How to Change the Oil in a 1990 Suzuki DR250

Shop parts for a 1990 Suzuki DR250 Dirt Bike.

Changing the oil in your 1990 Suzuki DR250 is essential maintenance to keep your bike running reliably. This guide provides detailed, step-by-step instructions with specific notes for your model. With a dry sump engine design, it’s important to follow these steps to ensure all old oil is removed and replaced with fresh lubricant.

Tools and Materials Needed

  • 14mm socket/wrench (for crankcase drain bolt)
  • 12mm socket/wrench (for frame drain bolt)
  • Screwdrivers (flat and Phillips)
  • Oil filter replacement (recommended with every change)
  • New crush washers (for drain bolts)
  • Drain pan
  • Funnel
  • Rags for cleaning
  • Socket extension (optional for hard-to-reach bolts)
  • High-quality 4-stroke engine oil (see owner's manual for grade, typically 10W-40)
  • Oil capacity: 1.9 liters (with filter change)
  • Torque wrench (optional, for precise bolt reinstallation)
  • Skid plate removal tool/set (if equipped with a skid plate)

Preparation

  • Ride your bike briefly or start it and let it idle until warm. Warm oil drains more thoroughly.
  • Park the bike on a level surface and secure it with a stand.
  • Allow the engine to cool slightly to avoid burns.

Step-by-Step Instructions

  1. Remove the skid plate (if installed):
    • Use your tools to unbolt the skid plate from the bike’s frame.
    • This is strongly recommended for a complete oil change, as it allows proper access to frame drain bolts and the oil screen filter. Skipping this step may limit access but is possible on some bikes if you’re only doing a partial change. For a 1990 DR250, full removal is best practice.
  2. Drain the engine oil (crankcase):
    • Locate the 14mm drain bolt on the bottom of the engine crankcase.
    • Position your drain pan under the bolt and carefully remove the bolt (be cautious, oil will flow out quickly).
    • Allow oil to drain completely. Clean the bolt and replace the crush washer with a new one.
  3. Drain the oil from the frame (oil reservoir):
    • Locate the 12mm drain bolt for the frame (typically on the lower frame tube).
    • Place the drain pan underneath and remove this bolt as well.
    • Also, replace the crush washer before reinstallation.
    • Let oil drain until nothing drips from either point.
  4. Inspect and clean the oil screen/filter:
    • The DR250 uses both an oil filter and a strainer screen located in the frame or near the oil pump lines.
    • Remove the screen cover bolt; slide out the oil strainer and inspect for debris.
    • Clean the strainer with solvent if necessary and reinstall securely.
    • Remove and replace the external oil filter if it’s due. Check for O-ring or gasket debris and install a new gasket if needed.
  5. Reinstall drain bolts and tighten:
    • Reinstall the crankcase and frame drain bolts (with new crush washers), tightening securely but not overtightening to avoid stripping the soft aluminum threads.
    • If using a torque wrench, refer to the service manual for recommended torque values.
  6. Add new oil:
    • With all bolts back in place and the oil screen and filter installed, pour in 1.9 liters of quality 4-stroke oil using a funnel at the filler cap location.
    • Add oil slowly, checking the dipstick or level window (if equipped). Do not overfill.
  7. Start and circulate:
    • Start the engine and let it idle for about a minute. Watch for any leaks at the drain bolts or filter cover.
    • Shut down the engine, wait 1–2 minutes, then check oil level again and top up if needed.
  8. Reinstall the skid plate and clean up spills.

1990 Suzuki DR250-Specific Callouts

  • Dry Sump Design: Oil must be drained from both the crankcase and the frame to avoid mixing new oil with old oil left in the reservoir.
  • No Oil Pan: The crankcase is the lowest point for drainage. Take care not to overtighten bolts as thread stripping is a common risk in older aluminum cases.
  • Oil Capacity: Double-check that you add only the recommended 1.9 liters with a filter change – overfilling can cause excess crankcase pressure and leaks.
  • Filter and Screen: Unlike some modern designs with just a paper filter, the DR250 includes a mesh screen in the frame. Do not neglect this component as it can accumulate sludge or debris.
  • Periodic Inspection: If the bike sees frequent dirt or off-road use, shorten your change interval and check the screen more often for sediment.
  • Use of Quality Oil: The engine relies on clean, consistent lubrication for maximum life. Always use motorcycle-specific oil, not automotive oil.

Final Notes

  • Proper disposal: Take your used oil and filter to a recycling center or authorized collection point.
  • Log the oil change date and mileage for future maintenance planning.

Keeping up with regular oil changes is among the best investments you can make in prolonging the life and performance of your 1990 Suzuki DR250. If you notice any metal shavings, excessive sludge, or coolant contamination in your old oil, investigate further before continuing to ride.

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Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your motorcycle's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.