Suzuki drz 400 2003 Offroad Motorcycle Manuals

Manuals and User Guides for Suzuki drz 400 2003 Offroad Motorcycle. We have 1 Suzuki drz 400 2003 Offroad Motorcycle manual available for free PDF download: Service Manual

Suzuki drz 400 2003 Service Manual

Suzuki drz 400 2003 Service Manual (232 pages)

Brand: Suzuki | Category: Motorcycle | Size: 33.64 MB

Table of Contents

Table of Contents

4
- Warning/Caution/Note
  5
- General Precautions
  5
- Serial Number Location
  7
  - Fuel
    7
  - Engine Oil
    8
  - Brake Fluid
    8
  - Front Fork Oil
    8
  - Engine Coolant
    8
- Break-In Procedures
  9
- Information Labels
  10
- Specifications
  11
- Country and Area Codes
  13
Table of Contents

14
- Periodic Maintenance Schedule
  15
  - Periodic Maintenance Chart
    15
- Maintenance and Tune-Up Procedures
  16
  - Air Cleaner
    16
  - Exhaust Pipe Nut and Bolt and Muffler Nut and Bolts
    17
  - Tappet Clearance
    18
  - Spark Plug
    22
  - Spark Arrester
    23
  - Engine Oil and Oil Filter
    24
  - Engine Oil Hoses
    25
  - Throttle Cable Play (Carburetor)
    26
  - Engine Idle Speed (Carburetor)
    27
  - Engine Coolant
    27
  - Radiator Hoses
    28
  - Clutch
    29
  - Drive Chain
    29
  - Brakes
    31
  - Brake Fluid
    32
  - Brake Hoses
    34
  - Tires
    34
  - Spoke Nipples
    35
  - Steering
    36
  - Front Fork
    36
  - Rear Suspension
    36
  - Evaporative Emission Control System (for E-33)
    36
  - Pair (Air Supply) System (for
    36
  - Chassis Nuts and Bolts
    37
  - General Lubrication
    39
- Compression Pressure Check
  40
  - Compression Test Procedure
    40
- Oil Pressure Check
  41
  - Oil Pressure Test Procedure
    41
Table of Contents

42
- Engine Components Removable with the Engine in Place
  43
- Engine Removal and Remounting
  44
  - Engine Remounting
    49
- Engine Disassembly
  52
- Engine Components Inspection and Service
  63
  - Cylinder Head
    71
  - Camshaft/Automatic Decompression Assembly
    72
  - Cylinder
    74
  - Piston and Piston Ring
    74
  - Conrod
    76
  - Crankshaft
    77
  - Starter Clutch
    77
  - Oil Pump
    78
  - Clutch
    79
  - Transmission
    81
  - Bearings
    84
  - Oil Seals
    87
  - Oil Check Valve
    88
- Engine Reassembly
  89
  - Crankshaft
    89
  - Gearshift Cam and Fork
    90
  - Crankcase
    91
  - Starter Clutch and Generator Rotor
    92
  - Balancer Shaft
    93
  - Primary Drive Gear
    94
  - Gearshift Cam Driven Gear
    94
  - Gearshift Shaft
    95
  - Oil Pump
    95
  - Cam Chain
    96
  - Clutch
    96
  - Right Crankcase Cover
    98
  - Clutch Cover
    98
  - Generator Rotor Cover
    98
  - Neutral Switch
    98
  - Starter Drive Gear Cover
    99
  - Piston Ring
    99
  - Piston and Cylinder
    100
  - Cylinder Head
    101
  - Camshaft/Automatic Decompression Assembly
    102
  - Cylinder Head Cover
    104
  - Cam Chain Tension Adjuster
    105
  - Removal
    106
  - Inspection
    106
  - Remounting
    107
Table of Contents

108
- Fuel Tank
  109
  - Removal
    109
  - Remounting
    109
- Fuel Valve Removal and Inspection
  110
  - Fuel Strainer
    110
  - Remounting
    110
- Carburetor
  111
  - Construction
    111
  - Specifications
    112
  - 1.0. No. Location
    112
  - Removal
    113
  - Disassembly
    113
  - Cleaning
    117
  - Inspection
    117
  - Reassembly
    119
  - Remounting
    119
- LUBRICATION System
  120
  - Engine Lubrication System Chart
    120
Table of Contents

