Suzuki drz 400 2000 User manual

SUZUKI
────────────
DR-Z400
────────────
M.Y 2000-2007
SERVICE MANUAL
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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 snown 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
CD F ro nt ax le
® Od ometer gearb ox
Q) Bea rin g (R)
® From wneel
® Spacer
(§) Bearing (L)
CD Dust seal
® ljr aKe Qi SC
® Sp acer
@) W as her
® Fr on t ax le nut
@ Br ake d iSc mo unt ing b ol t
ITEM N·m kgf-m
® 42 4.2
® 10 1.0
Ib-ft
30.5
7.0
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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 DEFINI TI ON
SYMBO L DEFINITI ON
~
Torque control required.
~
Apply THREAD LOCK "1342 ".
Data beside it indicates specified torque. 99000-32050
t~
Indicates service data.
~
Apply or use brake fluid.
~
Apply oil. Use engine oil unless other-
~
Measure in voltage range.
wise specified.
lir Apply molybdenum
oil solution.
~
Measure in resistance range.
(mixture of engine oil and SUZUKI
MOLY PASTE in a ratio of 1:1)
~
Apply SUZUKI SUPER GREASE "A ",
~
Measure in current range.
99000-25030 (For USA)
99000-25010 (For the other countries)
~
Apply SUZUKI SILICONE GREASE.
~
Measure in diode test rang e.
99000-25100
~
Apply SUZUKI MOLY PASTE .
~
Measure in continuity test range.
99000-25140
~ 1207 B]
Apply SUZUKI BOND "1207B".
.4 o oLi
Use special tool.
99104-31140
(ror USA)
99000-31140 (For the other countries)
-mm
Apply SUZUKI BOND "1215 ".
-em
Use engine coolant.
99000-31110 (Except USA) 99000-99032-11X (Except USA)
~
Apply THREAD LOCK SUPER "1303 ".
ED
Use fork oil.
99000-32030 99000-99001-SS5
..
Apply THREAD LOCK SUPER "1322 ",
99000-32110 (Except USA)
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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
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1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special informHtinn, thp. ~ymbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.
A WARNING
Indicates a potential hazard that could result in death or injury.
[A CAUT }ON]
Indicates a potential hazard that could result in motorcycle damage.
NOTE :
Indicates special information to make maintenance easier or instructions clearer.
rlease note, however, that the warnings and cautiun~ (;untaineu 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-
IN GS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you
are unsure about how to perform a particular service operation, ask a more experienced mechanic for
advice.
GENERAL PRECAUTIONS
A WARNING
.. Proper service and repair procedures are important for the safety of the service mechanic
and the safety and reliability of the motorcycle .
.. When two or more persons work together , pay attention to the safety of each other .
.. When it is necessary to run the engine indoors , make sure that exhaust gas is forced out-
doors .
.. When working with toxic or flammable materials, make sure that the area you work in Is well
ventilated and
that you follow all of the manufacturer 's instructions .
.. Never use gasoline as a cleaning solvent .
.. To avoid getting burned, do not touch the engine, engine oil , radiator, and exhaust system
until they have cooled .
.. After servicing the fuel, oil , engine coolant , exhaust or brake systems , check all 01 the lines ,
and
fittings related to the system for leaks.
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GENERAL INFORMATION 1-3
A CAUTION
• If parts replacement is necessary,replace the parts with SUZUKI Genuine Parts or their equiva-
lent.
• When
removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order.
• Be sure to use special tools when instructed .
• Make sure that all parts used in reassembly are clean. Lubricate them when specified .
.. Use the specified lubricants , bonds , or sealants.
• When
removing the battery, disconnect the e battery lead wire first , then the EEl battery lead
wire.
• When
reconnecting the battery, connect the EEl battery lead wire first , then the e battery lead
wire. Finally, cover the EEl battery terminal with the terminal cover .
• When performing service to electrical parts , disconnect the e battery lead wire , unless the
service procedure requires the battery power .
• When tightening cylinder head and crankcase nuts and bolts , tighten the larger sizes first.
Always tighten the nuts and bolts from the inside working out , diagonally and to the specified
torque .
• Whenever you remove oil seals, gaskets , packing , O-rings , self-locking nuts , locking wash -
ers. cotter pins. circlips. and other specified parts, be sure to replace them with new ones .
