Page 1 DR-Z400/E 9 9 5 0 0 - 4 3 0 2 2 - 0 1 E...
Page 2: Table Of Contents
GROUP INDEX FOREWORD This manual contains an introductory description on the SUZUKI DR-Z400/DR-Z400E and procedures for GENERAL INFORMATION its inspection, service, and overhaul of its main com- ponents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to famil- iarize yourself with the motorcycle and its maintenance.
Page 3 HOW TO USE THIS 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.
Page 4 Measure in voltage range. wise specified. 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.
Page 5: General Information
GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ................1- 2 GENERAL PRECAUTIONS ................1- 2 SUZUKI DR-Z400Y/DR-Z400EY (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 ....................
Page 6: Warning/Caution/Note
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. Indicates a potential hazard that could result in death or injury.
Page 7 GENERAL INFORMATION 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.
Page 8: Suzuki Dr-Z400Y/Dr-Z400Ey (2000-Model)
GENERAL INFORMATION SUZUKI DR-Z400Y/DR-Z400EY (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) 1 is stamped on the right side of the steering head pipe.
Page 9: Engine Oil
Use an antifreeze designed for aluminum radiators. SUZUKI recommends the use of SUZUKI COOLANT antifreeze. If this is not available, use an equivalent antifreeze for aluminum radiators.
Page 10: Break-In Procedures
GENERAL INFORMATION BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life.
Page 11: Information Labels
GENERAL INFORMATION INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME E-01 E-03 E-28 Engine starting label (DR-Z400E) Noise label ICES Canada label Manual notice label Warning safety label Frame serial number plate Compliance label Fuel information label 8 4 5...
Page 12: Specifications
GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..........2 235 mm (88.0 in) Overall width ............ 825 mm (32.5 in) Overall height ..........1 245 mm (49.0 in) Wheelbase ............1 475 mm (58.1 in) Ground clearance ..........325 mm (12.8 in) Seat height ............
Page 13 GENERAL INFORMATION CHASSIS Front suspension ..........Telescopic, coil spring, oil damped, rebound damping force 18-way adjustable, compression damping force 14-way ad- justable Rear suspension ..........Link type, coil spring, oil damped, spring preload fully adjust- able, rebound damping force 21-way adjustable, compres- sion damping force 26-way adjustable Front suspension stroke ........
Page 14: Country And Area Codes
1-10 GENERAL INFORMATION COUNTRY AND AREA CODES The following are codes and their applicable country or area. CODE COUNTRY OR AREA E-01 General E-03 E-28 Canada...
Page 15: Periodic Maintenance
PERIODIC MAINTENANCE 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 ................
Page 16: Periodic Maintenance Schedule
PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of hours. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART Interval Initial...
Page 17: Maintenance And Tune-Up Procedures
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. AIR CLEANER Inspect each time the motorcycle is ridden and clean as necessary. If the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in power output and an in- crease in fuel consumption.
Page 18: Exhaust Pipe Nut And Bolt And Muffler Nut And Bolts
PERIODIC MAINTENANCE EXHAUST PIPE NUT AND BOLT AND MUFFLER NUT AND BOLTS Tighten initially at five hours of operation and every 30 hours thereafter. Remove the right frame cover. ( 6-2) Tighten the exhaust pipe nut 1, exhaust pipe bolt 2, muffler connection bolt 3, muffler mounting bolt 4 and muffler mount- ing nut 5 to the specified torque.
Page 19: Tappet Clearance
PERIODIC MAINTENANCE TAPPET CLEARANCE Inspect initially at five hours of operation and every 60 hours thereafter. INSPECTION Remove the fuel tank. ( 4-2) Disconnect the spark plug cap and remove the spark plug. 2-9) Remove the cylinder head cover. The tappet clearance specification is different for both intake and exhaust valves.
Page 20 After ro- tating the crankshaft, check the tappet clearance again to make sure that it is within specification. When installing the cylinder head cover, apply SUZUKI BOND “1207B” to the cam end caps of the cylinder head cover gas- ket.
Page 21 PERIODIC MAINTENANCE INTAKE SIDE...
Page 22 PERIODIC MAINTENANCE EXHAUST SIDE...
Page 23: Spark Plug
PERIODIC MAINTENANCE SPARK PLUG Inspect every 30 hours of operation. Replace every 60 hours of operation. Remove the fuel tank. ( 4-2) Disconnect the spark plug cap and remove the spark plug. Cold type Standard Hot type CR9E CR8E CR7E CR10E U27ESR-N DENSO...
Page 24: Spark Arrester
2-10 PERIODIC MAINTENANCE SPARK ARRESTER Clean every 30 hours of operation. Remove the spark arrester. Remove the carbon deposits from spark arrester and muffler. FUEL LINE Inspect initially at five hours of operation and every 30 hours thereafter. Replace every four years of operation. Inspect the fuel hose for damage and fuel leakage.
Page 25: Engine Oil And Oil Filter
PERIODIC MAINTENANCE 2-11 ENGINE OIL AND OIL FILTER Replace initially at five hours of operation and every 60 hours thereafter. The oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be done together with the engine oil change.
Page 26: Engine Oil Hoses
2-12 PERIODIC MAINTENANCE OIL FILTER REPLACEMENT Drain the engine oil as described in the engine oil replace- ment procedure. Remove the oil filter cap 1 and oil filter 2. Replace the oil filter with a new one. NOTE: Before replacing the oil filter cap, make sure that the spring 3 and a new O-ring 4 are installed correctly.
Page 27: Throttle Cable Play
PERIODIC MAINTENANCE 2-13 THROTTLE CABLE PLAY Inspect initially at five hours of operation and every 30 hours thereafter. Remove the fuel tank. ( 4-2) A twin throttle cable system is used in this motorcycle. Cable 1 is for pulling and cable 2 is for returning. To adjust the cable play, adjust the returning cable first and then adjust the pulling cable.
Page 28: Engine Idle Speed
2-14 PERIODIC MAINTENANCE ENGINE IDLE SPEED Inspect initially at five hours of operation and every 30 hours thereafter. NOTE: Make this adjustment when the engine is hot. Connect the multi circuit tester to the high-tension cord. Start the engine and set the engine idle speed between 1 700 and 1 900 r/min by turning the throttle stop screw 1.
Page 29: Radiator Hoses
PERIODIC MAINTENANCE 2-15 ENGINE COOLANT REPLACEMENT Remove the radiator cap 1 and drain plug 2. Then drain the engine coolant. Tighten the drain plug 2. Pour the specified engine coolant slowly into the radiator. Engine coolant: Use an antifreeze designed for aluminum radiators mixed with distilled water only.
Page 30: Clutch
Excessive wear Missing O-ring seals If any damages are found, replace the drive chain with a new one. The standard drive chain is RK520KZO. SUZUKI rec- ommends to use this standard drive chain as a replace- ment. NOTE: When replacing the drive chain, replace the drive chain and sprockets as a set.
Page 31 PERIODIC MAINTENANCE 2-17 Count out 21 pins (20-pitch) on the drive chain and measure the distance between the two points. If the distance exceeds the service limit, replace the drive chain with a new one. 09900-20103: Vernier calipers Drive chain 20-pitch length Service Limit: 319.4 mm (12.57 in) Loosen or tighten both chain adjusters 1 until there is 40 –...
Page 32: Brakes
2-18 PERIODIC MAINTENANCE BRAKES Inspect initially at five hours of operation and every 30 hours thereafter. BRAKE PADS The extent of brake pad wear can be checked by observing the grooved limit line 1 on the brake pad. When the wear exceeds the grooved limit line, replace the pads with new ones.
Page 33: Brake Fluid
PERIODIC MAINTENANCE 2-19 BRAKE FLUID Inspect initially at five hours of operation and every 30 hours thereafter. Replace every two years of operation. BRAKE FLUID LEVEL Keep the motorcycle upright and place the handlebar straight. Check the brake fluid level by observing the lower limit line on the front and rear brake fluid reservoir.
Page 34 2-20 PERIODIC MAINTENANCE FRONT BRAKE Bleed air from the brake system. Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will re- move the tension of the brake lever causing it to touch the handlebar grip.
Page 35: Brake Hoses
PERIODIC MAINTENANCE 2-21 BRAKE HOSES Inspect initially at five hours of operation and every 30 hours thereafter. Replace every four years of operation. Check the brake hoses for leakage, cracks, wear and dam- age. If any damages are found, replace the brake hoses with new ones.
Page 36: Spoke Nipples
2-22 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be ad- versely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. COLD INFLATION TIRE PRESSURE kgf/cm FRONT...
Page 37: Steering
PERIODIC MAINTENANCE 2-23 STEERING Inspect initially at five hours of operation and every 60 hours thereafter. The steering should be adjusted properly for smooth turning of the handlebar and safe operation. Overtight steering prevents smooth turning of the handlebar and too loose steering will cause poor stability.
Page 38: Chassis Nuts And Bolts
2-24 PERIODIC MAINTENANCE CHASSIS NUTS AND BOLTS Tighten initially at five hours of operation and every 30 hours thereafter. Check that all chassis nuts and bolts are tightened to their specified torque. (Refer to page 2-25 for the locations of following the nuts and bolts.) ITEM N·m kgf-m...
Page 39 PERIODIC MAINTENANCE 2-25...
Page 40: General Lubrication
2-26 PERIODIC MAINTENANCE GENERAL LUBRICATION Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. 1 Odometer cable 5 Drive chain 9 Brake pedal pivot 2 Odometer gearbox 6 Swingarm pivot 0 Brake lever holder 3 Wheel bearing...
Page 41: Compression Pressure Check (Dr-Z400E)
PERIODIC MAINTENANCE 2-27 COMPRESSION PRESSURE CHECK (DR-Z400E) The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service.
Page 42: Oil Pressure Check
2-28 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Oil pressure: Above 40 kPa (0.4 kgf/cm , 5.7 psi) at 3 000 r/min, oil temp at 60°C Below 140 kPa (1.4 kgf/cm , 19.9 psi) Low or high oil pressure can indicate any of the following conditions:...
Page 43 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE ......3- 2 ENGINE REMOVAL AND REMOUNTING ................ 3- 3 ENGINE REMOVAL ...................... 3- 3 ENGINE REMOUNTING ....................3- 8 ENGINE DISASSEMBLY ....................3-11 ENGINE COMPONENTS INSPECTION AND SERVICE ..........3-22 CYLINDER HEAD ......................
Page 44 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and installed without removing the engine from the frame. Refer to the page listed in each section for removal and installation instructions. ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION...
Page 45: Engine Removal And Remounting
ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame, wash the engine us- ing a steam cleaner. Engine removal is sequentially explained in the following steps. Remove the seat and frame covers. ( 6-2) Drain the engine oil.
Page 46 ENGINE Remove the regulator/rectifier. Remove the engine coolant overflow tank mounting bolt. Disconnect the spark plug cap 1 , engine oil breather hose 2, engine oil hose 3, and engine oil tank 4. Remove the clutch release arm 5. Remove the starter motor 6. (DR-Z400E) Remove the kick lever.
Page 47 ENGINE Remove the exhaust pipe 1 and muffler 2. Disconnect the radiator hoses. Disconnect the decompression cable. (DR-Z400) Disconnect the engine oil pipe 3 and engine oil hose union bolt 4.
Page 48 ENGINE Remove the gearshift lever. Remove the engine sprocket cover. Flatten the washer 1 and remove the engine sprocket nut 2 while pressing down on the rear brake pedal. Remove the cotter pins and brake pedal. Replace the removed cotter pins with new ones. Remove the engine sprocket.
Page 49 ENGINE Remove the engine from the frame.
Page 50: Engine Remounting
ENGINE ENGINE REMOUNTING Remount the engine in the reverse order of engine removal. Install the engine mounting nuts and bolts. NOTE: Temporally tighten the nuts at this stage. The engine mounting nuts are self-locking. Once the nut has been removed, it is no longer of any use. Replace the engine mounting nuts with new ones.
Page 51 ENGINE Tighten the brake pedal bolt to the specified torque. Brake pedal bolt: 29 N·m (2.9 kgf-m, 21.0 lb-ft) NOTE: After installing the brake pedal, install the new cotter pins into the brake pedal bolt and pin. Install the engine sprocket, with side A of the sprocket facing toward the engine.
Page 52 3-10 ENGINE Tighten the exhaust pipe nut 1, exhaust pipe bolt 2, muf- fler connection bolt 3, muffler mounting bolt 4 and muffler mounting nut 5 to the specified torque. Exhaust pipe nut and bolt : 23 N·m (2.3 kgf-m, 16.5 lb-ft) Muffler connection bolt: 20 N·m (2.0 kgf-m, 14.5 lb-ft) Muffler mounting nut and bolt:...
