Suzuki DR-Z400S 2001 User manual

DR-Z400S
99500-43032-01E

FOREWORD
This manual contains an introductory description on
the SUZUKI DR-Z400S and procedures for its inspec-
tion, service, and overhaul of its main components.
Other information considered as generally known is not
included.
Read the GENERAL INFORMATION section to famil-
iarize yourself with the motorcycle and its maintenance.
Use this section as well as other sections as a guide
for proper inspection and service.
This manual will help you know the motorcycle better
so that you can assure your customers of fast and reli-
able service.
This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual motorcycle.
Illustrations in this manual are used to show
the basic principles of operation and work pro-
cedures.They may not represent the actual mo-
torcycle exactly in detail.
This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motorcycles.
If you do not have the proper knowledge and
tools, ask your authorized SUZUKI motorcycle
dealer to help you.
Inexperienced mechanics or mechanics with-
out the proper tools and equipment may not
be able to properly perform the services de-
scribed in this manual. Improper repair may
result in injury to the mechanic and may ren-
der the motorcycle unsafe for the rider and
passenger.
Overseas Service Department
© COPYRIGHT SUZUKI MOTOR CORPORATION 2000
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FUEL AND LUBRICATION
SYSTEM
COOLING SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
DR-Z400SK1 (’01-MODEL)
DR-Z400SK2 (’02-MODEL)
2
1
3
4
5
6
7
8
9
10

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.
4. The contents are listed on the first page of each sec-
tion to help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit there is an exploded view which provides work instructions and other
service information (e.g., tightening torque, lubricating points, and locking agent points).
Example: Front wheel
1Front axle
2Odometer gearbox
3Bearing (R)
4Front wheel
5Spacer
6Bearing (L)
7Dust seal
8Brake disc
9Spacer
0Washer
AFront axle nut
BBrake disc mounting bolt
ITEM N·m kgf-m lb-ft
A42 4.2 30.5
B10 1.0 7.0

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

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

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

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

1-4 GENERAL INFORMATION
SUZUKI DR-Z400SY (2000-MODEL)
FUEL, OIL, AND ENGINE COOLANT RECOMMENDATIONS
FUEL (FOR USA AND CANADA)
Use only unleaded gasoline of at least 87 pump octane ( ) method or 91 octane or higher rated by
the Research Method.
SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible.
Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted.
Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10%
ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion
inhibitors are present in it.
If the performance of the motorcycle is unsatisfactory while using blended gasoline/alcohol fuel, you
should switch to alcohol-free unleaded gasoline.
Failure to follow these guidelines could possibly void applicable warranty coverage. Check with your fuel
supplier to make sure that the fuel you intend to use meets the requirements listed above.
* 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) 1is stamped on the right side of the
steering head pipe. The engine serial number 2is located on the right side of the crankcase. These num-
bers are required especially for registering the machine and ordering spare parts.
RIGHT SIDE LEFT SIDE
R + M
2
1
2

GENERAL INFORMATION 1-5
FUEL (FOR THE OTHER COUNTRIES)
Use unleaded gasoline that is graded 91 octane or higher by the Research Method.
ENGINE OIL
Use a premium quality 4-stroke motor oil to ensure longer ser-
vice life of your motorcycle. Use only oils which are rated SF or
SG under the API service classification. The recommended vis-
cosity is SAE 10W-40. If an SAE 10W-40 motor oil is not avail-
able, select an alternative according to the following chart.
BRAKE FLUID
Specification and classification: DOT 4
This motorcycle uses a glycol-based brake fluid. Do not use or mix other types of brake fluid
such as silicone-based and petroleum-based fluids for refilling the system, otherwise seri-
ous damage will result to the brake system.
Do not use any brake fluid taken from old, used, or unsealed containers.
Do not reuse brake fluid left over from the last servicing or which has been stored for a long
period of time.
FRONT FORK OIL
Use SUZUKI FORK OIL SS-05 or an equivalent fork oil.
ENGINE COOLANT
Since antifreeze also has corrosion- and rust-inhibiting properties, always use engine coolant containing
antifreeze, even if the atmospheric temperature does not go below the freezing point.
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.
Mix only distilled water with the antifreeze. Other types of water can corrode and clog the aluminum radiator.
Mix distilled water and antifreeze at a ratio of 50:50 – 40:60.
For more information, refer to page 5-4 in the Cooling System section.
The percentage of antifreeze in the coolant should be between 50 to 60%. If the percentage of
antifreeze is above or below this range the coolant’s frost protection and rust-inhibiting capa-
bilities will be reduced. Always keep the antifreeze content above 50% even if the atmospheric
temperature does not go below the freezing point.
MULTIGRADE
TEMP.