Also , before installing these new parts , be sure to remove any left over material from the
mating surfaces.
.. Never reuse a circlip.When installing a new circlip ,take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip , always ensure it is
completely seated in its groove and securely fitted.
.. Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
• After reassembling, check parts for tightness and proper operation.
• To protect the environment , do not unlawfUlly dispose of used motor oil , engine coolant , all
other fluids , batteries, and tires .
• To protect the earth's natural resources, properly dispose of used motorcycles and parts.
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~UZUKI DR-Z400
·00.· ___ • E .. ,..,
._ ..... -
SERIAL NUMBER LOCATION
Tho __ ...... "'V!N""""""!E ~ ._1 ." 'S ! ...... ~_OZ .....
aLEE ... _.,.,. Tho onoo'It .. "" __ I .. .,.. .. ""'''''_,,,.. _ .... _" ..... ,,"' '- __
__ ,_"" ""'+" " "" '.1 " "II ..... , .oo...., "'".,.'" __ "", •
•
rUCL, OI L, AND CNGINE COOLANT AECOMMI!NDATIONS
FUEL (FOR USA AND CANADA)
· ~ ..... , " -
... r Ch" hid
• SUlIJI(C ... , •• *"'_0 ___ .. """,, ._',0 __
• 1,Iae<ll" ": , .. CCM ...... r.mIf:!PoW>a't....,IIU¥E .... ' .... " - !
• I,Iae <II' ": , .. ' '... ""' ... or, ''"'"_ ............. CCM 0 .. "'" _ ..... '<f'.
........ n .....· .. , ...... _, ............. , ... _.,,'CO_
.. _.-. , '''.
•.... _.......,. ..... ""*"' .... oo ""00 ' '" ' .... _ """'" 1', "EI Q' " ................. )<'0
-_ .. " ' .......... "" ..... '" ...
• ~ ., ...... _ goAa' ... """"'..,..oy....: ............. ~." ... __ CZ!oa won,.,.,. tuo!
.. ,,' '.,-.. .......... Il10 ..... )<'0_., ..... ..- ... ,_ .., .... __
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GENERAL INFORMATION 1-5
FUEL (FOR THE OTHER COUNTRIES)
Use unleaded gasoline Ihat is graded 91 octane or higher by the Research Method.
ENGINE OIL
.,
MULnGRADE
, ., .,
, ,
lOW 30
·c
)0 4 0
SUZUKI recommends the use of SUZUKI PERFORMANCE 4
MOTOR OIL to ensure longer service life of your motorcycle.
Use only oils which are rated SF or SG under the API service
classification. The recommended viscosity
is SAE 10W-40. If an
SAE 10W-40 motor oil is not available, select an alternative ac-
cording
to the following chart. TEMP
~ F - 22 _4 14 32 GO 68 86 104
BRAKE FLUID
~ Specification and classification: DOT 4
A WARNING
* 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 tne Orake 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.
rA CAUTION .
The percentage of antifreeze in the coolant should be between 50 to 60 %. If the percentage of
antifreeze Is aOove or Oelow tnls range the coolant's frost protection and rust-inniOiting capa-
bilities will be reduced. Always keep the antifreeze content above 50% even if the atmospheric
temperature does not go below the freezing point.
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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 periormance 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 112 thrott le
Up
to 1 600 km (1 000 m il es ): 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.
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GENERAL INFORMATION 1-7
INFORMATION LABELS
NO
LAO[L or [,LAT[ NAM[
APPLIED SPECIFICATION
E-02 E-03 E-19 E
-2B
E-33 E-S 4
CD
Engine starting label 0 0 0 0 0 0
® Noise label -0 --0 -
@ Inlormat
lo n la bel
0 0 -
@ IC ES Canada label - - - 0 - -
®
Fu el caution label 0 - - ---
® Manual no
ti ce label 0 0 -
(J) Tir e a ir pr ess ur e lab el
0 0 0 0 0 0
® Warning
sa fet y label 0 0 0 0 0 0
®
10 plate 0 -0 - - 0
@ Safe ty . pl ate -0 --0 -
@ Compliance label - - - 0 --
9 10 11
'" '"
CJ
o
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1-8 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall lenglh ...................................................2 310 mm (90.9 in )
Overall widlh .... .... .. .. .... . ... ............................ ... 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 Ibs)
ENGINE
Type................ .. ........... .. ................................. .. r our-stro ke, l iquid-cooled, DOHC
Number of cylinders ...................................... ... 1
Bo
re .... ............................................................. 90.0 mm (3 .543 in)
Stroke ............................................................... 62 .6 mm (2.465 In)
Pi ston displacement .......................................398 cm ' (24.3 cu . in)
Compression ratio ...........