Page 53: Engine Disassembly
ENGINE 3-11 ENGINE DISASSEMBLY Remove the cap bolt 1 and cam chain tension adjuster 2. Remove the top-dead-center (TDC) plug 3 and generator cover cap 4. Turn the generator rotor until the “T” line on the generator rotor is aligned with the center of the hole in the generator cover.
Page 54 3-12 ENGINE Remove the cam chain guide 1 and camshaft journal hold- ers 2. Remove the dowel pins 3, intake camshaft 4 and exhaust camshaft 5. NOTE: Do not drop the dowel pins into the crankcase. Remove the decompression lever assembly. (DR-Z400) Remove the cylinder head side bolt.
Page 55 ENGINE 3-13 Remove the cylinder head bolts, and then remove the cylinder head. NOTE: If the cylinder head does not come off easily, lightly tap it using a plastic mallet. Remove the cylinder head gasket 1 and dowel pins 2. Remove the cam chain guide 3.
Page 56 3-14 ENGINE Remove the generator rotor cover. (DR-Z400) Remove the starter drive gear cover 1 and starter drive gear 2. (DR-Z400E) Remove the generator rotor cover. (DR-Z400E) Remove the starter driven gear 3 , dowel pins 4 , and gasket 5. Remove the oil filter cap 6 and oil filter 7.
Page 57 ENGINE 3-15 Remove the water pump cover. Remove the clutch cover. Remove the right crankcase cover. Remove the dowel pins 1 and gasket 2. Loosen the clutch spring set bolts working in diagonal stages, and then remove them when they are fully loosened.
Page 58 3-16 ENGINE Remove the clutch pressure plate, clutch drive plates, and clutch driven plates. Remove the push rod, spring washer, and spring washer seat. Flatten the clutch sleeve hub washer. Hold the clutch sleeve hub using the special tool, and then remove the clutch sleeve hub nut.
Page 59 ENGINE 3-17 Remove the primary driven gear assembly and collar. Remove the cam chain tensioner 1 and cam chain 2. Remove the retainer 3, spacer 4 and kick starter driven gear 5. (DR-Z400) Remove the kick starter assembly 6. (DR-Z400) Remove the kick starter guide 7.
Page 60 3-18 ENGINE Remove the oil pump idle gear 1 and oil pump driven gear 2. Remove the pin 3 and oil pump assembly. Do not remove the circrip A, before separating the crankase to prevent the oil pump idle gear shaft from dropping into the crankcase.
Page 61 ENGINE 3-19 Remove the gearshift cam driven gear bolt. Hold the generator rotor using the special tool (DR-Z400) or a 26-mm offset wrench (DR-Z400E), and then remove the balancer driven gear nut. 09930-44913: Rotor holder Remove the washer, balancer driven gear, and key. Hold the generator rotor using the special tool (DR-Z400) or a 26-mm offset wrench (DR-Z400E), and then remove the primary drive gear nut.
Page 62 3-20 ENGINE Remove the left crankcase securing bolts. Remove the right crankcase securing bolts. Separate the crankcase using the special tool. 09920-13120: Crankcase separating tool NOTE: Fit the crankcase separating tool to the right side, so that the tool plate is paralleled with the end face of the crankcase. Remove the dowel pins.
Page 63 ENGINE 3-21 Remove the countershaft assembly 1 and driveshaft assem- bly 2. Remove the balancer shaft. Remove the crankshaft from the crankcase using the spe- cial tool. 09920-13120: Crankcase separating tool Remove the oil sump filter.
Page 64: Engine Components Inspection And Service
3-22 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD DISASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups (i.e., exhaust or in- take) so that they can be installed in their original posi- tions. Remove the intake pipe.
Page 65 ENGINE 3-23 Remove the oil seal with long-nose pliers. Remove the valve spring seat. NOTE: Removal of valves completes ordinary disassembling work. If valve guides have to be removed for replacement after inspect- ing the related parts, carry out the steps shown in the valve guide servicing.
Page 66 3-24 ENGINE VALVE HEAD RADIAL RUNOUT Support the valve using a V-block and measure the valve head radial runout using the dial gauge, as shown. If the runout ex- ceeds the service limit, replace the valve with a new one. 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm)
Page 67 ENGINE 3-25 VALVE GUIDE SERVICING Drive the valve guide out toward the camshaft side using the valve guide remover. 09916-44310: Valve guide remover/installer NOTE: Discard the removed valve guide. Only oversized valve guides are available as replacement parts. Refinish the valve guide holes in the cylinder head using the valve guide reamer and handle.
Page 68 3-26 ENGINE VALVE SEAT WIDTH Coat the valve seat uniformly with prussian blue. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.
Page 69 ENGINE 3-27 When installing the solid pilot 1, rotate it slightly. Seat the pilot snugly. Install the 45° cutter 2, attachment 3, and T-handle 4. INITIAL SEAT CUT Descale and clean up the seat using the 45° cutter. Rotate the cutter one or two turns. Measure the valve seat width W after every cut.
Page 70 3-28 ENGINE TOP NARROWING CUT If the contact area is too high on the valve, or if it is too wide, use the 30° cutter ( for the intake side ) and the 15° cutter (for the exhaust side) to lower and narrow the contact area. 30˚...
Page 71 ENGINE 3-29 VALVE SEAT SEALING CONDITION INSPECTION With the valve and valve spring assembled, pour a small quan- tity of gasoline into the intake or exhaust port. Check that no gasoline leaks through the valve seat. If leakage is found, correct the sealing surface. Gasoline is highly flammable and explosive.
Page 72 3-30 ENGINE REASSEMBLY Install each valve spring seat. Apply molybdenum oil solution to each oil seal and press-fit them into position. Do not reuse the oil seals. Apply molybdenum oil solution to the valve as shown, and then insert them into the valve guides. When inserting each valve into the valve guides, make sure not to damage the lip of the oil seal.
Page 73: Camshaft/Automatic Decompression Assembly
ENGINE 3-31 CAMSHAFT/AUTOMATIC DECOMPRES- SION ASSEMBLY Do not attempt to disassemble the camshaft/automatic decompression assembly. It is not serviceable. AUTOMATIC DECOMPRESSION Move the automatic decompression weight by hand to inspect if it is operating smoothly. If the automatic decompression weight does not operate smoothly, replace it with a new one.
Page 74 3-32 ENGINE CAMSHAFT JOURNAL WEAR Measure the oil clearance, with the camshaft installed, using the plastigauge. 09900-22301: Plastigauge 09900-22302: Plastigauge Camshaft journal oil clearance (IN & EX) Service Limit: 0.150 mm (0.0059 in) Tighten the camshaft journal holder bolts evenly and in diagonal stages to the specified torque.
Page 75: Cylinder
ENGINE 3-33 CYLINDER CYLINDER DISTORTION Check the gasket surface of the cylinder block for distortion us- ing a straightedge and thickness gauge. Take clearance read- ings at several places. If any clearance reading exceeds the ser- vice limit, replace the cylinder block with a new one. 09900-20803: Thickness gauge Cylinder distortion Service Limit: 0.05 mm (0.002 in)
Page 76 3-34 ENGINE PISTON-RING-TO-GROOVE CLEARANCE Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. If any clearance reading exceeds the service limit, replace both the piston and piston rings. 09900-20803: Thickness gauge 09900-20205: Micrometer (0 – 25 mm) Piston-ring-to-groove clearance Service Limit: 1st: 0.18 mm (0.0071 in)
Page 77: Conrod
ENGINE 3-35 PISTON PIN AND PIN BORE Measure the piston pin bore diameter using the small bore gauge. If the diameter exceeds the service limit, replace the piston with a new one. 09900-20602: Dial gauge (1/1000 mm) 09900-22403: Small bore gauge (18 – 35 mm) Piston pin bore Service Limit: 20.030 mm (0.7886 in) Measure the piston pin outside diameter at three positions us-...
Page 78: Crankshaft
3-36 ENGINE CRANKSHAFT CRANKSHAFT RUNOUT Support the crankshaft using V-blocks and measure the crank- shaft runout using the dial gauge, as shown. If the runout ex- ceeds the service limit, replace the crankshaft with a new one. 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09910-21304: V-block set (100 mm) Crankshaft runout...
Page 79: Starter Torque Limiter (Dr-Z400E)
OIL PUMP The oil pump case securing screw is applied with SUZUKI THREAD LOCK SUPER “1303”. If an attempt is made to overhaul the oil pump assembly, the screw may be damaged. Only the oil pump unit is available as a replacement.
Page 80: Gearshift Fork And Gear
3-38 ENGINE CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using vernier calipers. If any spring is not within the service limit, replace all of the springs with new ones. 09900-20101: Vernier calipers Clutch spring free length Service Limit: 49.9 mm (1.96 in) GEARSHIFT FORK AND GEAR GEARSHIFT-FORK-TO-GEARSHIFT-FORK GROOVE...
Page 81: Transmission
ENGINE 3-39 TRANSMISSION DISASSEMBLY Disassemble the transmission gears as shown. 1 Countershaft E Bearing 2 5th (top) drive gear F Oil seal 3 Circlip G 4th driven gear 4 3rd drive gear H 3rd driven gear 5 Circlip I Washer 6 4th drive gear J Circlip 7 2nd drive gear...
Page 82 3-40 ENGINE REASSEMBLY Reassemble the transmission in the reverse order of disassem- bly. Pay special attention to the following points: NOTE: Before installing the gears, apply engine oil to the inner surface of each gear and bushing. Never reuse a circlip. After a circlip has been re- moved from a shaft, it should be discarded and a new circlip must be installed.
Page 83 ENGINE 3-41 1 Countershaft 2 Driveshaft...
Page 84: Bearings
3-42 ENGINE BEARINGS Wash the bearing with a cleaning solvent and lubricate it with motor oil before inspection. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defec- tive and must be replaced with a new one as follows.
Page 85 ENGINE 3-43 DRIVESHAFT BEARINGS Remove the right and left driveshaft bearings using the spe- cial tool. 09921-20220: Bearing remover set Replace the removed bearings with new ones. Install the right and left driveshaft bearings using the special tool. 09913-70210: Bearing installer set CRANKSHAFT BEARINGS Remove the bearing retainer.
Page 86 3-44 ENGINE LEFT GEARSHIFT CAM BEARING Remove the left gear shift cam bearing. Replace the removed bearing with a new one. Install the left gearshift cam bearing. RIGHT BALANCER SHAFT BEARING Remove the right balancer shaft bearing using the special tool.
Page 87: Oil Seals
Install the oil seals into the crankcase, clutch housing case, and generator rotor cover. Pay attention to the following points: Replace the removed oil seals with new ones. Apply SUZUKI SUPER GREASE “A” to the lip of the oil seals. For USA 99000-25030: SUZUKI SUPER GREASE “A”...
Page 88 3-46 ENGINE Install the driveshaft oil seal into the left crankcase slowly, using the special tool. 09913-70210: Bearing installer set GEARSHIFT SHAFT OIL SEAL Remove the gearshift shaft oil seal from the left crankcase, slowly using the special tool. 09913-50121: Oil seal remover Replace the removed oil seal with a new one.
Page 89: Engine Reassembly
ENGINE 3-47 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. Pay special attention to the following points: NOTE: Apply engine oil to each running and sliding part before reas- sembling the engine. CRANKSHAFT 1 Bearing 2 Crankshaft (R) 3 Conrod 4 Bearing 5 Crank pin...
Page 90: Gearshift Cam And Fork
3-48 ENGINE GEARSHIFT CAM AND FORK 1 Gearshift fork No.1 2 Gearshift fork No.2 3 Gearshift fork shaft 4 Bearing 5 Pin 6 Gearshift cam 7 Bearing 8 Gearshift fork No.3 9 Gearshift fork shaft Install the gearshift forks into the gearshifting grooves in the correct position and direction.
Page 91: Crankcase
Install the dowel pins to the left crankcase. Apply engine oil to the conrod big end and to the transmis- sion gears. Apply SUZUKI BOND “1207B” or “1215” to the mating sur- face of the right crankcase and A part of both crankcases as shown.
Page 92: Starter Clutch And Generator Rotor
3-50 ENGINE Tighten the crankcase bolts to the specified torque. Crankcase bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) After the crankcase bolts have been tightened, check if the crankshaft, countershaft, and driveshaft rotate smoothly. If a large resistance is felt to rotation, try to free the shafts by tapping them with a plastic mallet.
Page 93: Balancer Shaft
ENGINE 3-51 BALANCER SHAFT 1 Washer 2 Balancer driven gear 3 Bearing 4 Pin 5 Balancer shaft 6 Bearing A Balancer shaft nut ITEM N·m kgf-m lb-ft 36.0 When installing the balancer drive gear, align the pin 1 with the groove 2. When installing the balancer driven gear, align the pin 3 with the groove 4.
