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Suzuki DR-Z400 2000-2007 Factory Workshop Manual
This is the same manual your local dealer will use when doing a repair. The manual for the Suzuki DR-Z400 2000-2007 has detailed illustrations as well as step by step instructions. All pages are printable, so run off what you need and take it with you into the garage or workshop. These manuals are your number one source for repair and service information. They are specifically written for the do-it-yourself as well as the experienced mechanic. Using this repair manual is an inexpensive way to keep your bike working properly. Each manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of illustrations, that guide the reader through each service and repair procedure.
Topics Covered
GENERAL INFORMATION
---------------------- CONTENTS ----------------------~
WARNINGICAUTIONINOTE ..... ................................................. .. .............. ....... I· 2
GENERAL PRECAUTIONS ............................................................................. I· 2
SUZUKI DR·Z400SY (2000·MODEL) .............................................................. I· 4
SERIAL NUMBER LOCATION ........................................................................ I· 4
FUEL, OIL, AND ENGINE COOLANT RECOMMENOATIONS ....................... 1· 4
FUEL .......... ....................................................................... .. ................. ......... I· 4
ENGINE OIL .... ............................................................................................. 1· 5
BRAKE FL UID ... ............................... ........................................................... I· 5
FRONT FORK OIL ............................... ........................................................ I· 5
ENGINE COOLANT .... ...... ..... .................. .............................. ...................... I· 5
BREAK·IN PROCEDURES ........ .................... .......................... ........................ I· 6
INFORMATION LABELS ........ .............................. ... ......................................... I· 7
SPECIFICA TlONS ............................................................................................ I· 8
COUNTRY AND AREA CODES ........................ ..................................... ......... 1·10
PERIODIC MAINTENANCE
-------------CONTENTS -------------;
PERIODIC MAINTENANCE SCHEDULE ..... ...... ....... ..................... ................ 2· 2
PERIODIC MAINTENANCE CHART ...... .. .. ......... .... ............... .......... .......... 2· 2
MAINTENANCE AND TUNE·UP PROCEDURES ... ................................... .. .. 2· 3
AIR CLEANER ..................... ................................................... .................... 2· 3
EXHAUST PIPE NUT AND BOLT AND MUFFLER NUT AND BOLTS ..... 2- 4
TAPPET CLEARANCE ...... .... ......................................... ......... ................... 2- 5
SPARK PLUG ................ .. .... .... ........................ ........... .............. ................... 2- 9
SPARK ARRESTER (FOR E-03, 28, 33) ............. ... ..... ............................... 2-10
FUEL LINE ................................. .......................... ....... .......... ...................... 2-10
ENGINE OIL AND OIL FILTER ............................................................. .. .... 2-11
ENGINE OIL HOSES .................................................. ......... ............. ........ .. 2-12
THROTTLE CABLE PLAY (CARBURETOR) ............................................. 2-13
ENGINE IDLE SPEED (CARBURETOR) .. ......................... ... ..................... 2-14
ENGINE COOLANT ......... .................. ........................ .... .. ....................... .... 2-14
RADIATOR HOSES .... ... ..................... ..... .. .. ..... .. ........ .. .... .......... ... .............. 2-15
CLUTCH ......... .. ..... ... ... ....................................... ... ......... ..... ........................ 2-16
DRIVE CHAIN ......... ......... .. .... ............................ ......................................... 2-16
BRAKES .................................................................................... .................. 2-18
BRAKE FLUID ....... .. ..... ... ............................... .... .... .................................... 2-19
BRAKE HOSES .......... .... ............................................................................ 2-21
TIRES ........................................... ........................ ... ............................... .. ... 2-2 I
SPOKE NIPPLES .................. .... ... ............. .................................................. 2-22
STEERING ............ ... .............................................. .... ... .. ... ........ ... .............. 2-23
FRONT FORK .. .......................................................... .. ....... ... ... ................ .. 2-23
REAR SUSPENSION .. ..................... ...... .......................... ................ ... .. ...... 2-23
EVAPORATIVE EMISSION CONTROL SYSTEM (FOR E-33) .................. 2-23
PAIR (AIR SUPPLY) SYSTEM (FOR E-02, 19, 54) ........ ............ ................ 2-23
CHASSIS NUTS AND BOLTS ..................... .... ........................................... 2-24
GENERAL WBRICATION .......................................................................... 2-26
COMPRESSION PRESSURE CHECK ........................................................... 2-27
COMPRESSION TEST PROCEDURE ............. ... ................... .. ... .. ...... ........ 2-27
OIL PRESSURE CHECK .... .. .. ... ....................... ... ............................ ... ... ......... 2-28
OIL PRESSURE TEST PROCEDURE ........................................ ... .. .. ... ... ... 2-28
ENGINE
--CONTENTS ------
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE .................................. 3· 2
ENGINE REMOVAL ANO REMOUNTING ................................................................................. 3· 3
