How to Change the Oil in a 1991 Suzuki DR250

Shop parts for a 1991 Suzuki DR250 Dirt Bike.

Keeping the oil fresh in your 1991 Suzuki DR250 is essential to maintain engine health and smooth performance on and off the trail. The DR250 uses a dry-sump oil system, which means draining oil from both the engine crankcase and the oil reservoir in the frame. Here's a proprietary guide from MotoSport.com on how to change the oil on your DR250, including model-specific call-outs and pro tips.

Tools and Supplies Needed

  • Socket wrench set (14mm and 12mm sockets)
  • Oil filter (OEM or compatible replacement)
  • Drain pan
  • Funnel
  • New engine oil (1.9 liters with filter change, recommended quality 10W-40 or 20W-50 for most riding conditions)
  • New crush washers for drain bolts
  • Clean shop rags
  • Flathead screwdriver (optional, for stubborn clips or hose clamps)
  • Torque wrench (recommended for drain bolts)
  • Rubber gloves (optional, for cleanliness)

Steps to Change the Oil on a 1991 Suzuki DR250

  1. Warm Up the Engine
    Run the motorcycle for 3-5 minutes to bring the oil to operating temperature. Warm oil drains more completely, carrying away more contaminants from internal passages.
  2. Remove the Skid Plate (if equipped)
    Most DR250 models have a skid plate protecting the frame and engine. Remove the bolts and take off the skid plate for complete access to the drain bolts and the oil screen. If your skid plate is already open around these points, removal may not be necessary, but doing so allows for easier cleaning and inspection .
  3. Drain the Engine Crankcase Oil
    Locate the 14mm drain bolt at the bottom of the engine. Place the drain pan underneath, then remove the bolt carefully and let the oil drain completely. Inspect and replace the crush washer to prevent future leaks. Be careful not to over-torque when reinstalling—stripped threads are costly to repair on this engine type .
  4. Drain the Oil Reservoir in the Frame
    The DR250's dry-sump system stores additional oil in the frame. Find the 12mm drain bolt on the frame (usually on a forward downtube). Use your socket to remove it and drain the oil into your pan. Again, replace the crush washer and do not overtighten on reinstallation .
  5. Remove and Inspect the Oil Screen
    Older DR models like the 1991 DR250 have a screen filter in the oil line or frame. Remove the oil line fitting (if needed), then remove and clean the oil screen. Check for debris or metal particles—excessive contamination may indicate engine wear .
  6. Change the Oil Filter
    Remove the oil filter cover (typically secured by two or three bolts). Remove the old filter and any gasket material, then insert the new filter. Ensure all gaskets and O-rings seat correctly, and reinstall the cover using the factory torque spec.
  7. Reinstall All Components
    Confirm all drain bolts are in place with new crush washers, the oil screen is reinstalled, and the oil filter cover is snug. If you removed the skid plate, reinstall it securely.
  8. Add New Oil
    Using a funnel, pour in the recommended 1.9 liters of fresh engine oil. Check your owner's manual for oil viscosity suitable for your climate (e.g., 10W-40 or 20W-50). Avoid overfilling.
  9. Prime the Oil System (Critical for Dry-Sump)
    Before starting, crank the engine over several times (use the kickstarter or electric start for 5-10 seconds with the kill switch off) to circulate oil through the system. This helps prevent dry starts which can damage the engine.
  10. Start and Check for Leaks
    Start the engine and let it run for 1-2 minutes. Watch for leaks near the filter, crankcase, and frame drain points. Shut down and let the bike sit for a minute, then check the dipstick or oil sight glass to ensure proper level. Add oil if needed.
  11. Dispose of Old Oil Properly
    Take used oil and the old filter to a recycling center or auto parts store that accepts used oil. Never pour it down a drain or onto the ground.

Model-Specific Call-Outs and Tips for 1991 Suzuki DR250

  • The DR250's dry-sump system requires draining both the main case and the oil in the frame, so don't skip either step or you'll blend fresh and old oil, reducing effectiveness .
  • Always replace crush washers at both drain bolts. Old washers can cause leaks, especially in the aluminum crankcase and steel frame.
  • Check and clean the oil screen in the frame or oil line (model variation exists depending on production year). This is a key spot for catching engine debris early.
  • When reinstalling drain bolts, avoid over-tightening. The case and frame threads can strip more easily in older motorcycles like the 1991 DR250 .
  • Double-check that the oil lines are secured if removed during the process. Air leaks here can starve the engine of oil.
  • Specifically for the 1991 DR250, total oil capacity (with filter change) is approximately 1.9 liters. Overfilling can cause foaming and leaks; underfilling can damage the engine .

Final Pro Tips

  • Consider using a high-quality synthetic oil formulated for motorcycles to improve engine protection and lifespan .
  • Record your oil change date and hours/mileage for future maintenance.
  • Inspect for other issues (loose bolts, leaks, damaged hoses) while you have the bike's guards removed.

Changing the oil in your 1991 Suzuki DR250 is a straightforward but vital task. Take your time, follow these steps, and you'll ensure years of reliable backcountry adventure. For all your filters, lubricants, and tools, check MotoSport.com for fast delivery and the best selection for your DR.

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Shop Oil Fillers and Drain Plugs for a 1991 Suzuki DR250 Dirt Bike.

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.