Page 94: Primary Drive Gear
3-52 ENGINE PRIMARY DRIVE GEAR Install the key 1 and primary drive gear 2. Hold the generator rotor using the special tool (DR-Z400) or a 26-mm offset wrench (DR-Z400E), and then tighten the primary drive gear nut to the specified torque. 09930-44913: Rotor holder Primary drive gear nut: 110 N·m (11.0 kgf-m, 79.5 lb-ft) GEARSHIFT CAM DRIVEN GEAR...
Page 95: Gearshift Shaft
ENGINE 3-53 GEARSHIFT SHAFT Tighten the gearshift arm stopper to the specified torque. Gearshift arm stopper: 19 N·m (1.9 kgf-m, 13.5 lb-ft) OIL PUMP Before mounting the oil pump, apply engine oil to the sliding surfaces of the oil pump case, outer rotor, inner rotor, and shaft.
Page 96: Kick Starter (Dr-Z400)
3-54 ENGINE KICK STARTER (DR-Z400) 1 Oil seal 2 Guide 3 Spring 4 Kick starter shaft 5 Kick starter drive gear 6 Washer 7 Circlip 8 Kick starter 9 Spring 0 Washer A Bolt B Kick starter guide C Kick starter stopper When installing the kick starter drive gear onto the kick starter shaft, align the punch mark 1 on the kick starter with the line 3 on the kick starter shaft.
Page 97: Cam Chain
ENGINE 3-55 CAM CHAIN Install the cam chain 1 on to the sprocket. Tighten the cam chain tensioner mounting bolt 2 to the speci- fied torque. Cam chain tensioner mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) CLUTCH 1 Clutch release camshaft 2 Bolt 3 Spring retainer 4 Spring...
Page 98 3-56 ENGINE Hold the clutch sleeve hub using the special tool, and then tighten the clutch sleeve hub nut to the specified torque. 09920-53740: Clutch sleeve hub holder Clutch sleeve hub nut: 70 N·m (7.0 kgf-m, 50.5 lb-ft) Bend the tongue of the washer securely. Install the spring washer seat 1 and spring washer 2 onto the clutch sleeve hub correctly.
Page 99: Right Crankcase Cover
ENGINE 3-57 RIGHT CRANKCASE COVER Install the dowel pins 1 and new gasket 2. Use a new gasket to prevent oil leakage. Tighten the right crankcase cover bolts securely. NOTE: Install the new gasket onto the right crankcase cover bolt A as shown.
Page 100: Starter Drive Gear Cover (Dr-Z400E)
3-58 ENGINE Tighten the generator rotor cover bolts securely. (DR-Z400E) STARTER DRIVE GEAR COVER (DR-Z400E) Tighten the starter drive gear cover screws securely. PISTON RING Install the oil ring first, the 2nd ring second, and the 1st ring last. NOTE: The 1st 1 and 2nd 2 piston rings differ in shape.
Page 101: Piston And Cylinder
ENGINE 3-59 First, install a spacer 1 into the oil ring groove, and then install the two side rails 2. The spacer and side rails do not have a designated top and bottom. They can be installed in any position. When installing the spacer, be careful not to allow its two ends to overlap in the groove.
Page 102: Cylinder Head
3-60 ENGINE Install the dowel pins 1 and new gasket 2 onto the crank- case. Use a new gasket to prevent oil leakage. Hold each piston ring with the piston ring sections positioned correctly and put it into the cylinder. Make sure that the piston rings are caught by the cylinder skirt.
Page 103: Camshaft/Automatic Decompression Assembly
ENGINE 3-61 With the head snugly seated on the cylinder, secure it by tightening the bolts in diagonal stages. Tighten the cylinder head bolts to the specified torque. Cylinder head bolt Initial: 25 N·m (2.5 kgf-m, 18.0 lb-ft) Final: 46 N·m (4.6 kgf-m, 33.5 lb-ft) NOTE: Apply engine oil to the threaded parts of the cylinder head bolts and its washers.
Page 104 3-62 ENGINE NOTE: Just before installing the camshaft into the cylinder head, apply molybdenum oil solution to the camshaft journals and cam faces. Also, apply engine oil to the camshaft journal holders. Place each camshaft into the correct position. NOTE: Camshafts which are marked “EX”...
Page 105: Cylinder Head Cover
CYLINDER HEAD COVER Thoroughly wipe off oil from the fitting surfaces of the cylin- der head and cover. Apply SUZUKI BOND “1207B” to the end caps of the cylinder head cover gasket as shown. For USA 99104-31140: SUZUKI BOND “1207B”...
Page 106: Cam Chain Tension Adjuster
3-64 ENGINE CAM CHAIN TENSION ADJUSTER Install the cam chain tension adjuster. Pay special attention to the following points: Apply engine oil to the push rod. Turn the adjusting screw clockwise with a flat-bladed screw- driver until the push rod is locked. Fit a new gasket to the chain tension adjuster body.
Page 107 FUEL AND LUBRICATION SYSTEM FUEL AND LUBRICATION SYSTEM CONTENTS FUEL TANK ....................4- 2 REMOVAL ....................4- 2 REMOUNTING ................... 4- 2 FUEL VALVE ....................4- 3 REMOVAL AND INSPECTION ..............4- 3 FUEL STRAINER ..................4- 3 REMOUNTING ................... 4- 3 CARBURETOR ....................
Page 108: Fuel Tank
FUEL AND LUBRICATION SYSTEM FUEL TANK REMOVAL Remove the seat and side covers. ( 6-2) Turn the fuel valve to the “OFF” position. Disconnect the fuel hose. Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. Remove the fuel tank.
Page 109: Fuel Valve
FUEL AND LUBRICATION SYSTEM FUEL VALVE REMOVAL AND INSPECTION Remove the fuel tank. ( 4-2) Drain the fuel completely. Remove the fuel valve. Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. Replace the removed O-ring with a new one to pre- vent fuel leakage.
Page 110: Carburetor
FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION 1 Top cap 2 Throttle valve lever 3 Throttle valve 4 Throttle lever assembly 5 Carburetor body 6 Intake joint 7 O-ring 8 Slow air jet 9 Main air jet 0 Air jet A Throttle position sensor B Starter plunger C Hose D Coasting richer pump assembly...
Page 111: Specifications
FUEL AND LUBRICATION SYSTEM SPECIFICATIONS SPECIFICATION ITEM DR-Z400 DR-Z400E E-01 E-03, 28 E-01 E-03, 28 ← ← ← Carburetor type KEIHIN FCR39H ← ← ← Bore size 39 mm (1.5 in) I.D. No. 29F0 29F1 29F3 29F4 ← ← ← Idle r/min 1800 ±...
Page 112: Slow System
FUEL AND LUBRICATION SYSTEM SLOW SYSTEM This system supplies fuel during engine operation when the piston valve 1 is fully closed or slightly open. The fuel from the float chamber 2 is metered by the pilot jet 3 where it mixes with air coming in through the pilot air jet 4.
Page 113: Main System
FUEL AND LUBRICATION SYSTEM MAIN SYSTEM As the piston valve 1 is opened, engine speed rises and vacuum in the venturi A is increased. The fuel in the float chamber 2 is metered by the main jet 3. The metered fuel enters the needle jet 4, mixes with the air admitted through the main air jet 5, and then forms an emulsion.
Page 114: Accelerator Pump System
FUEL AND LUBRICATION SYSTEM ACCELERATOR PUMP SYSTEM This system works only when the rider opens the throttle grip quickly as the accelerator pump sends the necessary amount of fuel to the carburetor bore to correct the air/fuel mixture ratio. When the rider opens the throttle grip quickly, the intake air volume increases and air velocity at the bottom of the piston valve is slow and sucking volume of fuel is less.
Page 115: Starter System
FUEL AND LUBRICATION SYSTEM STARTER (ENRICHER) SYSTEM Pulling the starter (enricher) knob causes fuel to be drawn into the starter circuit from the float chamber 1. The starter jet 2 meters this fuel, which then flows into the fuel passage 3 and mixes with the air coming from the float chamber.
Page 116: Removal
4-10 FUEL AND LUBRICATION SYSTEM REMOVAL Remove the fuel tank. ( 4-2) Remove the left frame cover. ( 6-2) Disconnect the throttle position sensor coupler. Disconnect the throttle cables. Disconnect the coasting richer pump hose. Loosen the carburetor clamp screws, and then remove the carburetor assembly.
Page 117 FUEL AND LUBRICATION SYSTEM 4-11 First, remove the air valve mounting nut 1, and then re- move the air valve mounting bolt 2 and air valve assembly 3. (DR-Z400) Remove the throttle position sensor. Remove the accelerating pump assembly. Replace the removed O-ring with a new one to prevent fuel leakage.
Page 118 4-12 FUEL AND LUBRICATION SYSTEM Remove the throttle lever assembly. Remove the throttle valve. Remove the intake joint. Replace the removed O-ring with a new one to prevent air leakage. Remove the float chamber. Replace the removed O-ring with a new one to prevent fuel leakage.
Page 119: Cleaning
FUEL AND LUBRICATION SYSTEM 4-13 Remove the following parts. 1 Valve seat 6 Starter jet 2 Main jet 7 Main air jet 3 Slow jet 8 Slow air jet 4 Pilot screw 9 Air jet 5 Needle jet NOTE: Before removing the pilot screw 4 , its setting must be deter- mined.
Page 120: Inspection
4-14 FUEL AND LUBRICATION SYSTEM INSPECTION Check the following items for any damage or clogging. If any damages are found, replace the damaged parts with new ones. Pilot jet Float O-ring Main jet Needle valve Throttle valve Main air jet Valve seat Diaphragm Pilot air jet 1...
Page 121: Remounting
FUEL AND LUBRICATION SYSTEM 4-15 THROTTLE POSITION SENSOR INSTALLATION Install the throttle position sensor as described below. Measure the resistance Ω between the throttle position sen- sor terminals as shown in the illustration. Ω Ω Throttle position sensor resistance Ω Approximately 5 kΩ...
Page 122: Lubrication System
4-16 FUEL AND LUBRICATION SYSTEM LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART CYLINDER WALL FRAME (OIL TANK) POSITION CONROD SMALL END IN & EX CAM FACE OIL SUMP FILTER CAM CHAIN CONROD BIG END BEARING CAMSHAFT JOURNAL CRANK PIN CYLINDER HEAD RIGHT CRANKSHAFT PISTON PIN CYLINDER...
Page 123 COOLING SYSTEM COOLING SYSTEM CONTENTS COOLING SYSTEM ..................5- 2 DESCRIPTION .................... 5- 2 CONSTRUCTION ..................5- 3 ENGINE COOLANT ..................5- 4 RADIATOR ...................... 5- 5 INSPECTION ....................5- 5 REMOVAL ....................5- 6 REMOUNTING .................... 5- 6...
Page 124: Cooling System
COOLING SYSTEM COOLING SYSTEM DESCRIPTION The engine is cooled by a forced flow of engine coolant that circulates through jackets, which are formed in the cylinder and cylinder head, and through the radiator. A high-capacity centrifugal pump is used for the water pump and a tube-and-fin type aluminum radiator, which is characterized by lightness in weight and good heat dissipation, is used.
Page 125: Construction
COOLING SYSTEM CONSTRUCTION 1 Radiator cap 2 Radiator (R) 3 Radiator (L) 4 Radiator inlet hose 5 Radiator outlet hose 6 Overflow hose 7 Overflow tank A Air bleeder bolt ITEM N·m kgf-m lb-ft 1 Circlip 2 Water pump driven gear 3 Pin 4 Washer 5 Circlip...
Page 126: Engine Coolant
COOLING SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol antifreeze. This mixture will provide optimum corrosion and heat protec- tion, and will protect the cooling system from freezing at above –31°C (–24°F).
Page 127: Radiator
COOLING SYSTEM RADIATOR INSPECTION RADIATOR Before removing the radiator and draining the engine coolant, check the following. Check the cooling system for leaks with a radiator tester 1. Remove the radiator cap and connect the radiator tester to the filler. Pressurize the cooling system with 120 kPa (1.2 kgf/cm 17 psi) of pressure, and then check if it holds the pressure for 10 seconds.
Page 128: Removal
COOLING SYSTEM REMOVAL Remove the side covers. ( 6-2) Drain the engine coolant. ( 2-15) Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or va- por. The engine must be cool before servicing the cool- ing system.
Page 129: Water Pump
COOLING SYSTEM WATER PUMP REMOVAL AND DISASSEMBLY Drain the engine coolant. ( 2-15) Drain the engine oil. ( 2-11) 92P50060 Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or va- por.
Page 130 COOLING SYSTEM INSPECTION WATER PUMP BEARING Inspect the inner race play of the water pump bearing by hand while it is in the water pump housing. Rotate the inner race by hand to inspect it for abnormal noise and smooth rotation. If ab- normal noise occurs or if rough movement is noted, replace the water pump bearing with a new one.