121
- Cooling System
  122
  - Description
    122
  - Construction
    123
- Engine Coolant
  124
- Radiator and Cooling Fan
  125
  - Inspection
    125
  - Removal
    126
  - Remounting
    127
- Cooling Fan Thermoswitch
  128
  - Removal
    128
  - Inspection
    129
  - INSTALLA Tlon
    129
- Engine Coolant Temperature Thermoswitch Removal
  130
  - Inspection
    130
  - Installation
    130
- Thermostat
  131
  - Removal
    131
  - Inspection
    131
  - Installation
    132
- Water Pump
  133
  - Removal and Disassembly
    133
  - Inspection
    134
  - Reassembly
    134
Table of Contents

136
- Exterior Parts
  137
  - Removal
    137
  - Remounting
    137
- Front Wheel
  138
  - Construction
    138
  - Removal and Disassembly
    140
  - Inspection
    141
  - Reassembly and Remounting
    143
- Front Fork
  145
  - Construction
    145
  - Removal and Disassembly
    146
  - Inspection
    148
  - Reassembly and Remounting
    149
  - Suspension Setting
    151
- Steering
  152
  - Removal and Disassembly
    153
  - Inspection
    156
  - Reassembly and Remounting
    156
- Rear Wheel
  159
  - Construction
    159
  - Removal and Disassembly
    161
  - Inspection
    162
  - Reassembly and Remounting
    162
- Rear Suspension
  165
  - Construction
    165
  - Rear Shock Absorber Removal
    167
  - Rear Shock Absorber Inspection
    168
  - Rear Shock Absorber Disposal
    168
  - Rear Shock Absorber Remounting
    169
  - Rear Shock Absorber Damping Force Adjustment
    170
  - Inspection and Disassembly
    172
  - Reassembly and Remounting
    174
  - Final Inspection and Adjustment
    175
- Front Brake
  176
  - Construction
    176
  - Brake Pad Replacement
    177
  - Brake Fluid Replacement
    178
  - Brake Caliper Removal and Disassembly
    178
  - Brake Caliper Inspection
    179
  - Brake Caliper Reassembly and Remounting
    180
  - Brake Disc Inspection
    181
  - Master Cylinder Removal and Disassembly
    182
  - Master Cylinder Inspection
    182
  - Master Cylinder Reassembly and Remounting
    183
- Rear Brake
  185
  - Brake Pad Replacement
    186
  - Brake Fluid Replacement
    187
  - Brake Caliper Removal and Disassembly
    188
  - Brake Caliper Inspection
    189
  - Brake Caliper Reassembly and Remounting
    189
  - Brake Disc Inspection
    190
  - Master Cylinder Removal and Disassembly
    190
  - Master Cylinder Inspection
    191
  - Master Cylinder Reassembly and Remounting
    192
Table of Contents

193
- CAUTIONS in Servicing
  194
  - Connectors
    194
  - Couplers
    194
  - Clamps
    194
  - Fuse
    194
  - Semiconductor Equipped Parts
    194
  - Battery
    195
  - CONNECTING the Battery
    195
  - Wiring Procedure
    195
  - Using the Multi Circuit Tester
    196
- Location of Electrical Components
  197
- Charging System
  199
  - Description
    199
  - Troubleshooting
    200
  - Inspection
    201
- Starter System
  204
  - Description
    204
  - Troubleshooting
    204
  - STARTER MOTOR REMOVAL and Disassembly
    205
  - Starter Motor Inspection
    206
  - Starter Motor Reassembly and Remounting
    207
  - Starter Relay Inspection
    208
  - Side Standiignition Interlock System Parts Inspection
    209
- IGNITION System
  211
  - Description
    211
  - Troubleshooting
    211
  - Inspection
    213
- Speedometer
  216
  - Removal
    216
  - Parts Names
    217
  - Operating Procedure
    217
- Lamps
  221
  - Headlight
    221
  - Front and Rear Turn Signal Light
    222
  - BRAKE Llghtitailllght
    223
- Relays
  224
  - Starter Relay
    224
  - TURN SIGNAUSIDE STAND Relay
    224
- Switches
  225
- Battery
  226
  - Removal
    226
  - Specifications
    226
  - Servicing
    226
  - Recharging Operation
    227

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