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Suzuki · Modern air-cooled single (2000-)

Burgman 200

Library entry covers 2009-2023

23 factory 33 guideline

Published source

Suzuki Burgman UH200K7 ('07-model) Service Manual, Periodic Maintenance Chart p. 2-2 (km chart)

Factory workshop manual. Covers 2007 (UH200K7 service manual; chart printed in km and months only).

Open the source

56 items for a 2011 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Automatic or semi-automatic
Final drive: Leather or rubber V-belt (veteran)
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2011 Suzuki Burgman 200

On the road: every 100 mi

1 item

Check drive belt tension and belt fastener

Pre-ride / on the road

Guideline

Leather and early rubber belts stretch and slip when wet. Carry a spare fastener and a belt punch.

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

Every 500 mi

1 item

Dress / clean V-belt and pulley rims

Final drive

Guideline

Every 1,000 mi or 6 months

1 item

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 1,864 mi

2 items

Cooling fan filter - clean

Engine

Factory

Factory: Clean every 3 000 km
Clean / inspect air filter

Fuel and air

Factory

Manual: Air cleaner element (polyurethane foam element) - clean. Factory: Clean every 3 000 km; non-woven element inspected at 5,000 and 10,000 km

Every 3,000 mi or 12 months

4 items

Adjust automatic / semi-automatic clutch

Primary and gearbox

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 3,107 mi or 15 months

12 items

Change engine oil

Engine

Factory

Manual: Engine oil - R. Factory: Initial 1,000 km/3 months; columns 1,000/5,000/10,000/15,000 km
Chassis bolts and nuts - T

Engine

Factory

Factory: Tighten; initial 1,000 km, then every column
Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance - I. Factory: Initial 1,000 km; then every column
Exhaust pipe nuts and muffler bolts - T

Engine

Factory

Factory: Tighten; initial 1,000 km, then every column
Inspect coolant hoses and clamps

Engine

Factory

Manual: Radiator hose - I. Factory: Every column from 5,000 km
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plug - I. Factory: Inspected at 5,000 and 15,000 km columns
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle cable play - I. Factory: Initial 1,000 km; then every column
Fuel line - I

Fuel and air

Factory

Factory: Every column from 5,000 km
Inspect drive belt, pulleys and tension

Final drive

Factory

Manual: Drive V-belt - I. Factory: Every column from 5,000 km
Check brake pads and discs

Brakes

Factory

Manual: Brakes - I. Factory: Initial 1,000 km; then every column
Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hose - I; replace every 4 years. Factory: Inspect every 5,000 km; replace every 4 years
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tires - I. Factory: Every column from 5,000 km

Every 4,000 mi or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 6,000 mi or 12 months

4 items

Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,214 mi or 30 months

6 items

Replace oil filter

Engine

Factory

Manual: Engine oil filter - R. Factory: Initial 1,000 km; then 10,000 km column
Replace spark plugs

Engine

Factory

Manual: Spark plug - R. Factory: Replaced at 10,000 km column
Check final drive for leaks and bearing play

Final drive

Factory

Manual: Final gear box oil - I. Factory: Only marked at 10,000 km column
Check steering head bearing adjustment

Front end

Factory

Manual: Steering - I. Factory: Initial 1,000 km; then 10,000 km column
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Front fork - I. Factory: Only marked at 10,000 km column
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Rear suspension - I. Factory: Only marked at 10,000 km column

Every 9,321 mi or 45 months

1 item

Replace air filter element

Fuel and air

Factory

Manual: Air cleaner element (non-woven fabric element) - R. Factory: Only R mark at 15,000 km column

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 2 years

3 items

Synchronize throttle bodies

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 24,000 mi or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

4 items

Replace coolant

Engine

Factory

Manual: Engine coolant - replace every 2 years. Factory: Time-based only
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Factory

Manual: Brake fluid - replace every 2 years. Factory: Inspected every 5,000 km; replaced every 2 years

Every 4 years

2 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.