Page 131 COOLING SYSTEM Apply SUZUKI SUPER GREASE “A” to the new O-rings. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A” When installing the water pump driven gear align the pin 1 with the groove 2.
Page 132 CHASSIS 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 ............................
Page 133: Exterior Parts
CHASSIS EXTERIOR PARTS REMOVAL SEAT Remove the seat 1. SIDE COVERS Remove the left and right side covers 1. FRAME COVERS Remove the left frame cover 1 and right frame cover 2. BATTERY COVER Remove the battery cover 1. REMOUNTING Remount the seat, side covers, frame covers, and battery cover in the reverse order of removal.
Page 134: Front Wheel
CHASSIS FRONT WHEEL CONSTRUCTION 1 Front axle 2 Odometer gearbox 3 Bearing (R) 4 Front wheel 5 Spacer 6 Bearing (L) 7 Dust seal 8 Brake disc 9 Spacer 0 Washer A Front axle nut B Brake disc mounting bolt ITEM N·m kgf-m...
Page 135 CHASSIS Left Right Right Left Right Left Spacer Clearance...
Page 136: Removal And Disassembly
CHASSIS REMOVAL AND DISASSEMBLY Disconnect the odometer cable. Remove the front axle nut 1 and loosen the front axle pinch bolts 2. Support the motorcycle with a jack or wooden block and re- move the front axle 3 and front wheel 4. Do not operate the brake lever during or after front wheel removal.
Page 137: Inspection
CHASSIS INSPECTION ODOMETER GEARBOX DUST SEAL Inspect the odometer gearbox dust seal for damage. If any dam- age is found, replace the odometer gearbox with a new one. WHEEL HUB DUST SEAL Inspect the wheel hub dust seal for damage. If any damage is found, replace the wheel hub dust seal with a new one.
Page 138 CHASSIS Remove the wheel bearings as follows: Remove the wheel hub dust seal. ( 6-6) Insert the bearing remover attachment 1 into the wheel bear- ing. Insert the wedge bar 2 from the opposite side and lock it into the slit of the bearing remover attachment. Drive out the wheel bearing by striking the wedge bar.
Page 139: Reassembly And Remounting
First, install the left wheel bearing, and then install the right wheel bearing. ( 6-4) WHEEL HUB DUST SEAL Apply SUZUKI SUPER GREASE “A” to the lip of dust seal. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A”...
Page 140 CHASSIS ODOMETER GEARBOX Apply SUZUKI SUPER GREASE “A” to the odometer gear- box dust seal. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A” Align the grooves 1 on the odometer gearbox with the lugs 2 on the wheel hub.
Page 141: Front Fork
6-10 CHASSIS FRONT FORK CONSTRUCTION 1 Air valve 2 O-ring 3 Push rod 4 Needle 5 Spring 6 Washer 7 Spring 8 Damper rod ring 9 Damper 0 Dust seal A Stopper ring B Oil seal C Oil seal retainer D Inner tube antifriction metal E Inner tube F Outer tube antifriction metal...
Page 142: Removal And Disassembly
CHASSIS 6-11 REMOVAL AND DISASSEMBLY Remove the front wheel. ( 6-5) Remove the front brake caliper. ( 6-47) Remove the headlight assembly. ( 7-27) Remove the brake hose clamp 1 and odometer cable guide 2. Remove the front fork after loosening the front fork upper clamp bolts 3 and lower clamp bolts 4.
Page 143 6-12 CHASSIS Invert the fork and stroke it several times to drain out the fork oil. NOTE: Hold the fork inverted for a few minutes to drain the oil. Remove the push rod 1, needle 2, and return spring 3. 3 2 1 Remove the dust seal 4 and stopper ring 5.
Page 144: Inspection
CHASSIS 6-13 Remove the damper 1. Slowly pull out the inner tube. NOTE: Be careful not to damage the inner tube. Remove the oil seal 2 , oil seal retainer 3 , outer tube antifriction metal 4 inner tube antifriction metal 5, and oil lock piece 6.
Page 145: Reassembly And Remounting
Apply front fork oil to the lip of oil seal lightly before installing 99000-99001-SS5: SUZUKI FORK OIL SS-05 Install the oil lock piece 1, outer tube antifriction metal 2, oil seal retainer 3, and oil seal 4 onto the inner tube.
Page 146 FORK OIL Place the front fork vertically without the spring. Pour the specified fork oil into the inner tube. 99000-99001-SS5: SUZUKI FORK OIL SS-05 Standard fork oil capacity (each leg): 720 ml (24.3 US oz, 25.4 Imp oz) Move the inner tube and inner rod slowly several times.
Page 147 6-16 CHASSIS PISTON ROD LOCKNUT AND FORK SPRING Install the piston rod locknut to the lowest position. Install the fork spring. NOTE: The end of the fork spring with the smaller inside diameter should be at the bottom of the front fork. Install a washer 1.
Page 148: Suspension Setting
CHASSIS 6-17 When remounting the front fork, align the groove 1 of the inner tube with the upper surface 2 of the steering stem up- per bracket. NOTE: Make sure that the air valve A is at the front position when in- stalling the front fork.
Page 149: Steering
6-18 CHASSIS STEERING CONSTRUCTION 1 Handlebar 2 Washer 3 Handlebar clamp 4 Steering stem head bracket 5 Steering stem nut 6 Bearing 7 Steering stem 8 Bearing A Handlebar clamp bolt B Steering stem head nut C Front fork upper clamp bolt D Front fork lower clamp bolt ITEM N·m...
Page 150: Removal And Disassembly
CHASSIS 6-19 REMOVAL AND DISASSEMBLY Remove the front fork. ( 6-11) Remove the master cylinder assembly. ( 6-51) Remove the front brake hose guide bolts. Remove the odometer assembly. Remove the clamps 1 and engine stop switch 2. Disconnect the main switch coupler 3 , starter button coupler 4 (DR-Z400E), and clutch lever position switch lead wires 5 (DR-Z400E).
Page 151 6-20 CHASSIS - Disconnect the clutch cable. Disconnect the decompression cable. (DR-Z400) Remove the front fender. Remove the handlebar 1 and ignition switch 2 (DR-Z400E). Remove the steering stem head nut.
Page 152: Inspection
CHASSIS 6-21 Remove the washer 1 and steering stem upper bracket 2. Remove the steering stem nut using the special tools. 09940-14911: Steering nut socket wrench 09940-14960: Steering nut wrench socket Remove the steering stem lower bracket. NOTE: Hold the steering stem lower bracket to prevent it from falling. Remove the steering stem upper bearing.
Page 153: Reassembly And Remounting
BEARINGS Press in the steering stem lower bearing using the special tool. 09925-18010: Steering bearing installer Apply SUZUKI SUPER GREASE “A” to the steering stem upper and lower bearings. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A”...
Page 154 Forward specified torque. Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) CLUTCH CABLE AND THROTTLE CABLES Apply SUZUKI SUPER GREASE “A” to the end of clutch cable and throttle cables. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries...
Page 155 6-24 CHASSIS FRONT WHEEL ............WIRE HARNESS, CABLE, AND HOSE ROUTING ........ 8-12 to 8-18 NOTE: Hold the front fork legs, move them back and forth and make sure that the steering is not loose. After performing the adjustment and installing the handlebars, “rock”...
Page 156: Rear Wheel
CHASSIS 6-25 REAR WHEEL CONSTRUCTION 1 Cotter pin (For E-03, 28) 2 Washer 3 Chain adjuster 4 Brake disc 5 Spacer 6 Dust seal 7 Bearing 8 Rear wheel 9 Rear sprocket 0 Spacer A Bearing B Bearing C Dust seal D Spacer E Rear axle A Rear axle nut...
Page 157 6-26 CHASSIS Left Right (Except E-03, 28) Left Left Right Right Spacer Clearance...
Page 158: Removal And Disassembly
CHASSIS 6-27 REMOVAL AND DISASSEMBLY Remove the cotter pin. (E-03, 28) Remove the rear axle nut. Replace the removed cotter pin with a new one. Support the motorcycle with a jack or wooden block and re- move the rear axle 1 and rear wheel. Do not operate the brake pedal during or after rear wheel removal.
Page 159: Inspection
Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay special attention to the follow- ing points: WHEEL BEARINGS Apply SUZUKI SUPER GREASE “A” to the wheel bearings. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A”...
Page 160 CHASSIS 6-29 WHEEL HUB DUST SEALS Apply SUZUKI SUPER GREASE “A” to the wheel hub dust seals. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A” Install the wheel hub dust seals using the special tool.
Page 161 6-30 CHASSIS REAR WHEEL Adjust the drive chain slack after installing the rear wheel axle. ( 2-16 and 2-17) Tighten the rear axle nut to the specified torque. Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft).. for E-03, 28 110 N·m (11.0 kgf-m, 79.5 lb-ft)..
Page 162: Rear Suspension
CHASSIS 6-31 REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 2 Spring adjuster 3 Spring 4 Spring seat 5 Circlip 6 Cushion lever rod 7 Cushion lever 8 Swingarm pivot shaft 9 Swingarm 0 Chain guide A Chain buffer A Rear shock absorber nut B Rear shock absorber compression adjuster assembly C Rear shock absorber spring adjuster...
Page 163 6-32 CHASSIS ITEM N·m kgf-m lb-ft 40.0 40.0 10.0 72.5 10.0 72.5 10.0 72.5 55.5...
Page 164: Rear Shock Absorber Removal
CHASSIS 6-33 REAR SHOCK ABSORBER REMOVAL Remove the muffler. ( 3-5) Remove the battery. (DR-Z400E) ( 7-30) Remove the clamps. Disconnect the taillight coupler 1, starter relay coupler 2 (DR-Z400E), and starter relay lead wires 3 (DR-Z400E). Disconnect the air cleaner breather hose and loosen the car- buretor clamp.
Page 165 6-34 CHASSIS Loosen the lockring 1 and turn the adjuster 2 using the special tool. 09910-60611: Universal clamp wrench Remove the circlip 3, spring seat 4, and spring 5.
Page 166: Rear Shock Absorber Inspection And Disassembly
CHASSIS 6-35 REAR SHOCK ABSORBER INSPECTION AND DISASSEMBLY Inspect the rear shock absorber for damage and oil leakage. If any damages are found, replace the spring or rear shock ab- sorber with a new one. REAR SHOCK ABSORBER DISPOSAL The rear shock absorber unit contains high-pressure nitrogen gas.
Page 167: Oil Replacement Procedure
6-36 CHASSIS OIL REPLACEMENT PROCEDURE TOOLS AND EQUIPMENT The following tools and equipment are required to perform oil replacement. 1 Screwdriver or small punch 2 Vise* 3 Drain pan 4 Specified shock oil (SS-25) 5 Rags 6 Nitrogen tank SERVICE MANUAL 7 Filler hose and nozzle 8 Regulator assembly...
Page 168 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 Oil capacity: Approximately 380 ml (12.8 US oz, 13.4 lmp oz) When fitting the orifice in the compression adjuster hole, face the conical side to the valve side.
Page 169: Rear Shock Absorber Reassembly And Remounting
6-38 CHASSIS Riding the motorcycle with abnormal gas pressure can damage the rear shock absorber unit. Low gas pres- sure can result in oil leakage. Abnormal gas pressure cannot provide normal performance of the rear shock absorber. Be sure to fill the rear shock absorber unit to the speci- fied pressure.
Page 170: Rear Shock Absorber Damping Force Adjustment
CHASSIS 6-39 Tighten the rear shock absorber upper and lower mounting nut to the specified torque. Rear shock absorber upper and lower mounting nut: 55 N·m (5.5 kgf-m, 40.0 lb-ft) Apply THREAD LOCK SUPER “1303” to the seat rail lower mounting bolt 4.
Page 171: Rear Swingarm And Cushion Lever Removal
6-40 CHASSIS REAR SWINGARM AND CUSHION LEVER REMOVAL Remove the rear wheel. ( 6-27) Remove the rear shock absorber. ( 6-33 and 6-34) Remove the rear brake caliper. ( 6-57) Remove the drive chain guide. Disconnect the brake hose from the brake hose guide. Remove the cushion lever mounting bolt and nut.
Page 172: Inspection And Disassembly
CHASSIS 6-41 Remove the cushion lever 1 and cushion lever rods 2. INSPECTION AND DISASSEMBLY SPACERS Remove the dust seals, washers and spacers from the swingarm and cushion lever. Inspect the spacers for any flaws or other damage. If any dam- ages are found, replace the spacers with new ones.
Page 173 6-42 CHASSIS SWINGARM Inspect the swingarm for damage. If any damages are found, replace the swingarm with a new one. CUSHION LEVER NEEDLE BEARINGS Insert the spacers into the needle bearings, move the spacer up and down and check for any play. If there is excessive play, re- place the bearings with new ones.
