How to Change the Oil in a 1991 Suzuki DR250S — A MotoSport.com Proprietary Guide

Shop Parts for a 1991 Suzuki DR250S Dirt Bike.

If you own a 1991 Suzuki DR250S, regular oil changes are critical to long engine life and consistent performance. This step-by-step guide, proprietary to MotoSport.com, provides everything you need to know to properly change your oil, including tools, model-specific tips, recommended fluids, and best practices for this classic dual-sport machine.

Tools and Supplies Needed

  • Socket wrench set (including 12mm and 17mm sockets)
  • Oil drain pan
  • Funnel
  • Rags or shop towels
  • New oil filter (check your owner's manual for the exact part number)
  • Fresh engine oil (1.9 liters with filter change; high quality 10W-40 motorcycle oil is recommended)
  • Replacement crush washer for drain bolt (optional but recommended)
  • Screwdriver (for any guards or covers)
  • Torque wrench (for precise reinstallation–optional but ideal)

Preparation

  • Warm up the motor for a couple of minutes to thin the existing oil. This helps it drain more thoroughly.
  • Turn off the engine and secure the bike on a stable, upright stand.
  • Ensure you have proper ventilation if working indoors.

Step-by-Step Instructions

  • Remove the Skid Plate and Any Guards (If Equipped):
    Some DR250S models are equipped with a skid plate underneath. Remove it using your socket wrench if you intend to check or clean the oil strainer and to access both the engine and frame drain plugs easily.
  • Locate and Remove Drain Plugs:
    • The DR250S uses a dry sump system—there are two oil drain plugs to remove: one on the engine case (“sump plug”) and one on the frame down tube ("frame plug"). Both need to be removed for a complete oil change. Place your oil pan under the frame drain first, as oil will drain quickly from here as well as the engine.
      Tip: Some models also have a pipe with a banjo bolt; inspect this for signs of oil leaks or debris, especially if you ride off-road frequently.
  • Drain the Oil:
    • Remove the engine and frame drain bolts with the appropriate socket.
      Allow oil to drain completely into the pan. This may take several minutes.
    • While oil drains, inspect the drain bolt and replace the crush washer if it's worn out.
    • Clean the oil strainer (if performing a full service, as recommended every few changes). The strainer may be accessible in the frame or attached to the banjo fitting. Inspect for debris and rinse carefully with a suitable cleaner.
  • Replace the Oil Filter:
    • Locate and remove the oil filter cover (typically held by two or three bolts). Watch for residual oil and have rags ready.
    • Remove the old oil filter. Ensure the gasket comes out with it.
    • Lightly oil the seal on the new filter and install. Refit the cover and tighten to spec (be careful not to overtighten).
  • Reinstall Drain Bolts & Guards:
    • Reinstall the cleaned or replaced drain plug washers and torque the frame and engine drain plugs to the specification found in your owner's manual.
    • If you removed the skid plate or other guards, reinstall them at this stage.
  • Refill with Oil:
    • Use a funnel to pour 1.9 liters of high-quality motorcycle oil into the oil fill cap on the frame.
    • Check your owner's manual or reputable oil brand fitment guide for recommended viscosity. 10W-40 is a safe bet for most climates. Synthetic or semi-synthetic oil can improve performance and longevity.
  • Check for Leaks and Verify Oil Level:
    • Start the motor, let it idle for a minute, and then shut it off. Wait a minute and then check for leaks around the drain bolts and oil filter housing.
    • Check the oil level dipstick (located on the frame) and top up if necessary until oil is within the safe marks.
  • Dispose of Old Oil and Filter Properly:
    • Take used oil and filters to a recycling center or auto parts store. Don't dump it down the drain or onto the ground.

Model-Specific Call-Outs and Tips

  • The 1991 Suzuki DR250S uses a dry sump oil system. This means oil is stored in the frame and has two distinct drain points. Skipping either drain may result in old oil remaining in the system, reducing the benefits of fresh oil.
  • If the bike was stored or just purchased, always check and clean the oil strainer along the frame oil line for debris or clogging. Strainers are often overlooked and can affect oil flow and engine health.
  • If you find metal shavings during oil strainer inspection, monitor engine performance closely. Minor amounts after the break-in period are normal, but excessive shavings indicate internal wear.
  • Bolts and fasteners can seize with age. Use proper torque specs–check your service manual–and never overtighten sump plugs or filter covers.
  • Using a premium synthetic oil, like those offered by leading brands, can offer superior engine protection, especially if you ride aggressively or in extreme conditions.

Conclusion

By following the steps above, your 1991 Suzuki DR250S will continue to run strong for years to come. Regular oil changes, filter replacement, and attention to the dry sump's frame and engine drain points are key to reliability. For all your parts, oils, and riding essentials, trust MotoSport.com–and ride with confidence.

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Shop Oil Fillers and Drain Plugs for a 1991 Suzuki DR250S 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.