure that it isn't too tight or lose in any one spot. You can probably have about 1/2" to 3/4" tolerance when measuring the spots on the chain. If a spot on the chain differs more than that you may have a bent sprocket.

Snug up rear axle bolt

Snug up the rear axle bolt but don't torque it.

Lower the bike from the jack

Lower the bike from the jack. Make sure the kickstand is down so the bike doesn't fall over when you lower it.

Torque the rear axle bolt

Torque the rear axle bolt to 58 ft/lbs., make sure that both sides of the axle bolt have the same spacing.

Replacing Headlight

Required Tools

Required Parts

Remove the front plastic covering the light

Be careful when taking the screws out not to lose the little spacers.

Take a #2 philips and remove the screw on the right side of the bike.

Repeat this again for the left side of the bike.

The third and last screw that needs to be removed is on the front of the bike.

Once the screws are removed you can thread them back into their holes to prevent losing them.

Remove the old bulb

Remove the plug from the back of the bulb.

Remove the rubber cover.

Once the rubber cover is off you'll see a metal clip. Press down(towards the front of the bike) and then lift the clip up to disconnect it.

The bulb should now be free to remove.

To install the new bulb repeat these steps in reverse, make sure that the rubber seal is facing the right direction. You'll see a "Top"marking on the seal, make sure that it's pointing up or else the water may get in the bulb. Also, make sure that you don't touch the bulb as the oil from your skin will reduce the life of the bulb.(ref1,ref2)

Replacing Tail Light

Installing a cigarette lighter on a 1998 Suzuki DR200

Required parts for Installing a cigarette adapter on a 1998 Suzuki DR200

Changing Engine Oil

Oil Filter:K&N KN-132

Suzuki Original Oil Filter part number could be any one of these: 16510-19B00, 16510-24501, 16510-25C00

Replacing the Helmet Lock on a 1998 Suzuki DR200

Replacement options

Lithium Replacement Batteries for Suzuki DR200SE

Custom Suzuki DR200SE Wind Fairings

Rear Tires Compatible with Suzuki DR200SE