Page 174: Reassembly And Remounting
Reassemble and remount the rear suspension in the reverse order of removal and disassembly. Pay special attention to the following points: SWINGARM NEEDLE BEARINGS Apply SUZUKI SUPER GREASE “A” to the spacers, dust seals and needle bearings. For USA 99000-25030: SUZUKI SUPER GREASE “A”...
Page 175: Final Inspection And Adjustment
6-44 CHASSIS Tighten the swingarm pivot shaft nut to the specified torque. Pivot shaft nut: 77 N·m (7.7 kgf-m, 55.5 lb-ft) Tighten the cushion lever mounting nut to the specified torque. Cushion lever mounting nut: 100 N·m (10.0 kgf·m, 72.5 lb-ft) FINAL INSPECTION AND ADJUSTMENT After installing the rear wheel, adjust the following before riding.
Page 176: Front Brake
CHASSIS 6-45 FRONT BRAKE CONSTRUCTION 1 Cap 2 Diaphragm 3 Master cylinder 4 Piston set 5 Brake hose 6 Caliper holder 7 Caliper 8 Pad set 9 Piston 0 Piston and dust seal A Master cylinder mounting bolt B Brake hose union bolt C Air bleeder valve D Brake caliper mounting bolt E Brake pad mounting pin...
Page 177: Brake Pad Replacement
6-46 CHASSIS BRAKE PAD REPLACEMENT Remove the brake pad mounting pin. Remove the brake pads. Do not operate the brake lever during or after brake pad removal. Replace the brake pads as a set, otherwise braking performance will be adversely affected. Install the new brake pads.
Page 178: Brake Fluid Replacement
CHASSIS 6-47 BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handle- bar straight. Remove the master cylinder reservoir cap and diaphragm. Remove as much old brake fluid as possible. Fill the reservoir with new brake fluid. Specification and classification: DOT 4 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle.
Page 179: Brake Caliper Inspection
6-48 CHASSIS Remove the brake pads. ( 6-46) Remove the brake caliper holder. Remove the spring. Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using com- pressed air. Do not use extremely high pressure air to remove the brake caliper pistons, otherwise damage to the pistons will result.
Page 180: Brake Caliper Reassembly And Remounting
Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly. PISTON SEALS Install the piston seals 1 and dust seals 2 as shown. BRAKE CALIPER HOLDER Apply SUZUKI SILICON GREASE to the brake caliper holder. 99000-25100: SUZUKI SILICONE GREASE...
Page 181: Brake Disc Inspection
6-50 CHASSIS Tighten the brake pad mounting pin 1, brake caliper mount- ing bolts 2, and brake hose union bolt 3 to the specified torque. Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) Brake caliper mounting bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft) Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) NOTE:...
Page 182: Master Cylinder Removal And Disassembly
CHASSIS 6-51 MASTER CYLINDER REMOVAL AND DISASSEMBLY Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid. Remove the brake hose union bolt and disconnect the brake hose. Immediately wipe off any brake fluid contacting any part of the motorcycle.
Page 183: Master Cylinder Inspection
6-52 CHASSIS Remove the piston assembly. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one. PISTON AND RUBBER PARTS Inspect the piston surface, primary/secondary cup, and dust boot for any scratches, wear or damage.
Page 184 CHASSIS 6-53 When remounting the master cylinder on the handlebar, align the master cylinder holder’s mating surface 1 with the punch mark 2 on the handlebar, and then tighten the upper clamp bolt first. Master cylinder clamp bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) A Master cylinder B Master cylinder upper clamp bolt C Handlebar...
Page 185: Rear Brake
6-54 CHASSIS REAR BRAKE CONSTRUCTION 1 Cap 2 Diaphragm 3 Master cylinder 4 Piston set 5 Brake hose 6 Reservoir cover 7 Caliper cover 8 Caliper 9 Caliper holder 0 Piston and dust seal A Piston B Pad set A Master cylinder mounting bolt B Brake hose union bolt C Rear brake rod locknut D Plug...
Page 186: Brake Pad Replacement
CHASSIS 6-55 BRAKE PAD REPLACEMENT Remove the brake pad mounting pin. Remove the brake pads. Do not operate the brake pedal during or after brake pad removal. Replace the brake pads as a set, otherwise braking performance will be adversely affected. Install the new brake pads.
Page 187: Brake Fluid Replacement
6-56 CHASSIS BRAKE FLUID REPLACEMENT Remove the reservoir cover. Remove the reservoir cap and diaphragm. Replace the brake fluid. ( 6-46) Specification and classification: DOT 4 Bleed air from the brake system. 2-19 and 2-20)
Page 188: Brake Caliper Removal And Disassembly
CHASSIS 6-57 BRAKE CALIPER REMOVAL AND DISASSEMBLY Remove the rear wheel. ( 6-27) Disconnect the brake hose from the brake caliper by remov- ing the brake hose union bolt and allow the brake fluid to drain into a suitable receptacle. Remove the brake caliper.
Page 189: Brake Caliper Inspection
6-58 CHASSIS Place a rag over the brake caliper piston to prevent them from popping out and then force out the piston using com- pressed air. Do not use extremely high pressure air to remove the brake caliper piston, otherwise damage to the piston will result.
Page 190: Brake Disc Inspection
PISTON SEAL Install the piston seal 1 and dust seal 2 as shown. BRAKE CALIPER HOLDER Apply SUZUKI SILICON GREASE to the brake caliper holder. 99000-25100: SUZUKI SILICONE GREASE Tighten the brake hose union bolt to the specified torque. Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Page 191: Master Cylinder Removal And Disassembly
6-60 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY Remove the reservoir cover. ( 6-56) Remove the reservoir mounting bolt. Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid. Remove the brake hose union bolt and disconnect the brake hose.
Page 192: Master Cylinder Inspection
CHASSIS 6-61 Remove the push rod 1 and piston assembly 2. MASTER CYLINDER INSPECTION MASTER CYLINDER ..........6-52 PISTON AND RUBBER PARTS ........ 6-52 MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse or- der of removal and disassembly. Pay special attention to the fol- lowing points: Wash the master cylinder components with new brake fluid before reassembly.
Page 193 6-62 CHASSIS Tighten the master cylinder mounting bolts 1, brake rod lock- nut 2, and brake hose union bolt 3 to the specified torque. Master cylinder mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) Brake rod locknut: 18 N·m (1.8 kgf-m, 13.0 lb-ft) Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Bleed air from the brake system after reassembling the...
Page 194: Electrical System
ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................7- 2 CONNECTORS ................... 7- 2 COUPLERS ....................7- 2 CLAMPS ..................... 7- 2 FUSE (DR-Z400E) ..................7- 2 SEMICONDUCTOR EQUIPPED PARTS ............ 7- 2 BATTERY (DR-Z400E) ................7- 3 CONNECTING THE BATTERY (DR-Z400E) ..........7- 3 WIRING PROCEDURE ................
Page 195: Cautions In Servicing
ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS When disconnecting a connector, be sure to hold the termi- nals; do not pull the lead wires. When connecting a connector, push it in so it is firmly attached. Inspect the connector for corrosion, contamination and any breakage in the cover.
Page 196: Battery (Dr-Z400E)
ELECTRICAL SYSTEM BATTERY (DR-Z400E) The battery has been pre-filled with electrolyte so there is no need to add fluid at any time. The MF battery used in this motorcycle does not require main- tenance (e.g., electrolyte level inspection, distilled water re- plenishment).
Page 197: Using The Multi Circuit Tester
ELECTRICAL SYSTEM USING THE MULTI CIRCUIT TESTER Properly use the multi circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. If the voltage and current values are not known, begin mea- suring in the highest range. When measuring the resistance, make sure that no voltage is applied.
Page 198: Location Of Electrical Components
ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 CDI unit 2 Ignition coil 3 Ignition switch (DR-Z400E) 4 Starter button (DR-Z400E) 5 Starter relay (DR-Z400E) 6 Condenser (DR-Z400)
Page 199 ELECTRICAL SYSTEM 7 Engine stop switch 8 Clutch lever position switch (DR-Z400E) 9 Starter motor (DR-Z400E) 0 Regulator/rectifier A Fuse (DR-Z400E) B Battery (DR-Z400E) C Generator (DR-Z400E) D Throttle position sensor E Generator (DR-Z400)
Page 200: Charging System (Dr-Z400E)
ELECTRICAL SYSTEM CHARGING SYSTEM (DR-Z400E) DESCRIPTION The charging system consists of a generator, regulator/rectifier, and battery. The AC current, which is gener- ated by the generator, is converted by the regulator/rectifier into DC current. The regulator/rectifier is one unit with two functions. The regulator prevents overcharging of the battery by grounding the excessive AC current.
Page 201: Troubleshooting
ELECTRICAL SYSTEM TROUBLESHOOTING Battery runs down quickly. Check accessories which use excessive Accessories • Remove accessories amounts of electricity. are installed No accessories Check the battery for current leak- Current leaks • Short circuit of the wire age. 7-9) harness •...
Page 202: Inspection
ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAKAGE (DR-Z400E) Turn the ignition switch to the “OFF” position. Remove the battery cover. ( 6-2) Disconnect the - battery lead wire. Measure the current between the - battery terminal and the - battery lead wire using the multi circuit tester. If the reading ex- ceeds the specified value, leakage is evident.
Page 203 7-10 ELECTRICAL SYSTEM REGULATED VOLTAGE (DR-Z400E) Remove the battery cover. ( 6-2) Start the engine and run the engine at 5 000 r/min. Measure the DC voltage between the + and - battery termi- nals using the multi circuit tester. If the voltage is not within the specified value, inspect the generator and regulator/rectifier.
Page 204 ELECTRICAL SYSTEM 7-11 AC GENERATOR NO-LOAD PERFORMANCE Remove the left frame cover. ( 6-2) Disconnect the stator coil lead wire coupler. Start the engine and run it at 5 000 r/min. Measure the AC voltage between the lead wires of the genera- tor using the multi circuit tester.
Page 205: Starter System (Dr-Z400E)
7-12 ELECTRICAL SYSTEM STARTER SYSTEM (DR-Z400E) DESCRIPTION The starter system consists of the following components: the starter motor, starter relay, clutch lever position switch, starter button, ignition switch, and battery. Pressing the starter button energizes the starter relay, causing the contact points to close, thus, completing the circuit from the starter motor to the battery. The starter motor draws about 80 amperes to start the engine.
Page 206: Starter Motor Removal And Disassembly
ELECTRICAL SYSTEM 7-13 Measure the starter relay voltage at the starter relay connectors (between Y/B No voltage • Faulty ignition switch and B/W ) when the starter button is • Faulty starter button pushed. • Faulty clutch lever position switch •...
Page 207: Starter Motor Inspection
7-14 ELECTRICAL SYSTEM Disassemble the starter motor, as shown. ITEM N·m kgf-m lb-ft STARTER MOTOR INSPECTION CARBON BRUSHES Inspect the carbon brushes for abnormal wear, cracks, or smooth- ness in the brush holder. If any damages are found, replace the brush assembly with a new one.
Page 208: Starter Motor Reassembly And Remounting
Pay special attention to the follow- ing points: Replace the removed O-rings with new ones to pre- vent oil leakage and moisture. Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A”...
Page 209: Starter Relay Inspection
7-16 ELECTRICAL SYSTEM STARTER RELAY INSPECTION Remove the right frame cover. ( 6-3) Disconnect the starter motor lead wire, battery lead wire, and starter relay coupler at the starter relay. Remove the starter relay. Apply 12 V to the terminals and check for continuity between the positive and negative terminals using the multi circuit tester.
Page 210: Ignition System (Dr-Z400)
ELECTRICAL SYSTEM 7-17 IGNITION SYSTEM (DR-Z400) DESCRIPTION In the capacitor discharged ignition system, the electrical energy generated by the generator charges the capacitor. This energy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil.
Page 211 7-18 ELECTRICAL SYSTEM Measure the ignition coil primary peak voltage. 7-19) Inspect the spark plug. NOTE: The ignition coil peak voltage Correct 2-9) inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Correct Incorrect Incorrect •...
Page 212: Inspection
ELECTRICAL SYSTEM 7-19 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Remove the fuel tank. ( 4-2) Remove the spark plug cap and spark plug. Connect a new spark plug to spark plug cap and ground it to the cylinder head. NOTE: Make sure that the spark plug cap and spark plug are connected properly.
Page 213 7-20 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE Remove the fuel tank. ( 4-2) Disconnect the ignition coil lead wire, and then remove the ignition coil. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi circuit tester. If the resistance in both the primary and secondary windings is close to the speci- fied values, the windings are in sound condition.
Page 214 ELECTRICAL SYSTEM 7-21 PICKUP COIL AND SIGNAL COIL RESISTANCE Remove the left frame cover. ( 6-2) Disconnect the generator coupler 1. Measure the resistance between the lead wires using the multi circuit tester. If the resistance is not within the specified value, the pickup coil and signal coil must be replaced.
