Suzuki DRZ 400 DRZ400 Service Repair Manual

GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 FUEL AND LUBRICATION SYSTEM 4 COOLING SYSTEM 5 CHASSIS 6 ELECTRICAL SYSTEM 7 SERVICING INFORMATION 8 EMISSION CONTROL INFORMATION 9 FOREWORD This manual contains an introductory description on the SUZUKI DR-Z400S and procedures for its inspection, service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to famil- iarize yourself with the motorcycle and its maintenance. Use this section as well as other sections as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reli- able service.  IMPORTANT All street-legal SUZUKI motorcycles with engine dis- placement of 50cc or greater are subject to Environ- mental Protection Agency (EPA) emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific information required to properly inspect and service the DR- Z400S in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and Carburetion be thor- oughly reviewed before any type of service work is performed. Further information concerning the EPA emission regulations and U.S. SUZUKI’s emission control program can be found in the U.S. SUZUKI EMISSION CON- TROL PROGRAM MANUAL/SERVICE BULLETIN. © COPYRIGHT SUZUKI MOTOR CORPORATION 2000 * This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. Inexperienced mechanics or mechanics with- out the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.

DR-Z400SK1 (’01-MODEL) 10 DR-Z400SK2 (’02-MODEL) 11 DR-Z400SK3 (’03-MODEL) 12 DR-Z400SK4 (’04-MODEL) 13 DR-Z400SK5 (’05-MODEL) 14 DR-Z400SMK5 (’05-MODEL) 15 DR-Z400SK6 (’06-MODEL) 16 DR-Z400SMK6/USMK6 (’06-MODEL) 17 SUPPLEMENTS DR-Z400SK7 (’07-MODEL) 18 DR-Z400SMK7 (’07-MODEL) 19 DR-Z400 SMK (’0 -MODEL) 8 8 20 S/ DR-Z400 SMK (’0 -MODEL) 9 9 21 S/

HOWTO USETHIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on the first page of each section to help you find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit there is an exploded view which provides work instructions and other service information (e.g., tightening torque, lubricating points, and locking agent points). Example: Front wheel CD Front axle ® Odometer gearbox @ Bearing (R) G) Front wheel ® Spacer ® Bearing (L) !J) Dust seal ® Brake disc ® Spacer ® Washer ® Front axle nut ® Brake disc mounting bolt ITEM N·m kgf-m @ 42 4.2 ® 10 1.0 Ib-ft 30.5 7.0

SYMBOLS Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION ~ Torque control required. -tE1 Apply THREAD LOCK "1342". Data beside it indicates specified torque. 99000-32050 IW Indicates service data. ~ Apply or use brake fluid. ~ Apply oil. Use engine oil unless other- ~ Measure in voltage range. wise specified. ;ill Apply molybdenum oil solution. ~ Measure in resistance range. (mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) ~ Apply SUZUKI SUPER GREASE "A". ~ Measure in current range. 99000-25030 (For USA) 99000-25010 (For the other countries) ~ Apply SUZUKI SILICONE GREASE. ~ Measure in diode test range. 99000-25100 ~ Apply SUZUKI MOLY PASTE. ~ Measure in continuity test range. 99000-25140 ~1207B] Apply SUZUKI BOND "1207B". ,4ooh Use special tool. 99104-31140 (For USA) 99000-31140 (For the other countries) ~1215] Apply SUZUKI BOND "1215". em Use engine coolant. 99000-31110 (Except USA) 99000-99032-11 X (Except USA) • Apply THREAD LOCK SUPER "1303". -GIl Use fork oil. 99000-32030 99000-99001-SS5 • Apply THREAD LOCK SUPER "1322" . 99000-32110 (Except USA)

GENERAL INFORMATION 1-1 GENERAL INFORMATION ~---------------------CONTENTS--------------------~ WARNING/CAUTION/NOTE ............................................................................. 1- 2 GENERAL PRECAUTIONS ............................................................................. 1- 2 SUZUKI DR-Z400SY (2000-MODEL) .............................................................. 1- 4 SERIAL NUMBER LOCATION ........................................................................ 1- 4 FUEL, OIL, AND ENGINE COOLANT RECOMMENDATIONS ....................... 1- 4 FUEL ............................................................................................................. 1-4 ENGINE OIL ................................................................................................. 1- 5 BRAKE FLUID ............................................................................................. 1- 5 FRONT FORK OIL ....................................................................................... 1- 5 ENGINE COOLANT ..................................................................................... 1- 5 BREAK-IN PROCEDURES .............................................................................. 1- 6 INFORMATION LABELS .................................................................................. 1- 7 SPECIFICATIONS ............................................................................................ 1- 8 COUNTRY AND AREA CODES ...................................................................... 1-10

1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. A WARNING Indicates a potential hazard that could result in death or injury. I A CAUTION I Indicates a potential hazard that could result in motorcycle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN- INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. GENERAL PRECAUTIONS A WARNING * Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle. * When two or more persons work together, pay attention to the safety of each other. * When it is necessary to run the engine indoors, make sure that exhaust gas is forced out- doors. * When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the manufacturer's instructions. * Never use gasoline as a cleaning solvent. * To avoid getting burned, do not touch the engine, engine oil, radiator, and exhaust system until they have cooled. * After servicing the fuel, oil, engine coolant, exhaust or brake systems, check all of the lines, and fittings related to the system for leaks.

GENERAL INFORMATION 1-3 I A CAUTION I * If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order. * Be sure to use special tools when instructed. * Make sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricants, bonds, or sealants. * When removing the battery, disconnect the e battery lead wire first, then the (±) battery lead wire. * When reconnecting the battery, connect the (±) battery lead wire first, then the e battery lead wire. Finally, cover the (±) battery terminal with the terminal cover. * When performing service to electrical parts, disconnect the e battery lead wire, unless the service procedure requires the battery power. * When tightening cylinder head and crankcase nuts and bolts, tighten the larger sizes first. Always tighten the nuts and bolts from the inside working out, diagonally and to the specified torque. * Whenever you remove oil seals, gaskets, packing, O-rings, self-locking nuts, locking wash- ers, cotter pins, circlips, and other specified parts, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. * Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure it is completely seated in its groove and securely fitted. * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. * After reassembling, check parts for tightness and proper operation. * To protect the environment, do not unlawfully dispose of used motor oil, engine coolant, all other fluids, batteries, and tires. * To protect the earth's natural resources, properly dispose of used motorcycles and parts.

1-4 GENERAL INFORMATION SUZUKI DR-Z400SY (2000-MODEL) RIGHT SIDE LEFT SIDE * Difference between photographs and the actual motorcycle depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) G) is stamped on the right side of the steering head pipe. The engine serial number ® is located on the right side of the crankcase. These num- bers are required especially for registering the machine and ordering spare parts. FUEL, OIL, AND ENGINE COOLANT RECOMMENDATIONS FUEL (FOR USA AND CANADA) • Use only unleaded gasoline of at least 87 pump octane ( R ~ M ) method or 91 octane or higher rated by the Research Method. • SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible. • Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. • Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it. • If the performance of the motorcycle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. • Failure to follow these guidelines could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above.

Suzuki DRZ 400 DRZ400 Service Repair Manual

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