2000-2006 Suzuki DR-Z400 DR-Z400E DRZ400E Service & Repair Manual

M477 Ell SUZUKI DR-Z400E, S& SM • 2000-2006 SERVICE • REPAIR • MAINTENANCE A Prism Business Media Publication

CLYMER: SUZUKI OR-Z400E, S & SM • 2000-2006 ClYMER: PO. Box ]290]. Overland Park. Kansas 66282-290]

Chapter One General Information Chapter Two Troubleshooting Chapter Three Lubrication, Maintenance and Tune-up Chapter Four Engine Top End Chapter Five Engine Lower End Chapter Six Clutch, External Shift Mechanism and Lubrication System Chapter Seven Transmission and Internal Shift Mechanism Chapter Eight Fuel System Chapter Nine Electrical System Chapter Ten Cooling System Chapter Eleven Wheels, Tires and Drive Chain Chapter Twelve Front Suspension and Steering Chapter Thirteen Rear Suspension Chapter Fourteen Brakes Chapter Fifteen Body Index Wiring Diagrams

CONTENTS QUICK REFERENCE DATA ............................... IX CHAPTER ONE . GENERAL INFORMATION Manual organization Warnings, cautions and notes Safety Serial numbers Fasteners Shop supplies CHAPTER TWO . . . . . ... TROUBLESHOOTING Engine operating requirements Engine starting Engine spark test Starting system Engine performance Engine noise . 1 Tools Measuring tools Electrical system fundamentals Basic service methods Storage Specifications . 31 Motorcycle noise Engine leakdown test Clutch Shift mechanism and transmission Brakes Steering and handling

CHAPTER THREE ................ LUBRICATION, MAINTENANCE AND TUNE-UP Fuel type Pre-ride inspection Engine break-in Service intervals Battery Periodic lubrication Maintenance and inspection CHAPTER FOUR. ENGINE TOP END Exhaust system Cylinder head cover Camshafts and cam chain tensioner Cylinder head CHAPTER FIVE . ... ENGINE LOWER END Engine Crankcase Crankcase seals Crankcase bearings ............ . 44 Tune-up Valve clearance Carburetor Ignition timing Compression test Spark plugs Specifications . 75 Valves Cylinder Piston and piston rings Specifications . 105 Engine balancer Oil strainer Crankshaft Specifications CHAPTER SIX ...................................... 120 CLUTCH, EXTERNAL SHIFT MECHANISM AND LUBRICATION SYSTEM Clutch cover Clutch Right crankcase cover Oil pump Cam chain and rear guide Balancer driven gear Primary and balancer drive gears Shift lever External shift mechanism Clutch eable replacement Specifications CHAPTER SEVEN .................................... 143 TRANSMISSION AND INTERNAL SHIFT MECHANISM Transmission operation Transmission service Input shaft Output shaft Transmission inspection Shift drum and forks Specifications

CHAPTER EIGHT. .... FUEL SYSTEM Fuel system precautions Carburetor Throttle position sensor Carburetor systems CHAPTER NINE .... ELECTRICAL SYSTEM Troubleshooting Ignition and charging system operation Upper idle gear cover Alternator cover Lower idle gear Stator assembly Rotor and starter clutch Starter Starting system switches CHAPTER TEN. .. COOLING SYSTEM Safety precautions Fan and switch (S and SM models) Radiators and warning light switch CHAPTER ELEVEN ......... WHEELS, TIRES AND DRIVE CHAIN Front wheel Rear wheel Front and rear hubs Wheel service CHAPTER TWELVE ........... FRONT SUSPENSION AND STEERING Handlebar Steering stem and head Front fork CHAPTER THIRTEEN REAR SUSPENSION Shock absorber Shock absorber linkage Swing ann . 154 Fuel vahe baporative emissions control system Throttle cable replacement Specifications . 182 Ignition systcm Charging system Radiator fan (S and SM models) Temperature vvarning circuit (S and SM models) Headlight Taillight Turn signals Specifications . .206 Thermostat (S and SM models) Water pum[) Specitlcations . 217 Drive chain Sprockets Tires Specitlcations ....... . 236 Front fork service Front fork adj ustment S[)ecitications ....... . 276 Swing ann servicc Shock absorber adjustment Specifications

CHAPTER FOURTEEN. BRAKES Brake service Front brake pads Front brake caliper Front master cylinder Rear brake pads Rear brake caliper CHAPTER FIFTEEN BODY Side covers Seat Radiator covers Fuel tank Headlight cowl INDEX . WIRING DIAGRAMS . . 290 Rear master cylinder Rear brake pedal Brake system bleeding Brake disc Specitications ......... . 316 Engine covers Skid plate Subframe Specifications .320 .326