ENGINE REMOVAL ............................................................................................................... 3· 3
ENOINE REMOUNT/NO ........................................................................................................ 3- 8
ENGINE DISASSEMBLY .. ... ................................................................. ...................................... 3-1 t
ENGINE COMPONENTS INSPECTION ANO SERVICE ........................................................... 3·22
CYLINDER HEAD ................................................................................................................. 3·22
CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBLy ............................................... 3·31
CYLINDER ............................................................................................................................. 3·33
PISTON AND PISTON RING ................................................................................................. 3·33
CONROO ............................................................................................................................... 3·35
CRANKSHAFT ...................................................................................................................... 3-36
STARTER CLUTCH ............................................................................................................... 3-36
STARTER TORQUE LIMITER ... .... ........................................................................................ 3-37
OIL PUMP .............................................................................................................................. 3·37
CLUTCH ................................................................................................................................ 3·38
CEAnSHlrr ronK AND aeAn .................................. .... .. .............. ........ ............................. 3-39
TRANSMISSION ................................................................................................................... 3-40
BEARINGS ............................................................................................................................ 3-43
OIL SEALS ............................................................................................................................ 3·46
OIL CHECK VALVE ............................................................................................................... 3·47
ENGINE REASSEMBLY ............................................................................................................. 3-48
CRANKSHAFT ...................................................................................................................... 3-48
GEARSHIFT CAM ANO FORK ............................................................................................. 3-49
CRANKCASE.. .............. ........................................................................................................ 3·50
STARTER CLUTCH AND GENERATOR ROTOR ................................................................. 3·51
BALANCER SHAFT ..................... ..................................... ........ ...... ................................. ..... 3-52
PRIMARY DRIVE GEAR ....................................................................................................... 3·53
GEARSHIFT CAM DRIVEN GEAR ....................................................................................... 3·53
GEARSH/~ SHAn ..... . ................................................ ....................................................... 3 5 4
OIL PUMP .............................................................................................................................. 3-54
CAM CHAIN .......................................................................................................................... 3·55
CLUTCH ................................................................................................................................ 3·55
RIGHT CRANKCASE COVER .............................................................................................. 3·57
CLUTCH COVER .................................................................. ................................................. 3-57
GENERATOR ROTOR COVER ............................................................................................. 3·57
NEUTRAL SWITCH ............................................................................................................... 3·57
STARTER DRIVE GEAR COVER ......................................................................................... 3-58
PISTON RING ........................................................................................................................ 3-58
PISTON AND CYLINDER .............................. .... ... ............... .................................................. 3-59
CYLINDER HEAD ................................................................................................................. 3·60
CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBLy ............................................... 3-61
C VIIND~R HED COV~R ......... ......................................................................................... 3-63
CAM CHAIN TENSION ADJUSTER ..................................................................................... 3-64
PAIR (AIR SUPLYj SYSTEM (FOR E·02, 19,54) ......................................... .. .... .... ............ .. ...... 3-65
REMOVAL .............................................................................................................................. 3·65
INSPECTION ......................................................................................................................... 3-65
REMOUNTING ...................................................................................................................... 3-66
FUEL AND LUBRICATION SYSTEM
----------------------- CONTENTS ----------------------~
