the DR200 thread

Discussion in 'Thumpers' started by klxrdr, May 13, 2007.

  1. Sateev

    Sateev Been here awhile

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    One mark, but you can see it on compression (when the valves are closed) OR during overlap. So it should be "actually at tdc ON THE COMPRESSION STROKE".

    As for the feeler gauges, try to find ones with narrower, tapered ends, and bend the one you need about 45 degrees, 3/4" from the end. It will slip in much easier that way. It's nesrly impossible to do with the standard width feeler gauges.
  2. Jodaddy

    Jodaddy Been here awhile

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    Guess I better try again. Does the mark on the flywheel have an "0" at the top of it? Thanks, Joe
  3. Jodaddy

    Jodaddy Been here awhile

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    So I did it again and now I have rattlesnakes in the motor instead of squirrels. Tapping like crazy. Any insight here? Pic of the flywheel mark? I might just pull the whole cover tomorrow so I can see the cam and cam sprocket while I rotate the motor. Lobes down and piston up marks on flwheel and cover aligning should be tdc. Think I need a can of patience before I touch another wrench. Thanks. Joe
  4. no

    no kidding

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    I don't have a picture of the mark, but I think it's just a hashmark on the flywheel. Watch the motion of the valves as you slowly turn the motor counter-clockwise. Shortly after the intake valve closes, the hashmark should come around. Make sure the spark plug is out so the engine's easy to turn.
  5. Jodaddy

    Jodaddy Been here awhile

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    That is exactly how i did it. Round three here we go. Thanks everybody for your help. Joe
  6. Jodaddy

    Jodaddy Been here awhile

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    Much better. Squirrels are back. Took a bent feeler to get in there for me feel comfortable with the settings. Thanks again for the help. Ive got one more question. What is your favorite online parts store and why? Cheap is good but service and getting the proper parts is more important to me.
  7. no

    no kidding

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    I usually just order from Bikebandit. Shopping around a little probably could get you lower prices, but I'm lazy.
  8. Sateev

    Sateev Been here awhile

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    There is a Suzuki OEM part number (12140-19B10-050) for a 0.5mm oversize piston/ring set, which leads me to believe that the cylinder is machinable, and the dealer is full of the well-known article. Probably has a cylinder on the shelf he wants to get rid of...
  9. bradluke0

    bradluke0 Been here awhile

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    Hi all ! Talked to Suzuki USA and they don't know if the cylinder is serviceable or not . Called a different local dealer and they don't know either . Hard to believe I'm the first person to ever put a set of rings in a DR200 . If it is iron I would hone and use new rings , if not I will just put it back together . Being they make a .5 mm larger piston makes me believe it's iron , looking at it I see no sleeve and it looks all aluminum . My gaskets won't be here until tomorrow so if I can't find out for sure I will just reassemble it .
  10. Andyinhilo

    Andyinhilo Long timer

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    They do know, but did not realize it...

    Just check here: http://www.suzukicycles.com/Product%20Lines/Cycles/Products/DR200SE/2013/DR200SE.aspx#Features

    For this statement:
    <table id="FeaturesTable" cellpadding="0" cellspacing="0"><tbody><tr><td class="" width="30px">
    </td><td class="FeaturesData">Suzuki Composite Electrochemical Material (SCEM)-plated cylinder for durability, lightweight and superior heat transfer
    </td></tr></tbody></table>
  11. bross

    bross Where we riding to?

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    Was trying to learn something here myself and came across this...