1-6 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. Refer to the following break-in engine speed recommendations.
Keep to these brake-in throttle positions during the break-in period.
Break-in throttle position
Initial 800 km (500 miles): Less than 1/2 throttle
Up to 1 600 km (1 000 miles): Less than 3/4 throttle
Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full
throttle operation for short periods of time.

GENERAL INFORMATION 1-7
INFORMATION LABELS
NO LABEL or PLATE NAME APPLIED SPECIFICATION
E-02 E-03 E-19 E-28 E-33 E-54
1Engine starting label
2Noise label — —— —
3Information label — —— —
4ICES Canada label — — — ——
5Fuel caution label —————
6Manual notice label — —— —
7Tire air pressure label
8Warning safety label
9ID plate ———
0Safety plate — —— —
ACompliance label — — — ——
76
5
8
A
0
2
4
9
3
1
8

1-8 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ................................................... 2 310 mm (90.9 in)
Overall width .................................................... 875 mm (34.4 in)
Overall height ................................................... 1 240 mm (48.8 in)
Wheelbase ....................................................... 1 485 mm (58.5 in)
Ground clearance ............................................ 300 mm (11.8 in)
Seat height ....................................................... 935 mm (36.8 in)
Dry mass .......................................................... 132 kg (291 lbs)
ENGINE
Type.................................................................. Four-stroke, liquid-cooled, DOHC
Number of cylinders ......................................... 1
Bore ................................................................. 90.0 mm (3.543 in)
Stroke ............................................................... 62.6 mm (2.465 in)
Piston displacement ........................................ 398 cm3(24.3 cu. in)
Compression ratio............................................ 11.3 : 1
Carburetor ........................................................ MIKUNI BSR36
Air cleaner ........................................................ Polyurethane foam element
Starter system .................................................. Electric
Lubrication system ........................................... Dry sump
TRANSMISSION
Clutch ............................................................... Wet multi-plate type
Transmission .................................................... 5-speed constant mesh
Gearshift pattern .............................................. 1-down, 4-up
Primary reduction ratio .................................... 2.960 (74/25)
Final reduction ratio ......................................... 2.933 (44/15)
Gear ratios,Low ............................................... 2.285 (32/14)
2nd ................................................ 1.733 (26/15)
3rd ................................................. 1.375 (22/16)
4th ................................................. 1.090 (24/22)
Top ................................................ 0.863 (19/22)
Drive chain ....................................................... RK520KZO, 112 links