FUEL TANK ............ ... ....... .................................................. ............................... 4· 2
REMOVAL ................................. ............................................. ...................... 4· 2
Rt:.MOUN rtNG .......................................................................... ...... ..... ........ 4· L
FUEL VALVE ................................. .. ..................... .............. ....... .. ....... ............... 4· 3
REMOVAL AND INSPECTION ..... ... ..... ...... ................................................. 4· 3
FUEL STRAINER ..................................................... ...... ... .............. .......... ... 4· 3
REMOUNTING .......................................................... .............. ............... .. .... 4· 3
CARBURETOR ...... .. ............ ... .. ............................. ........................................... 4- 4
CONSTRUCTION ......................................................................................... 4- 4
SPECIFICATIONS .............. ......... ............................................... .................. 4- 5
I.D. NO. LOCATION ...................................................................................... 4- 5
REMOVAL .... ... ............................................................................................. 4- 6
DISASSEMBLY ............ ................... ............. ...... ........ .................... ... ..... ... ... 4- 6
CLEANING ................... ...... ........................ ..... ............................................. 4-10
INSPECTION ...................... ...................................... ........ ........... .............. ... 4-10
REASSEMBLY .............................................................. ........... .......... ..... ..... 4-12
REMOUNTING .............................. .. ... .. ...... ................. .. ............................... 4-12
LUBRICATION SySTEM ........ ..... ................ ............... ................... ...... ......... .... 4-13
ENGINE LUBRICATION SYSTEM CHART ........ ........... ...... ... .............. ....... 4-13
COOLING SYSTEM
----------------------- CONTENTS ----------------------~
COOLING SYSTEM ........................................................................... ..... ... ..... 5· 2
DESCRIPTION ............................................................................................ 5- 2
CONSTRUCTION ............................................ ........ ..................... ............... 5- 3
ENGINE COOLANT ........................................................................................ 5- 4
RADIATOR AND COOLING FAN .................................................................... 5- 5
INSPECTION .......... ............ ...................... ................... ................................ 5- 5
REMOVAL ................................................................................................... 5- 6
REMOUNTING ............................................................................................ 5- 7
COOLING FAN THERMOSWITCH .......................................... ......................... 5- 8
REMOVAL .................................................................................................... 5- 8
INSPECTION ........................................................................... ..................... 5- 9
INSTALLATION ............................................................................................ 5- 9
ENGINE COOLANT TEMPERATURE THERMOS WITCH ............. ........ .......... 5-10
REMOVAL ............. .... ................................................................................... 5-10
INSPECTION ....................... ............................... .......................................... 5-10
INSTALLATION ............. ..... ... ....................................................................... 5-10
THERMOSTAT .................................................................................................. 5-11
REMOVAL ....................................... ............................................................. 5-11
INSPECTION ............. .................... ............................................ ................... 5-11
INSTALLATION ...... ...................... ........ .. .... ......................... __ ... ................... 5-12
WATER PUMP .................................................................................................. 5-13
REMOVAL AND DISASSEMBLy ................................................................. 5-13
INSPECTION ................................................................................................ 5-14
REASSEMBLY .......................... ... ..... .......... .................. ...... .............. ..... ...... 5-14
CHASSIS
---------------------~ CONTENTS ----------------------~
EXTERIOR PARTS ......................................................................................... .... ....... ........... .... ........... ....... ... 6· 2
REMOVAL ................................................................................................................................................ 6· 2
REMOUNTING ... ....... ............................................................................................................................... 6- 2
FRONT WHEEL ............................................................................................................................................ 6- 3
CONSTRUCTION .................................................................................................................................... 6· 3
REMOVAL AND DISASSEMBLY ............................................................................................................ 6· 5
INSPECTION ........................................................................................................................................... 6· 6
REASSEMBLY AND REMOUNTING ...................................................................................................... 6· 8