Page 215: Ignition System (Dr-Z400E)
7-22 ELECTRICAL SYSTEM IGNITION SYSTEM (DR-Z400E) DESCRIPTION In the capacitor discharged ignition system, the battery’s electrical energy charges the capacitor. This en- ergy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil.
Page 216 ELECTRICAL SYSTEM 7-23 Measure the ignition coil primary peak voltage. 7-24) Inspect the spark plug. NOTE: The ignition coil peak voltage Correct 2-9) inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Correct Incorrect Correct Incorrect Incorrect...
Page 217: Inspection
7-24 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Remove the fuel tank. ( 4-2) Remove the spark plug cap. Connect a new spark plug to the spark plug cap and ground it to the cylinder head. NOTE: Make sure that the spark plug cap and spark plug are connected properly and the battery is fully charged.
Page 218 ELECTRICAL SYSTEM 7-25 PICKUP COIL AND SIGNAL COIL PEAK VOLTAGE NOTE: Make sure that all of the couplers are connected properly. Remove the left frame cover. ( 6-2) Disconnect the wire harness coupler 1 at the CDI unit. Measure the pickup coil and signal coil peak voltage in the following procedure.
Page 219: Odometer
7-26 ELECTRICAL SYSTEM ODOMETER REMOVAL Remove the headlight assembly. ( 7-27) Disconnect the odometer cable. Remove the odometer assembly.
Page 220: Lamps
ELECTRICAL SYSTEM 7-27 LAMPS HEADLIGHT Headlight bulb : 12V 55W BULB REPLACEMENT Disconnect the bands and screw. Disconnect the headlight coupler and remove the headlight assembly.
Page 221: Taillight
7-28 ELECTRICAL SYSTEM Remove the rubber cap. Remove the bulb. Install the new bulb in the reverse order of removal. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy wa- ter to prevent premature bulb failure.
Page 222: Switches
ELECTRICAL SYSTEM 7-29 SWITCHES Measure each switch for continuity using a multi circuit tester. If any abnormality is found, replace the re- spective switch assemblies with a new one. 09900-25008: Multi circuit tester set IGNITION SWITCH (DR-Z400E) Color Position ENGINE STOP SWITCH Color Position STARTER BUTTON (DR-Z400E)
Page 223: Battery (Dr-Z400E)
7-30 ELECTRICAL SYSTEM BATTERY (DR-Z400E) REMOVAL Remove the battery cover. ( 6-2) Remove the battery holder. Remove the battery. NOTE: Disconnect the - battery lead wire, first. SPECIFICATIONS Type designation GT7B-4 Capacity 12 V, 23.4 kC (6.5 Ah)/10 HR SERVICING Visually inspect the surface of the battery container.
Page 224: Recharging Operation
ELECTRICAL SYSTEM 7-31 RECHARGING OPERATION Measure the battery voltage using the multi circuit tester or digital volt meter. If the voltage reading is less than the 12.6 V (DC), recharge the battery with a MF battery charger. When recharging the battery, remove the battery from the motorcycle.
Page 225: Servicing Information
SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING ..................8- 2 ENGINE ...................... 8- 2 CARBURETOR ................... 8- 5 CHASSIS ....................8- 6 BRAKES ..................... 8- 7 ELECTRICAL ....................8- 8 BATTERY (DR-Z400E) ................8- 9 WIRING DIAGRAM ..................8-10 DR-Z400 ...................... 8-10 DR-Z400E ....................
Page 226: Troubleshooting
SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Worn cylinder. Replace. 2. Worn piston ring. Replace. 3. Worn valve guide or improper valve seating. Repair or replace. 4.
Page 227 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine is noisy. Excessive valve chatter 1. Excessive tappet clearance. Adjust. 2. Weak or broken valve spring. Replace. 3. Worn camshaft. Replace. 4. Worn or burnt camshaft journal. Replace. Noise seems to come from the piston 1.
Page 228 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Transmission jumps 1. Worn gear. Replace. out of gear. 2. Worn or distorted gearshift fork. Replace. 3. Weakened gearshift stopper spring. Replace. 4. Worn gearshift pawl. Replace. Engine idles poorly. 1. Tappet clearance out of adjustment. Adjust.
Page 229: Carburetor
SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats. 1. Carbon buildup on piston crown. Clean. 2. Insufficient amount of engine oil. Check level and add. 3. Defective oil pump. Replace. 4. Clogged oil circuit. Clean. 5. Float chamber fuel level too low. Adjust float height.
Page 230: Chassis
SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Steering is heavy. 1. Overtightened steering stem nut. Adjust. 2. Broken bearing in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Low tire pressure. Regulate. Handlebar wobbles. 1. Loss of balance between right and left front forks. Adjust or replace.
Page 231: Brakes
SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Brake power insuffi- 1. Leakage of brake fluid. Repair or replace. cient. 2. Worn brake pad. Replace. 3. Oil on brake pad surface. Clean brake disc and brake pads. 4. Worn brake disc. Replace.
Page 232: Electrical
SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil. Replace. sparking. 2. Defective spark plug. Replace. 3. Defective generator. Replace. 4. Defective CDI unit. Replace. Spark plug is wet or 1. Excessively rich air/fuel mixture. Adjust carburetor.
Page 233: Battery (Dr-Z400E)
SERVICING INFORMATION BATTERY (DR-Z400E) Complaint Symptom and possible causes Remedy Sulfation or spots on 1. Cracked battery case. Replace. surfaces cell 2. Battery has been left in a run-down condition for a long Replace. plates. time. Battery runs down 1. Incorrect charging method. Check generator, regulator/ quickly.
Page 234: Wiring Diagram
8-10 SERVICING INFORMATION WIRING DIAGRAM DR-Z400...
Page 235: Dr-Z400E
SERVICING INFORMATION 8-11 DR-Z400E...
Page 236: Wire Harness, Cable, And Hose Routing
8-12 SERVICING INFORMATION WIRE HARNESS, CABLE, AND HOSE ROUTING WIRE ROUTING...
Page 237 SERVICING INFORMATION 8-13...
Page 238: Cable Routing
8-14 SERVICING INFORMATION CABLE ROUTING...
Page 239: Fuel Hose And Fuel Tank Mounting
SERVICING INFORMATION 8-15 FUEL HOSE AND FUEL TANK MOUNTING...
Page 240: Oil Return Tank Hose Routing
8-16 SERVICING INFORMATION OIL RETURN TANK HOSE ROUTING 1 Face the tip of clip to the front 2 Face the tip of clip to the bottom...
Page 241: Cooling System Hose Routing
SERVICING INFORMATION 8-17 COOLING SYSTEM HOSE ROUTING...
Page 242: Front Brake Hose Routing
8-18 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING REAR BRAKE HOSE ROUTING...
Page 243: Special Tools
SERVICING INFORMATION 8-19 SPECIAL TOOLS 09900-00401 09900-00410 Hexagon wrench Hexagon wrench 09900-06104 09900-06105 09900-06108 Snap ring pliers Snap ring pliers Snap ring pliers 09900-20202 09900-20204 09900-09004 09900-20101 09900-20103 Micrometer Micrometer Impact driver set Vernier calipers Vernier calipers (25 – 50 mm) (75 –...
Page 244 8-20 SERVICING INFORMATION 09913-70210 09915-64510 09913-50121 Bearing installer 09915-63310 Compression 09915-70610 Oil seal remover Adapter gauge set Adapter 09915-74510 09916-20610 Oil pressure gauge 09916-10911 09916-14510 09916-14910 Seat cutter Valve lapper set Valve lifter Attachment (N-121) 09916-21110 09916-22420 09916-22430 09916-24311 Valve seat Valve seat cutter Valve seat cutter Solid pilot...
Page 245 SERVICING INFORMATION 8-21 09924-84510 09924-84521 09925-18010 09930-30102 09923-74510 Bearing installer Bearing installer Steering bearing Sliding hammer Bearing remover installer 09940-14911 09940-14960 09930-44913 09930-31921 Steering stem nut Steering stem nut 09940-34520 Rotor holder Rotor remover set wrench wrench socket T handle 09940-52841 09940-52861 09940-54821...
Page 246: Tightening Torque
8-22 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt 10.0 Spark plug Cylinder head bolt 33.5 Cylinder head side bolt 10.0 Cylinder nut Decompression shaft bolt (DR-Z400) Decompression shaft lever nut (DR-Z400) 16.5 Camshaft journal holder bolt Balancer shaft nut 36.0 Primary drive gear nut...
Page 247: Chassis
SERVICING INFORMATION 8-23 CHASSIS ITEM N·m kgf-m lb-ft Handlebar clamp bolt 16.5 Front fork upper clamp bolt 21.5 Front fork lower clamp bolt 23.0 Steering stem head nut 65.0 Front fork cap bolt 16.5 Front fork damper rod bolt 58.0 Front fork inner rod locknut 16.0 Front brake master cylinder mounting bolt...
Page 248: Tightening Torque Chart
8-24 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A A A A A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft...
Page 249: Service Data
SERVICING INFORMATION 8-25 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diameter — (1.42) — (1.14) Tappet clearance (when cold) 0.10 – 0.20 — (0.0039 – 0.0079) 0.20 – 0.30 — (0.0079 – 0.0118) Valve-guide-to-valve-stem clearance 0.010 –...
Page 250 8-26 SERVICING INFORMATION CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.910 – 36.960 36.610 (1.4531 – 1.4551) (1.4413) 36.880 – 36.930 36.580 (1.4520 – 1.4539) (1.4402) Camshaft journal oil clearance 0.019 – 0.053 0.150 IN. & EX. (0.0007 –...
Page 251 SERVICING INFORMATION 8-27 ITEM STANDARD LIMIT Piston ring groove width 0.78 – 0.80 (0.0307 – 0.0315) — 1.30 – 1.32 (0.0512 – 0.0520) 0.81 – 0.83 — (0.0319 – 0.0327) 2.01 – 2.03 — (0.0791 – 0.0799) Piston ring thickness 0.71 –...
Page 252 8-28 SERVICING INFORMATION CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch drive plate thickness 2.92 – 3.08 2.62 (No. 1 & No. 2) (0.115 – 0.121) (0.103) Clutch drive plate claw width 13.7 –...
Page 253 SERVICING INFORMATION 8-29 CARBURETOR SPECIFICATION ITEM DR-Z400 DR-Z400E E-01 E-03, 28 E-01 E-03, 28 ← ← ← Carburetor type KEIHIN FCR39H ← ← ← Bore size 39 mm (1.5 in) I.D. No. 29F0 29F1 29F3 29F4 ← ← ← Idle r/min 1800 ±...
Page 254 8-30 SERVICING INFORMATION BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake pedal height — (0.2) Brake disc thickness 3.0 ± 0.2 Front (0.118 ± 0.008) (0.10) 4.5 ± 0.2 Rear (0.177 ± 0.008) (0.16) Brake disc runout Front &...
Page 255 (20.1) (19.7) Front fork oil level (without spring) — (4.8) Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil — Front fork oil capacity (each leg) 720 ml — (24.3 US oz, 25.4 lmp oz) Front fork damping force adjuster...
Page 256 8-32 SERVICING INFORMATION ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: CR8E Type DENSO: U24 ESR-N 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. 0.1 – 1.0 Ω Ignition coil resistance Primary Terminal –...
Page 257 SERVICING INFORMATION 8-33 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 90 pump R + M octane ( Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28 Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corro- sion inhibitor is permissible.
Page 258: Dr-Z400Ey (E-24 Model)
DR-Z400EY (E-24 MODEL) DR-Z400EY (E-24 MODEL) This chapter describes service specifications, service data and servicing procedures which dif- fer from those of the DR-Z400Y/EY (E-01, 03 and 28 models). NOTE: * Any difference between the DR-Z400Y/EY (E-01, 03 and 28 models) and DR-Z400EY (E-24 model) in specifications and service data are clearly indicated with an asterisk (*).
Page 259: Specifications
DR-Z400EY (E-24 MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ........... 2 310 mm (90.9 in) Overall width ............ 825 mm (32.5 in) Overall height ........... 1 245 mm (49.0 in) Wheelbase ............1 475 mm (58.1 in) Ground clearance ..........315 mm (12.4 in) Seat height ............
Page 260 DR-Z400EY (E-24 MODEL) CHASSIS Front suspension ..........Telescopic, coil spring, oil damped, rebound damping force 18-way adjustable, compression damping force 14-way ad- justable Rear suspension ..........Link type, coil spring, oil damped, spring preload fully ad- justable, rebound damping force 21-way adjustable, com- pression damping force 26-way adjustable Front fork stroke ..........
Page 261: Service Data
DR-Z400EY (E-24 MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.42) ——— (1.14) Tappet clearance (when cold) 0.10 – 0.20 ——— (0.0039 – 0.0078) 0.20 – 0.30 ——— (0.0078 – 0.0118) Valve guide to valve stem 0.010 –...