QUICK REFERENCE DATA MOTORCYCLE INFORMATION MODEL: YEAR: _ VIN NUMBER: _ ENGINE SERIAL NUMBER: _ CARBURETOR SERIAL NUMBER OR 1.0. MARK: _ MAINTENANCE SPECIFICATIONS Battery type and capacity 2000 models 2001-on models Brake lever free play Brake pad lining minimum thickness Brake pedal height E and S models SM models Clutch lever free play Drive chain free play Drive chain length wear limit (20 pitch/21 pins) Radiator cap relief pressure Rim runout (radial and lateral) Throttle grip free play Tire pressure E models Front Rear S models Front Rear SM models Front Rear GT7B-4, 12 volt, 6.5 amp-hour YT7B-B5, 12 volt, 6 amp-hour 0.1-0.3 mm (0.004-0.012 in.) 1.0 mm (0.040 in.) 0-10 mm (0-0.4 in.) below top of peg 0-5 mm (0-0.2 in.) 10-15 mm (0.4-0.6 in.) at lever end 40-50 mm (1.6-2.0 in.) 319 mm (12.6 in.) 95-125 kPa (13.8-18.1 psi) 2.0 mm (0.08 in.) 2-4 mm (0.08-0.16 in.) 100 kPa (15 psi) 100 kPa (15 psi) 125 kPa (18 psi) 150-175 kPa (22-25 psi) 175 kPa (25 psi) 220-225 kPa (29-33 psi) FUEL, LUBRICANTS AND FLUIDS Air filter Brake fluid type Control cables Cooling system capacity Coolant type Coolant mixture Drive chain Engine oil Acceptable grades for extreme temperatures Engine oil capacity Engine rebuild With filter change Without filter change Foam air filter oil DOT 4 Cable lube 1.25 liters (1.3 qt.) Ethylene glycol containing anti-corrosion inhibitors for aluminum engines 50:50 (antifreeze/distilled water) O-ring type chain lubricant SG classified, or SH/SJ with JASO MA classification 4-stroke engine oil, SAE 10W-40 SAE 10W-30, 1OW-50, 15W-40, 15W-50 or 20W-50 1.9 liters (2 qt.) 1.8 liters (1.9 qt.) 1.7 liters (1.8 qt.) (continued) IX

FUEL, LUBRICANTS AND FLUIDS (continued) Fork oil grade Fork oil capacity (each leg) E models S models SM models Inner Outer Fork tube oil level (from top edge of inner tUbe) E models (without spring) 2000-on S models (without spring) 2000 and 2001 2002-on SM models 2005-on Fuel type E models Sand SM models Fuel tank capacity (including reserve) Reserve capacity Suzuki SS-05, or equivalent 5-weight fork oil 720 cc (24.3 oz.) 710 cc (24.0 oz.) 182 ml (6.15 oz.) 350 ml (11.8 oz.) 122 mm (4.8 in.) 165 mm (6.5 in.) 129 mm (5.08 in.) NA Unleaded gasoline; 90 octane minimum (R+M/2) Unleaded gasoline; 95 octane minimum (RON) Unleaded gasoline; 87 octane minimum (R+M/2) Unleaded gasoline; 91 octane minimum (RON) 10 liters (2.6 gaL) 2.3 liters (0.61 gaL) E models 2000-2003 2004 S models 2000-2001 2002-on SM models 2005-on justers can occur. STANDARD FORK SETTINGS Spring preload adjuster Compression adjuster clicks out* Rebound adjuster clicks out* - - 12 12 13 15 Third groove from top - 7 13 - 16 - 13 17 'Number of clicks out after the adjusters have been fully turned in (maximum damping force). Turning the adjusters out decreases damping force. Do not force the adjusters beyond their normal travel. Damage to the ad- STANDARD REAR SHOCK ABSORBER SETTINGS Compression damping Compression damping Rebound damping clicks out* turns out* clicks out* E models 2000-2001 12 - 13 2002-on 10 (low speed) 1 1/4 (high speed) 13 S models 2000-2001 11 - - 2002-on 10 (low speed) 1 1/4 (high speed) 13 SM models 2005-on 10 1 1/8 (high speed) 14 'Number of clicks/turns out after the adjusters have been fully turned in (maximum damping force). Turning the adjusters out decreases damping force. Do not force the adjusters beyond their normal travel. Damage to the adjusters can occur. x

MAINTENANCE TORQUE SPECIFICATIONS Nom in.-Ib. ft.-lb. Axle nut Front* E and S models Initial 20 - 15 Final 42 - 31 SM models Initial 20 - 15 Final 39 - 29 Rear 100 - 74 Coolant air bleeder bolt 6 53 - Cylinder head cover bolts 14 - 10 Exhaust system fasteners 23 - 17 Front axle pinch bolts 18 - 13 Handlebar clamp bolts 23 - 17 Muffler clamp 20 - 15 Muffler spark arrester bolts 11 - 8 Oil drain plug Crankcase 21 - 15 Frame 18 - 13 Oil hose bolt and strainer 23 - 17 Spark plug 11 - 8 Spokes 3 27 - *Refer to the text for tightening procedure. Xl

2000-2006 Suzuki DR-Z400 DR-Z400E DRZ400E Service & Repair Manual

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