FRONT FORK ........ .. ................ ...................................................................................................................... 6-10
CONSTRUCTION .................................................................................................................................... 6-10
REMOVAL AND DISASSEMBLY ...................................................................... ...................................... 6·1 1
INSPECTION ... ............ ............................................................................................................................ 6-13
REASSEMBLY AND REMOUNTING ...... ........... .. ................................................................................... 6-14
SUSPENSION SETTING ......................................................................................................................... 6· I 6
STEERING ........................................................................................ .................. ..... ...................................... 6· I 7
CONSTRUCTION ................. ....................... ....... ......... ..... ......... . ................. ........... 6·17
REMOVAL AND DISASSEMBLY ............................................................................................................ 6·18
INSPECTION ...... ................................................................................. .. ............ ..... ......... ........ .......... ...... 6-21
REASSEMBLY AND REMOUNTING .............................................................................. ........ .............. .. 6·21
REAR WI-IEEL . __ ____ __ . ____________________ . &.24
CONSTRUCTION .................................................... .................................................... ............................ 6-24
REMOVAL AND DISASSEMBLY ............................................................................................................ 6-26
INSPECTION ............ ................................... .................. ..................... ..................................................... 6·27
REASSEMBLY AND REMOUNTING ...................................................................................................... 6·27
REAR SUSPENSION .................................................................................................................................... 6·30
CONSTRUCTION ............... .. ..................................................................................... ....... ....................... 6·30
REAR SHOCK ABSORBER REMOVAL ................................................................................................ 6·32
REAR SHOCK ABSORBER INSPECTION ............................................................................................ 6·33
REAR SHOCK ABSORBER DISPOSAL ......................... ................................... ........... ........ .......... ...... 6-33
REAR SHOCK ABSORBER REMOUNTING ................... ...................................................................... 6-34
REAR SHOCK ABSORBER DAMPING FORCE ADJUSTMENT .... ....... .............................................. 6·35
REAR SWINCARM AND CUSHION LEVER REMOVAL ..................................................................... .. 6·36
INSPECTION AND DISASSEMBLY ...... .. ..... .............................................................................. ............ 6-37
REASSEMBLY AND REMOUNTING ...................................................................................................... 6·39
FINAL INSPECTION AND ADJUSTMENT ............................................................................................ 6-40
FRONT DRAKe ................................. ......................................... .................. ...................................... ........... 0-41
CONSTRUCTION ................................................................. ............................. ...................................... 6·41
BRAKE PAD REPLACEMENT ................................................................................................................ 6-42
BRAKE FLUID REPLACEMENT .................................................... ........ .......... ..... ...... ........... ................ 6-43
BRAKE CALIPER REMOVAL AND DISASSEMBLY ............................................................................. 6·43
BRAKE CALIPER INSPECTION ...... ...................... ................................................................................ 6-44
BRAKE CALIPER REASSEMBLY AND REMOUNTlNG ....................................................................... 6-45
BRAKE DISC INSPECTION .................................................................................................................... 6·46
MASTER CYLINDER REMOVAL AND DISASSEMBLY ........................................................................ 6-47
MASTER CYLINDER INSPECTION ........................................ ................................................... ............ 6·48
MASTER CYLINDER REASSEMBLY AND REMOUNTING ....... ..... .................... .................................. 6-48
REAR BRAKE ........................................................................................... ........... ... .... .................................. 6·50
CONSTRUCTION ................................................................................................................. ..... .. ..... ....... 6·50
BRAKE PAD REPLACEMENT ................................................................................................................ 6·51
BRAKE FLUID REPLACEMENT ...................................................................... .. .................................... 6-52
BRAKE CALIPER REMOVAL AND DISASSEMBLY ............................................................................. 6-53
BRAKE CALIPER INSPECTION ... ........................ ............... .................................................................. 6-54