Page 262 DR-Z400EY (E-24 MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.910 – 36.960 36.610 (1.4531 – 1.4551) (1.4413) 36.880 – 36.930 36.580 (1.4520 – 1.4539) (1.4402) Camshaft journal oil clearance 0.019 – 0.053 0.150 IN. & EX. (0.0007 –...
Page 263 DR-Z400EY (E-24 MODEL) ITEM STANDARD LIMIT Piston ring groove width 0.78 – 0.80 ——— (0.0307 – 0.0315) 1.30 – 1.32 ——— (0.0512 – 0.0520) 0.81 – 0.83 ——— (0.0319 – 0.0327) 2.01 – 2.03 ——— (0.0791 – 0.0799) Piston ring thickness 0.71 –...
Page 264 DR-Z400EY (E-24 MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 – 15 ——— (0.4 – 0.6) Drive plate thickness 2.92 – 3.08 2.62 (No. 1 & No. 2) (0.115 – 0.121) (0.103) Drive plate claw width 13.7 –...
Page 265 DR-Z400EY (E-24 MODEL) ITEM SPECIFICATION Slow jet (S.J.) Slow air jet (S.A.J.) Air jet (A.J.) Pilot screw (P .S.) * 2¾ turns back Throttle cable play 2 – 4 mm (pulling cable) (0.08 – 0.16 in) RADIATOR + ENGINE COOLANT ITEM STANDARD/SPECIFICATION NOTE...
Page 266 Rear shock absorber gas 900 kPa ——— pressure (9.0 kgf/cm , 128 psi) Rear shock absorber oil type SUZUKI REAR SUSPENSION OIL SS-25 ——— or an equivalent suspension oil Rear shock absorber oil capacity 380 ml ——— (12.8/13.4 US/Imp oz) Rear shock absorber spring 258.0...
Page 267: Battery
9-10 DR-Z400EY (E-24 MODEL) ITEM STANDARD/SPECIFICATION LIMIT Rear wheel travel ——— (11.6) Swingarm pivot shaft runout ——— (0.01) ELECTRICAL ITEM SPECIFICATION NOTE Spark plug DENSO: U24ESR-N Type NGK: CR8E 0.7 – 0.8 mm (0.028 – 0.031 mm) Spark performance Over 8 mm (0.3 in) at 1 atm. Ignition coil resistance Terminal –...
Page 268 DR-Z400EY (E-24 MODEL) 9-11 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 95 octane or higher. An unleaded gasoline is recommended. Fuel tank including reserve 10.0 L (2.6/2.2 US/lmp gal) reserve 2.3 L (0.6/0.5 US/lmp gal) Engine oil type SAE 10W/40, API SF or SG Engine oil capacity...
Page 269: Side-Stand/Ignition Interlock System
9-12 DR-Z400EY (E-24 MODEL) SIDE-STAND/IGNITION INTERLOCK SYSTEM This side-stand/ignition interlock system is to prevent starting the motorcycle with the side-stand left down. SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester. Then apply 12 V to terminals D and C (+ to D and - to C) and check the continuity between D and E.
Page 270: Switches
DR-Z400EY (E-24 MODEL) 9-13 SWITCHES Measure each switch for continuity using a multi circuit tester. If any abnormality is found, replace the respec- tive switch assemblies with a new one. [ 09900-25008: Multi circuit tester set IGNITION SWITCH STARTER BUTTON Color Color Position...
Page 271: Speedometer
9-14 DR-Z400EY (E-24 MODEL) SPEEDOMETER PARTS NAMES 1 Turn signal indicator light TIME 2 Neutral indicator light CLOCK 3 High beam indicator light km/h 4 Engine coolant temperature TRIP TRIP TOTAL indicator light 5 Tripmeter A 6 Speedometer TIME/ – TRIP TIME TRIP...
Page 272 DR-Z400EY (E-24 MODEL) 9-15 With each press of the MODE TIME button, the display changes between the clock, the stopwatch and the timer as shown below. Clock Stopwatch Timer TRIP TIME TIME TIME TIME CLOCK CLOCK CLOCK MODE " To avoid riding with only one hand, do not operate the buttons while riding.
Page 273 9-16 DR-Z400EY (E-24 MODEL) CLOCK Displays the time (hours, minutes and seconds) on a 24-hour clock TRIP TIME TIME CLOCK MODE Setting the time TIME/ TRIP TIME TRIP Hold down the MODE TIME The setting that is flashing TRIP TIME CLOCK button for three seconds.
Page 274: Wiring Diagram
DR-Z400EY (E-24 MODEL) 9-17 WIRING DIAGRAM...
Page 275: Wire, Cable And Hose Routing
9-18 DR-Z400EY (E-24 MODEL) WIRE, CABLE AND HOSE ROUTING WIRE ROUTING Clamp Wire harness battery lead wire Clamp battery terminal battery terminal Wire harness Fuse battery lead wire Side stand switch Neutral switch battery lead wire Clamp battery lead wire Wire harness Starter moter Clamp...
Page 276 DR-Z400EY (E-24 MODEL) 9-19 Clamp Clamp Handlebar switch (L) Clamp Handlebar switch (R) Clutch switch Wire harness Clutch cable Clamp Wire harness Engine stop switch Clamp Throttle cable Generator Regulator/rectifier Side stand switch Neutral switch battery lead wire Throttle position sensor Generator Regulator/rectifier Side stand switch...
Page 277 9-20 DR-Z400EY (E-24 MODEL) CABLE ROUTING...
Page 278 DR-Z400EY (E-24 MODEL) 9-21 SPEEDOMETER CABLE ROUTING Speedometer assembly Headlight bracket Clamp Speedometer cable Speedometer gearbox stopper VIEW Speedometer cable Front fork stopper...
Page 279 9-22 DR-Z400EY (E-24 MODEL) FRONT BRAKE HOSE ROUTING Align the green mark on the brake hose with the lower end of the brake hose clamp. Green mark VIEW 1 After touching the brake hose union to the stopper, tighten the union bolt to the specified torque. 2 Set brake hose in front of throttle cables.
Page 280: Dr-Z400/Ek1 ('01-Model)
DR-Z400/EK1 (’01-MODEL) 10-1 DR-Z400/EK1 (’01-MODEL) This chapter describes specifications, service data and servicing procedures which differ from those of the DR-Z400/EY (’00-MODEL). NOTE: * Any differences between DR-Z400/EY (’00-MODEL) and DR-Z400/EK1 (’01-MODEL) in speci- fications and service data are clearly indicated with the asterisk mark (*). * Please refer to the chapter 1 through 9 for details which are not given in this chapter.
Page 281: Specifications
10-2 DR-Z400/EK1 (’01-MODEL) SPECIFICATIONS DR-Z400/E (For E-01, 03 and 28) DIMENSIONS AND DRY MASS Overall length ............2 235 mm (88.0 in) Overall width ............825 mm (32.5 in) Overall height ............1 245 mm (49.0 in) Wheelbase ............. 1 475 mm (58.1 in) Ground clearance ..........
Page 282 DR-Z400/EK1 (’01-MODEL) 10-3 CHASSIS Front suspension ........... Telescopic, coil spring, oil damped, rebound damping force 18-way adjustable, compression damping force 14-way adjustable Rear suspension ............ Link type, coil spring, oil damped, spring preload fully adjustable, rebound damping force 21-way adjustable, compression damping force 26-way adjustable Front suspension stroke ........
Page 283: Dr-Z400E (For E-24)
10-4 DR-Z400/EK1 (’01-MODEL) DR-Z400E (For E-24) DIMENSIONS AND DRY MASS Overall length ............2 310 mm (90.9 in) Overall width ............825 mm (32.5 in) Overall height ............1 245 mm (49.0 in) Wheelbase ............. 1 475 mm (58.1 in) Ground clearance ..........
Page 284 DR-Z400/EK1 (’01-MODEL) 10-5 CHASSIS Front suspension ........... Telescopic, coil spring, oil damped, rebound damping force 18-way adjustable, compression damping force 14-way adjustable Rear suspension ............ Link type, coil spring, oil damped, spring preload fully adjustable, rebound damping force 21-way adjustable, compression damping force 26-way adjustable Front fork stroke .............
Page 285: Service Data
10-6 DR-Z400/EK1 (’01-MODEL) SERVICE DATA DR-Z400/E (For E-01, 03 and 28) VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.42) ——— (1.14) Tappet clearance (when cold) 0.10 – 0.20 ——— (0.0039 – 0.0078) 0.20 – 0.30 ———...
Page 286 DR-Z400/EK1 (’01-MODEL) 10-7 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.910 – 36.960 36.610 (1.4531 – 1.4551) (1.4413) 36.880 – 36.930 36.580 (1.4520 – 1.4539) (1.4402) Camshaft journal oil clearance 0.019 – 0.053 0.150 IN. & EX. (0.0007 –...
Page 287 10-8 DR-Z400/EK1 (’01-MODEL) ITEM STANDARD LIMIT Piston ring groove width 0.78 – 0.80 ——— (0.0307 – 0.0315) 1.30 – 1.32 ——— (0.0512 – 0.0520) 0.81 – 0.83 ——— (0.0319 – 0.0327) 2.01 – 2.03 ——— (0.0791 – 0.0799) Piston ring thickness 0.71 –...
Page 288 DR-Z400/EK1 (’01-MODEL) 10-9 CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 – 15 ——— (0.4 – 0.6) Drive plate thickness 2.92 – 3.08 2.62 (No. 1 & No. 2) (0.115 – 0.121) (0.103) Drive plate claw width 13.7 –...
Page 289 10-10 DR-Z400/EK1 (’01-MODEL) SPECIFICATION ITEM DR-Z400 DR-Z400E E-01 E-03, 28 E-01 E-03, 28 Main jet (M.J.) #165 #142 #165 #142 ← ← ← Jet needle (J.N.) OBDXP-4th Needle jet (N.J.) 2.9 mm ← ← ← (0.11 in) ← ← ← Slow jet (S.J.) ←...
Page 290 510.6 (20.1) (19.7) Front fork oil level ——— (without spring) (4.8) Front fork oil type SUZUKI FORK OIL SS-05 ——— or an equivalent fork oil Front fork oil capacity 720 ml ——— (each leg) (24.3/25.4 US/Imp oz) Front fork damping force adjuster...
Page 291 Rear shock absorber gas 900 kPa ——— pressure (9.0 kgf/cm , 128 psi) Rear shock absorber oil type SUZUKI REAR SUSPENSION OIL SS-25 ——— or an equivalent suspension oil Rear shock absorber oil capacity 380 ml ——— (12.8/13.4 US/Imp oz) Rear shock absorber spring 258.0...
Page 292 DR-Z400/EK1 (’01-MODEL) 10-13 WATTAGE Unit: W ITEM SPECIFICATION Headlight Taillight FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 90 pump R + M octane ( Gasoline containing MTBE (MethyI Tertiary ButyI E-03, 28 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.
Page 293: Dr-Z400E (For E-24)
10-14 DR-Z400/EK1 (’01-MODEL) DR-Z400E (For E-24) VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.42) ——— (1.14) Tappet clearance (when cold) 0.10 – 0.20 ——— (0.0039 – 0.0078) 0.20 – 0.30 ——— (0.0078 – 0.0118) Valve guide to valve stem 0.010 –...
Page 294 DR-Z400/EK1 (’01-MODEL) 10-15 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.910 – 36.960 36.610 (1.4531 – 1.4551) (1.4413) 36.880 – 36.930 36.580 (1.4520 – 1.4539) (1.4402) Camshaft journal oil clearance 0.019 – 0.053 0.150 IN. & EX. (0.0007 –...
Page 295 10-16 DR-Z400/EK1 (’01-MODEL) ITEM STANDARD LIMIT Piston ring groove width 0.78 – 0.80 ——— (0.0307 – 0.0315) 1.30 – 1.32 ——— (0.0512 – 0.0520) 0.81 – 0.83 ——— (0.0319 – 0.0327) 2.01 – 2.03 ——— (0.0791 – 0.0799) Piston ring thickness 0.71 –...
Page 296 DR-Z400/EK1 (’01-MODEL) 10-17 CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 – 15 ——— (0.4 – 0.6) Drive plate thickness 2.92 – 3.08 2.62 (No. 1 & No. 2) (0.115 – 0.121) (0.103) Drive plate claw width 13.7 –...
Page 297 10-18 DR-Z400/EK1 (’01-MODEL) ITEM SPECIFICATION Slow jet (S.J.) Slow air jet (S.A.J.) Air jet (A.J.) Pilot screw (P .S.) 2¾ turns back Throttle cable play 2 – 4 mm (pulling cable) (0.08 – 0.16 in) RADIATOR + ENGINE COOLANT ITEM STANDARD/SPECIFICATION NOTE Radiator cap valve opening...