GENERAL INFORMATION 1-9
CHASSIS
Front suspension ............................................. Telescopic, coil spring, oil damped, spring preload fully ad-
justable, compression damping force 11-way adjustable
Rear suspension .............................................. Link type, coil spring, oil damped, spring preload fully adjust-
able, compression damping force 26-way adjustable
Front fork stroke ............................................... 288 mm (11.3 in)
Rear wheel travel ............................................. 295 mm (11.6 in)
Caster .............................................................. 27° 10’
Trail................................................................... 107 mm (4.21 in)
Steering angle ................................................. 45° (right & left)
Turning radius .................................................. 2.2 m (7.2 ft)
Front brake ....................................................... Disc brake
Rear brake ....................................................... Disc brake
Front tire size ................................................... 80/100-21 51P
Rear tire size .................................................... 120/90-18 65P
ELECTRICAL
Ignition type .....................................................Electronic ignition (CDI)
Ignition timing ................................................... 7° BTDC at 1 500 r/min
Spark plug ........................................................ NGK: CR8E
DENSO: U24ESR-N
Generator ......................................................... Three-phase A.C. generator
Fuse ................................................................. 20 A
Battery ............................................................. 12 V 23.4 kC (6.5 Ah)/10 HR
Headlight .......................................................... 12 V 60/55 W
Position light ..................................................... 12 V 4 W ................... For E-02, 19, 54
Brake light/taillight ............................................ 12 V 21/5 W
Turn signal light ................................................ 12 V 21 W
CAPACITIES
Fuel tank, including reserve ............................ 9.5 L (2.5 US gal, 2.1 Imp gal) ........ For E-33
10.0 L (2.6 US gal, 2.2 Imp gal) ......For the other countries
reserve ............................................ 2.3 L (0.6 US gal, 0.5 Imp gal)
Engine oil, oil change ...................................... 1 700 ml (1.8 US qt, 1.5 Imp qt)
oil and filter change ....................... 1 800 ml (1.9 US qt, 1.6 Imp qt)
engine overhaul ............................. 1 900 ml (2.0 US qt, 1.7 Imp qt)
Front fork oil .....................................................709 ml (24.0 US oz, 25.0 Imp oz)
Engine coolant ................................................. 1 250 ml (1.3 US qt, 1.1 Imp qt)
NOTE:
These specifications are subject to change without notice.

1-10 GENERAL INFORMATION
COUNTRY AND AREA CODES
The following are codes and their applicable country or area.
CODE COUNTRY OR AREA
E-02 UK
E-03 USA
E-19 EU
E-28 Canada
E-33 California (USA)
E-54 Israel

PERIODIC MAINTENANCE 2-1
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE ....................................................... 2- 2
PERIODIC MAINTENANCE CHART .......................................................... 2- 2
MAINTENANCE AND TUNE-UP PROCEDURES .......................................... 2- 3
AIR CLEANER ............................................................................................ 2- 3
EXHAUST PIPE NUT AND BOLT AND MUFFLER NUT AND BOLTS ..... 2- 4
TAPPET CLEARANCE ............................................................................... 2- 5
SPARK PLUG .............................................................................................. 2- 9
SPARK ARRESTER (FOR E-03, 28, 33) .................................................... 2-10
FUEL LINE .................................................................................................. 2-10
ENGINE OIL AND OIL FILTER ................................................................... 2-11
ENGINE OIL HOSES .................................................................................. 2-12
THROTTLE CABLE PLAY (CARBURETOR) ............................................. 2-13
ENGINE IDLE SPEED (CARBURETOR) ................................................... 2-14
ENGINE COOLANT .................................................................................... 2-14
RADIATOR HOSES ..................................................................................... 2-15
CLUTCH ...................................................................................................... 2-16
DRIVE CHAIN ............................................................................................. 2-16
BRAKES ...................................................................................................... 2-18
BRAKE FLUID ............................................................................................ 2-19
BRAKE HOSES .......................................................................................... 2-21
TIRES .......................................................................................................... 2-21
SPOKE NIPPLES ........................................................................................ 2-22
STEERING .................................................................................................. 2-23
FRONT FORK ............................................................................................. 2-23
REAR SUSPENSION .................................................................................. 2-23
EVAPORATIVE EMISSION CONTROL SYSTEM (FOR E-33) .................. 2-23
PAIR (AIR SUPPLY) SYSTEM (FOR E-02, 19, 54) .................................... 2-23
CHASSIS NUTS AND BOLTS .................................................................... 2-24
GENERAL LUBRICATION .......................................................................... 2-26
COMPRESSION PRESSURE CHECK ........................................................... 2-27
COMPRESSION TEST PROCEDURE ........................................................ 2-27
OIL PRESSURE CHECK ................................................................................ 2-28
OIL PRESSURE TEST PROCEDURE ........................................................ 2-28
2