BRAKE CALIPER REASSEMBLY AND REMOUNTING ....................................................................... 6-54
BRAKE DISC INSPECTION .................................................................................................................... 6-55
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...... .................. ................................................ 6·55
MASTER CYLINDER INSPECTION ....................................................................................................... 6-56
MASTER CYLINDER REASSEMBLY AND REMOUNnNG .................................................................. 6-57
ELECTRICAL SYSTEM
,----------------------- CONTENTS -----------
CAUTIONS IN SERViCiNG ........................................................... .. ....................... 7- 2
CONNECTORS ....................................................................... .......................... 7- 2
COUPLERS ...................................................... ........................ ......................... 7- 2
CLAMPS ........................... ... ... .............. ............................................................ 7- 2
FUSE .............................. ................................................................................... 7- 2
SEMICONDUCTOR EQUIPPED PARTS ........................................ ................. 7- 2
BATTERY ......... ... ......... ...... .................... .......................................................... 7- 3
CONNECTING THE BATTERy .............................................. .......................... 7- 3
WIRING PROCEDURE ............................................ ............ .............................. 7- 3
USING THE MULTI CIRCUIT TESTER ............................................................ 7- 4
LOCATION OF ELECTRICAL COMPONENTS ............... ..................................... 7- 5
CHARGING SYSTEM ............ .............................................................................. 7- 7
DESCRIPTION ................. ........ .............................. ............................................ 7- 7
TROUBLESHOOTING ............................................. ....................... ................... 7- 8
INSPECTION ........................................................................................... .......... 7- 9
STARTER SYSTEM ............................................................................................... 7-12
DESCRIPTION ................................................................................................ 7-12
TROUBLESHOOTING ....................................................................................... 7-12
STARTER MOTOR REMOVAL AND DiSASSEMBLy ...................................... 7-13
STARTER MOTOR INSPECTION ........................................................... .......... 7-14
STARTER MOTOR REASSEMBLY AND REMOUNTING .............................. 7-15
STARTER RELAY INSPECTION ...................................................................... 7-16
SIDE STANDnGNITION INTERLOCK SYSTEM PARTS INSPECTION .......... 7-17
IGNITION SySTEM ................................................ ........ ........................................ 7-19
DESCRiPTION ........... ......... ................... ............................................... ............. 7-19
TROUBLESHOOTING .............................................. ..................... ................ .... 7-19
INSPECTION ................................................................................................... 7-21
SPEEDOMETER ...... .............................................................................................. 7-24
REMOVAL ...... ................................................................................................. 7-24
PARTS NAMES .................................................................................................. 7-25
OPERATING PROCEDURE .............................................................................. 7-25
LAMPS .................................... ............................................................ .......... ......... 7-29
HEADLIGHT ...................................................................................................... 7-29
FRONT AND REAR TURN SIGNAL LIGHT ..................................................... 7-30
BRAKE LlGHTffAILLlGHT ................................... .............. ....... ...................... 7-31
RELAYS .............................................................................................................. 7-32
STARTER RELAY ............................................................................................. 7-32
TURN SIGNAUSIDE STAND RELAy .............................................................. 7-32
SWiTCHES ........................................................................................ ... .................. 7-33
BATTEnY ....... ........................... ... ... ..... .. ..... .. ... .... .................. ...... ....... .. .................. 7-34
REMOVAL .... ...................... ........... .................................................................... 7-34
SPECIFICATIONS ........................................................................................... 7-34
SERVICING ............. ........ ... ............................................................................... 7-34
RECHARGING OPERATION ................................................................... ......... 7-35
EMISSION CONTROL INFORMATION
,---------------CONTENTS - - --- ---------,
EMISSION CONTROL CARBURETOR COMPONENTS ............. .................... 9- 2
EVAPORATIVE EMISSION CONTROL SYSTEM (FOR E-33) ... ....... .............. 9- 3
CANISTER HOSE ROUTING .................. ... ............................................ !/- 4
INSPECTION ................... ......................... .................................................... 9- 5
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