    All of the Japanese motorcycle manufacturers caution against using any type of hone in a plated cylinder. Its not that its an impossible task, its just because it’s a difficult thing to do correctly. Here are some basic rules for honing light scratches, burnt oil, and minor aluminum scuffs on nickel-plated cylinders. 1) Use a ball-hone with a diameter that is 10% smaller than the cylinder bore size, 240-360 grit, and made of aluminum-oxide material. 2) Never ever use a three-shoe stone hone because they will chip the port edges. 3) Coat the cylinder and ball-hone in oil before honing the cylinder. 4) Chuck the ball-hone in a drill and put the hone in the cylinder completely before turning. 5) Run the drill at a slow speed and stroke the hone back and forth in the bore for about ten strokes. Cylinders that are nickel-plated are very hard (83 Rockwell C Scale) so you can’t remove any metal with a ball-hone. I usually hone a cylinder every time I change the piston assembly. Ball-honing polishes down high spots and sharp port edges without damaging the plating. Ball-honing will insure that the piston and rings have a smooth cross-hatched surface to mate with. Kawasaki cylinders use a different bore material and plating method. The tungsten material is very thin and vulnerable. For those cylinders I suggest using a piece of Scotch-Brite to hand strip the cylinder bore of burnt oil. Whenever you hone a cylinder you should clean the cylinder in mineral spirits solvent and then hot soapy water. Spray the cylinder with penetrating oil to displace the water left over from cleaning.


    Post #8 of this thread on Dirtriders "Suzuki cylinders...to hone or not to hone"

    http://www.dirtrider.net/forums3/showthread.php?t=63608
  12. Sateev

    Sateev Been here awhile

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    Don't think 10% UNDERSIZE is viable; don't know who Eric (on Dirtrider) is, and don't accept his authority on this subject, although the sheep over there seem to quote him like a God.

    OK, here's the deal, from http://www.aera.org/engine-professional/nikasil®-and-alusil/:

    Don't understand why Suzuki offers a 0.5mm (.020") oversize, unless they think a re-coating of the cylinder wall is viable (and a vendor accessible). Sounds like big bucks to me, likely a lot more than a new cylinder, so draw your own conclusion.

    My DR is for sale, BTW, if anyone in Thailand has a hankering.

    Edit: this: http://kustom-kraft.com/NEWNIKASIL.html is a link to a complete re-bore/re-coat/new piston service for small motors (like ours). Go figure...
  13. bradluke0

    bradluke0 Been here awhile

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    Hi all ! US Suzuki called me back this morning and said the cylinder is not serviceable . So, would you guys put new rings in and hope they seat or just use the old ones? The old ones are at .006" for the top ring and .007" for the second one . Still don't have my service book so don't really know if they are in spec . Thx again you guys for all the great info.......brad
  14. no

    no kidding

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    My instinct would be just to throw it all back together and not worry about it.
  15. acif

    acif Adventurer

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    about the cylinder:

    suzuki makes 2 types of cylinders for the dr200.
    1. aluminium cylinder with ferreous sleeve.
    2. all aluminium cylinder with SCEM coating applied directly to the cylinder (no sleeve).

    the first type is the older type and can be rebored (this is why there are oversize pistons and rings).
    the newer type (SCEM) can't be rebored (no oversize pistons, only standard bore).

    the older type doesent has any special marks and the sleeve is clearly visible.
    the newer type has a clearly stamped SCEM above the 199cc mark.

    older vrs newer:
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
  16. Andyinhilo

    Andyinhilo Long timer

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    I would do as Klay said, just put it back together with new gaskets. The rings will be fine.
  17. Sateev

    Sateev Been here awhile

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    Thank you for that info, ACIF. It really takes the mystery out of it.

    So, unless it's marked SCEM, I would hone it, replace the rings, and put it back together...

    I think I have mine sold, but I'm headed back to the US, so maybe I'll pick up another one. I'll be watching for that 'SCEM' marking on the cylinder - and avoid it.

    Thanks again.
  18. no

    no kidding

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    Ours are apparently the non-plated version...2001 model DR200s.
  19. Sateev

    Sateev Been here awhile

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    Yeah, I wondered about the model year - Andy's brochure post was from I believe, a 2004.

    Mine is a 2002, and definitely not plated.

    (Bummer: another Craigslist dipwad just cancelled, so the bike is still for sale.)
  20. Sateev

    Sateev Been here awhile

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