2-2 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 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.
PERIODIC MAINTENANCE CHART
Interval km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 15 000
Item months 1 6 12 18 24
Air cleaner – I I R I
Exhaust pipe nut and bolt and muffler T–T–T
nut and bolts
Tappet clearance – – – – I
Spark plug – I R I R
Spark arrester (For E-03, 28, 33) – C C C C
Fuel line – I I I I
Replace every four years.
Engine oil R R R R R
Engine oil filter R – – R –
Engine oil hoses I I I I I
Carburetor I I I I I
Engine coolant Replace every two years.
Radiator hose – I I I I
Clutch – I I I I
Drive chain I I I I I
Lubricate every 1 000 km (600 miles)
Brakes I I I I I
Brakes fluid – I I I I
Replace every two years.
Brake hoses – I I I I
Replace every four years.
Tires – I I I I
Spoke nipples I I I I I
Steering I – I – I
Front fork – – I – I
Rear suspension – – I – I
Evaporative emission control system Inspect every 12 000 km (7 500 miles)
(For E-33) Replace vapor hoses every four years.
PAIR (Air supply) system (For E-02, 19, 54) –– I – I
Chassis nuts and bolts T T T T T
I = Inspect and adjust, clean, lubricate, or replace as necessary.
R = Replace
T = Tighten
C = Clean

PERIODIC MAINTENANCE 2-3
MAINTENANCE AND TUNE-UP
PROCEDURES
This section describes the servicing procedures for each item
mentioned in the periodic maintenance chart on the previous
page.
AIR CLEANER
Inspect every 6 000 km (4 000 miles, 6 months).
Replace every 18 000 km (11 000 miles, 18 months).
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. Check and clean the air cleaner el-
ement in the following manner.
Remove the left frame cover. ( 6-2)
Remove the air cleaner element.
Separate the polyurethane foam element 1and element
frame 2.
Fill a wash pan of a proper size with a nonflammable cleaning
solvent. Immerse the air cleaner element in the cleaning sol-
vent and wash it.
Press the air cleaner element between the palms of both hands
to remove the excess solvent: do not twist or wring the ele-
ment or it will tear.
Immerse the element in motor oil, and then squeeze out the
excess oil leaving the element slightly wet.
ANonflammable cleaning solvent
BMotor oil SAE #30 or SAE 10W-40
Inspect the air cleaner element for tears. A torn ele-
ment must be replaced.
The surest way to accelerate engine wear is to oper-
ate the engine without the element or with one that
is torn. Make sure that the air cleaner element is in
good condition at all times. Life of the engine de-
pends largely on this component!
Remove the drain plug 3to allow any water to drain out.
21
3

2-4 PERIODIC MAINTENANCE
EXHAUST PIPE NUT AND BOLT AND
MUFFLER NUT AND BOLTS
Tighten initially at 1 000 km (600 miles, 1 month) and
every 12 000 km (7 500 miles, 12 months) 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 5to 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:
23 N·m (2.3 kgf-m, 16.5 lb-ft)
1
2
4
3
5

PERIODIC MAINTENANCE 2-5
TAPPET CLEARANCE
Inspect every 24 000 km (15 000 miles, 24 months).
INSPECTION
Remove the fuel tank. ( 4-2)
Drain the engine oil. ( 2-11)
Disconnect the spark plug cap and remove the spark plug.
(2-9 and 2-10)
Loosen the horn mounting bracket bolt.
Remove the cylinder head cover.
The tappet clearance specification is different for both intake and
exhaust valves.
Tappet clearance adjustment must be checked and adjusted: 1)
at the time of periodic inspection, 2) when the valve mechanism
is serviced, and 3) when the camshafts are removed for servic-
ing.
NOTE:
The piston must be at top dead center (TDC) on the compres-
sion stroke in order to check or adjust the tappet clearance.
The tappet clearance should only be checked when the en-
gine is cold.
Remove the generator cover cap 1and valve timing inspec-
tion plug 2.
Insert a thickness gauge between the tappet and the cam. If
the clearance is out of specification, adjust it to specification
as follows.
09900-20803: Thickness gauge
Tappet clearance (when cold)
IN: 0.10 – 0.20 mm (0.0039 – 0.0079 in)
EX: 0.20 – 0.30 mm (0.0079 – 0.0118 in)
Rotate the crankshaft with a box wrench to set the piston at
TDC on the compression stroke. (Rotate the crankshaft until
the “T” line on the generator rotor is aligned with the center of
the hole in the generator cover.)
2
1