.. .. ............................. 11 .3 : 1
Carburetor ........................................................MIKUNI BSR36
Air cleaner...................................
.... ............... Polyuretha ne foam element
Starter system ................................................Electric
Lubrication system .................
.. ......... .. ............ Dry sump
TRANSMISSION
Clutch .... ......... .. .................................. ... .. ........ Wet multi-plate type
Tran smission ................. .. .................................5-speed constant mesh
Gearshift pattern ..............................................
l·down , 4·up
Primary reducti
on ratio ....................................2.960 (74/25)
Fin~1 rF!rluction ratio ........................ .. ............... 2.933 (441 15)
Gear ra
ti os, Low ...................... .... ................... 2.285 (32/14)
2nd ................................................ 1.733 (26/
15 )
3rd .................................................1. 375 (221 16 )
4th .................. .. ............................. 1.090 (24/22)
Top ........................ .... .................. .. 0.863 (19/22)
Dr ive chain ....................................................... RK520KZO, 112 links
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GENERAL INFORMATION 1-9
CHASSIS
Fronl Slls[lp.nsion ....................... .. .. ................. Tp.lp.sr.orir. , r.oil s[lring, oil rl",mrprl, spring preload fully ad-
justable, compression damping force l1-way adjuslable
Rear suspension ....................... ,." ..........." .... ,Link Iype, coil spring, oil damped, spring preload fully adjusl-
able, compression dampin9 force 26-way adjustable
Front fork stroke ......... .. ............ .. .. 288 mm (11.3 in)
Rear wheel Iravel .......
.. .. .. ....................295 mm (11,6 in)
C,,;;ler ........ ..... .. .......... .. .. ...... ", ..... """".""",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 iQnition (CDI)
Ignition timing ......................"...........................
7' BTDC at 1 500 r/min
Spark plug ........................"
.. ..... .. ...... NGK: CR8E
Generator ......................."
.. . ... ..
Fuse ." .........................." .........
DEN SO: U24ESR·N
...........Three-phase A.C. generator
.. ........ 20 A
Battery .........
".
... " ......" ............ "" ....... 12 V 23.4 kC (6 .5 Ah) / l0 HR
Headlight
Position light....
Brake lightllaillight.......
Turn signal light... ........
.. ...
CAPACITIES
Fuel tank, including re serve
...............
12 V 60 /55 W
..."........ 12 V 4 W ..... .. ........... For E-02, 19 ,5 4
.. .......... 12V21 / 5W
.. ............. 12 V 21 W
............. 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 countri
es
re se rve .... ............. .. ".. .. .. ... 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)
o il 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.
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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
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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
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2-2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work ne cessary 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 firs t.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
~ ~
I<m 1000
0000
12000 18000
miles 600 4000
7500
11 000
Item months 1 6 12 18
Air cleaner -I I R
Exhaust pipe nut and boit and muHler T -T -
nut and boits
Tappet clearance - - - -
Spark plug -I R I
Spark arrester (For E-03, 28, 33) -C C C
Fuel line -I I I
Replace every four years.
Enoine
oil
R R R R
Engine oil filter R --R
Engine oil hoses I I I I
Carburetor I I I I
Engine coolant Replace every two years.
Radiator hose -I I I
Clutch -I I I
Drive chain I I I I
Lubricate every 1 000 km (600 miles)
tlraKes I I I I
Brakes fluid -I I I
Replace eve ry tw o years.
Brake hoses -I I I
Replace every four years.
Tires -I I I
Spoke nipples I I I I
Steering I -I -
Front fork --I -
Rear suspension --I -
Evaporative emission control system Inspect every
12 000 km (7500 miles)
(For C-OO)
R"fJld"" VdfJUI Ilu~e~ every four year s.