Page 298 Rear shock absorber gas 900 kPa ——— pressure (9.0 kgf/cm , 128 psi) Rear shock absorber oil type SUZUKI REAR SUSPENSION OIL SS-25 ——— or an equivalent suspension oil Rear shock absorber oil capacity 380 ml ——— (12.8/13.4 US/Imp oz) Rear shock absorber spring 258.0...
Page 299 10-20 DR-Z400/EK1 (’01-MODEL) ITEM STANDARD/SPECIFICATION LIMIT Rear wheel travel ——— (11.6) Swingarm pivot shaft runout ——— (0.01) ELECTRICAL ITEM SPECIFICATION NOTE Spark plug DENSO: U24ESR-N Type NGK: CR8E 0.7 – 0.8 mm (0.028 – 0.031 mm) Spark performance Over 8 mm (0.3 in) at 1 atm. Ignition coil resistance Terminal –...
Page 300 DR-Z400/EK1 (’01-MODEL) 10-21 FUEL + OIL ITEM SPECIFICATION NOTE Gasoline used should be graded 95 octane or Fuel type higher. An unleaded gasoline is recommended. Fuel tank including reserve 10.0 L (2.6/2.2 US/lmp gal) reserve 2.3 L (0.6/0.5 US/lmp gal) Engine oil type SAE 10W/40, API SF or SG Engine oil capacity...
Page 301: Battery (Dr-Z400E)
10-22 DR-Z400/EK1 (’01-MODEL) BATTERY (DR-Z400E) SPECIFICATIONS Type designation YT7B-BS Capacity 12V, 21.6 kC (6 Ah)/10HR INITIAL CHARGING Filling electrolyte • Remove the aluminum tape 1 sealing the battery electrolyte filler holes. • Remove the caps 2. NOTE: * After filling the electrolyte completely, use the removed cap 2 as the sealed caps of battery-filler holes.
Page 302 DR-Z400/EK1 (’01-MODEL) 10-23 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery.
Page 303 10-24 DR-Z400/EK1 (’01-MODEL) RECHARGING OPERATION • Using the multi circuit tester, check the battery voltage. If the voltage reading is less than the 12.0 V (DC), recharge the bat- tery with a battery charger. * When recharging the battery, remove the battery from the motorcycle.
Page 304: Dr-Z400/Ek2 ('02-Model)
DR-Z400/EK2 (’02-MODEL) 11-1 DR-Z400/EK2 (’02-MODEL) This chapter describes specifications, service data and servicing procedures which differ from those of DR-Z400/EK1 (’01-MODEL). NOTE: * Any difference between DR-Z400/EK1 (’01-MODEL) and DR-Z400/EK2 (’02-MODEL) in speci- fications and service data are cleary indicated with the asterisk mark (*). * Please refer to the chapter 1 through 10 for details which are not given in this chapter.
Page 305: Specifications
11-2 DR-Z400/EK2 (’02-MODEL) SPECIFICATIONS DR-Z400/E (For E-01, 03 and 28) DIMENSIONS AND DRY MASS Overall length ............2 235 mm (88.0 in) Overall width ............825 mm (32.5 in) Overall height ............1 235 mm (48.6 in) Wheelbase ............. 1 475 mm (58.1 in) Ground clearance ..........
Page 306: Dr-Z400E (E-24)
DR-Z400/EK2 (’02-MODEL) 11-3 CHASSIS Front suspension ........... Telescopic, coil spring, oil damped Rear suspension ............ Link type, coil spring, oil damped Front suspension stroke ........288 mm (11.3 in) Rear wheel travel ........... 295 mm (11.6 in) Caster ..............27° 20’ Trail .................
Page 307 11-4 DR-Z400/EK2 (’02-MODEL) DR-Z400E (For E-24) DIMENSIONS AND DRY MASS Overall length ............2 310 mm (90.9 in) Overall width ............825 mm (32.5 in) Overall height ............1 235 mm (48.6 in) Wheelbase ............. 1 475 mm (58.1 in) Ground clearance ..........
Page 308 DR-Z400/EK2 (’02-MODEL) 11-5 CHASSIS Front suspension ........... Telescopic, coil spring, oil damped Rear suspension ............ Link type, coil spring, oil damped Front fork stroke ............. 288 mm (11.3 in) Rear wheel travel ........... 295 mm (11.6 in) Caster ..............27° 20’ Trail .................
Page 309: Periodic Maintenance Schedule (For E-24)
11-6 DR-Z400/EK2 (’02-MODEL) PERIODIC MAINTENANCE SCHEDULE (FOR E-24) The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months, and are dependent on whichever comes first. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.
Page 310: Service Data
DR-Z400/EK2 (’02-MODEL) 11-7 SERVICE DATA DR-Z400/E (For E-01, 03 and 28) VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.42) ——— (1.14) Tappet clearance (when cold) 0.10 – 0.20 ——— (0.0039 – 0.0078) 0.20 – 0.30 ———...
Page 311 11-8 DR-Z400/EK2 (’02-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.910 – 36.960 36.610 (1.4531 – 1.4551) (1.4413) 36.880 – 36.930 36.580 (1.4520 – 1.4539) (1.4402) Camshaft journal oil clearance 0.019 – 0.053 0.150 IN. & EX. (0.0007 –...
Page 312 DR-Z400/EK2 (’02-MODEL) 11-9 ITEM STANDARD LIMIT Piston ring groove width 0.78 – 0.80 ——— (0.0307 – 0.0315) 1.30 – 1.32 ——— (0.0512 – 0.0520) 0.81 – 0.83 ——— (0.0319 – 0.0327) 2.01 – 2.03 ——— (0.0791 – 0.0799) Piston ring thickness 0.71 –...
Page 313: Dr-Z400E (E-24)
11-10 DR-Z400/EK2 (’02-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 – 15 ——— (0.4 – 0.6) Drive plate thickness 2.92 – 3.08 2.62 (No. 1 & No. 2) (0.115 – 0.121) (0.103) Drive plate claw width 13.7 –...
Page 314 DR-Z400/EK2 (’02-MODEL) 11-11 SPECIFICATION ITEM DR-Z400 DR-Z400E E-01 E-03, 28 E-01 E-03, 28 Main jet (M.J.) #165 #142 #165 #142 ← ← ← Jet needle (J.N.) OBDXP-4th Needle jet (N.J.) 2.9 mm ← ← ← (0.11 in) ← ← ← Slow jet (S.J.) ←...
Page 315 510.6 (20.1) (19.7) Front fork oil level ——— (without spring) (4.8) Front fork oil type SUZUKI FORK OIL SS-05 ——— or an equivalent fork oil Front fork oil capacity 720 ml ——— (each leg) (24.3/25.4 US/Imp oz) Front fork damping force adjuster...
Page 316 Rear shock absorber gas 900 kPa ——— pressure (9.0 kgf/cm , 128 psi) Rear shock absorber oil type SUZUKI REAR SUSPENSION OIL SS-25 ——— or an equivalent suspension oil Rear shock absorber oil capacity 380 ml ——— (12.8/13.4 US/Imp oz) Rear shock absorber spring 258.0...
Page 317 11-14 DR-Z400/EK2 (’02-MODEL) WATTAGE Unit: W ITEM SPECIFICATION Headlight Taillight FUEL + OIL ITEM SPECIFICATION NOTE Use only unleaded gasoline of at least 90 pump Fuel type R + M octane ( Gasoline containing MTBE (MethyI Tertiary ButyI E-03, 28 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.
Page 318 DR-Z400/EK2 (’02-MODEL) 11-15 DR-Z400E (For E-24) VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.42) ——— (1.14) Tappet clearance (when cold) 0.10 – 0.20 ——— (0.0039 – 0.0078) 0.20 – 0.30 ——— (0.0078 – 0.0118) Valve guide to valve stem 0.010 –...
Page 319 11-16 DR-Z400/EK2 (’02-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.910 – 36.960 36.610 (1.4531 – 1.4551) (1.4413) 36.880 – 36.930 36.580 (1.4520 – 1.4539) (1.4402) Camshaft journal oil clearance 0.019 – 0.053 0.150 IN. & EX. (0.0007 –...
Page 320 DR-Z400/EK2 (’02-MODEL) 11-17 ITEM STANDARD LIMIT Piston ring groove width 0.78 – 0.80 ——— (0.0307 – 0.0315) 1.30 – 1.32 ——— (0.0512 – 0.0520) 0.81 – 0.83 ——— (0.0319 – 0.0327) 2.01 – 2.03 ——— (0.0791 – 0.0799) Piston ring thickness 0.71 –...
Page 321 11-18 DR-Z400/EK2 (’02-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 – 15 ——— (0.4 – 0.6) Drive plate thickness 2.92 – 3.08 2.62 (No. 1 & No. 2) (0.115 – 0.121) (0.103) Drive plate claw width 13.7 –...
Page 322 DR-Z400/EK2 (’02-MODEL) 11-19 ITEM SPECIFICATION Slow jet (S.J.) Slow air jet (S.A.J.) Air jet (A.J.) Pilot screw (P .S.) 2¾ turns back Throttle cable play 2 – 4 mm (pulling cable) (0.08 – 0.16 in) RADIATOR + ENGINE COOLANT ITEM STANDARD/SPECIFICATION NOTE Radiator cap valve opening...
Page 323 Rear shock absorber gas 900 kPa ——— pressure (9.0 kgf/cm , 128 psi) Rear shock absorber oil type SUZUKI REAR SUSPENSION OIL SS-25 ——— or an equivalent suspension oil Rear shock absorber oil capacity 380 ml ——— (12.8/13.4 US/Imp oz) Rear shock absorber spring 258.0...
Page 324 DR-Z400/EK2 (’02-MODEL) 11-21 ITEM STANDARD/SPECIFICATION LIMIT Rear wheel travel ——— (11.6) Swingarm pivot shaft runout ——— (0.01) ELECTRICAL ITEM SPECIFICATION NOTE Spark plug DENSO: U24ESR-N Type NGK: CR8E 0.7 – 0.8 mm (0.028 – 0.031 mm) Spark performance Over 8 mm (0.3 in) at 1 atm. Ignition coil resistance Terminal –...
Page 325 11-22 DR-Z400/EK2 (’02-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 95 octane or higher. An unleaded gasoline is recommended. Fuel tank including reserve 10.0 L (2.6/2.2 US/lmp gal) reserve 2.3 L (0.6/0.5 US/lmp gal) Engine oil type SAE 10W/40, API SF or SG Engine oil capacity...
Page 326: Rear Shock Absorber
DR-Z400/EK2 (’02-MODEL) 11-23 REAR SHOCK ABSORBER OIL REPLACEMENT PROCEDURE TOOLS AND EQUIPMENT • The following tools and equipment are required to perform oil replacement. 1 Screwdriver or small punch 2 Vise* 3 Drain pan 4 Specified shock oil (SS-25) 5 Rags 6 Nitrogen tank 7 Filler hose and nozzle 8 Regulator assembly...
Page 327 [ 99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25 Oil capacity: Approximately 380 ml (12.8 US oz, 13.4 lmp oz) •...
Page 328: Reassembly And Remounting
DR-Z400/EK2 (’02-MODEL) 11-25 Riding the motorcycle with abnormal gas pressure can damage the rear shock absorber unit. Low gas pressure can result in oil leakage. Abnormal gas pressure cannot provide normal performance of the rear shock absorber. Be sure to fill the rear shock absorber unit to the speci- fied pressure.
Page 329: Damping Force Adjustment
11-26 DR-Z400/EK2 (’02-MODEL) • Apply THREAD LOCK SUPER “1303” to the seat rail lower mounting bolt 4. F99000-32030: THREAD LOCK SUPER “1303” • Tighten the seat rail upper mounting nut 3 and lower mount- ing bolts 4 to the specified torque. !Seat rail upper mounting nut: 35 N·m (3.5 kgf-m, 25.5 lb-ft) !Seat rail lower mounting bolt:...
Page 330: Wiring Diagram
DR-Z400/EK2 (’02-MODEL) 11-27 WIRING DIAGRAM DR-Z400...
Page 331 11-28 DR-Z400/EK2 (’02-MODEL) DR-Z400E...
Page 332: Cooling System Hose Routing
DR-Z400/EK2 (’02-MODEL) 11-29 COOLING SYSTEM HOSE ROUTING...
Page 333 Prepared by 3rd Ed. February, 2002 1st Ed. December, 1999 Part No. 99500-43022-01E Printed in Japan...
Page 334 Printed in Japan Y K1 K2...

Suzuki drz 400E Service Manual

Group Index

Periodic Maintenance

Engine

Fuel and Lubrication System

Cooling System

Chassis

Electrical System

Servicing Information

Dr-Z400Ey (E-24 Model)

Dr-Z400/Ek1 ('01-Model)

Dr-Z400/Ek2 ('02-Model)

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Suzuki drz 400E