PAIR (Air supply) system (For E-02 , 19 , 54)
--I -
Chassis nuts and boits T T T T
I = Inspect and adjust, clean, lubricate, or replace as necessary
R = Replace
T = Tighten
C = Clean
24000
15000
24
I
T
I
R
C
I
R
-I
I-
I
I
I
I
I
I
I
I
I
I
I
I
T
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MAINTENANCE AND TUNE-UP
PROCEDURES
This seclion describes the servicing procedures for each item
menlioned
in the periodic maintenance chari on Ihe 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 ai r cleaner is clogged wilh dust, intake resistance will be
increased,
wi th a resultant decrease in power output and an in-
crease in fu el consumpt io n. Check and clean the ai r cleaner el-
em en t in th e following manner.
• Rpmnvp the left frame cover . (c:::r 6-2)
• Rem ove the ai r cleaner elemen t.
• Separate Ihe polyurethane foam element Q) and element
frame ®.
• Fill a wash pan of a proper size wi th a nonflammable cleaning
solvent. Immerse the air cleaner element
in the cleaning sol-
vent and wash it.
• Press the air cleaner element betweenthe palms of both hands
to rem ove th e excess solvent: do not twist or wring the ele-
ment or it wi ll t ear.
• Immerse the element in motor oi l, and then squeeze out the
excess
oil leaving the element slightly wet.
® N on fl amma b le cl eaning so l vent
® Motor 0 ,1 S AE ~30 or S AE 1OW -40
[A CAUTION [
* 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 @ to allow any water to drain out.
PERIODIC MAINTENANCE 2-3
l
® !
•
o
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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 (7500 miles , 12 months) thereafter.
• Remove the right frame cover. (c:::::r 6-2)
• Tiohten the exhaust pipe n"t (j). p.xh",,!'<' rirp. hnl t (2). muffl'"
connection bo lt0), mufflermounting bolt 0, and mufflermount-
ing nut ® to the specified torque.
(!)Exhaust pipe nut and bolt: 23 N·m (2.3 kgf-m, 16.5 Ib-ft)
Muffler
connection bolt : 20 N·m (2.0 kgf-m , 14.5 Ib-ft)
Muffler mounting nut and bolt :
23 N·m (2.3
kgf-m , 16.5 Ib-ft)
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Note: In this photo the Suzuki mechanic is checking the valve tappet
clearance on the EXHAUST STROKE! Ignore this picture!
clearance on the EXHAUST STROKE! Ignore this picture!
TAPPET CLEARANCE
Inspect every 24 000 km (15 000 miles , 24 months) .
INSPECTION
• Remove the fuel tank. (c::7' 4-2)
• Drain the engine oil. (c::7' 2-11)
• Disconnect the spark plug cap and remove the spark plug.
(c:::r 2-9 and 2-10)
• Loosen the horn mounting bracket bolt.
• Remove the cylinder head cover.
The tappet clearance specification is diHerent 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:
• Tile /J;;;luII IIlu;;1 ue dllu/J uedu I;ellle{ (TOe) UII /lIe I;ulrlpres-
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 CD and valve timing inspec-
tion plug ®.
• 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 .)
• Insert a thickness gauge between the tappet and the cam. If
the clearance is out of specification. adjust
it to specification
as follows.
S 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.Q118 in)
PERIODIC MAINTENANCE 2-5
'-,-----'
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2-6 PER I ODIC MAINTENANCE
ADJUSTMENT
The clearance is adjusted by replacing the existing tappet shim
with a thicker or thinner shim.
• Remove the intake or exhaust camshafts. (c::7 3-12)
• Remove the tappet and shim by hand or with a magnet.
(c::7 3-22)
• Check the numbers printed on the tappet shim.These num-
bers Indicate the thickness of the tappet shim, as illustrated.
• Select a replacement tappet sh im that will provide t he proper
clearance.Tappet shims are available
in 25 sizes, ranging from
2.30 to 3.50 mm (0.09 to 0.14 in) in increments of 0. 05 mm
(0.002 in). Install the selected shim CD at the valve stem end,
with t
he numbers facing towards the tappet. Be sure to mea-
su re th e shim wi th a micrometer to ensure that it is of the
proper size.
Refer to the tappet shim selection table for details.
NOTE:
* Be sure to apply molybdenum oil solution to the top and bot-
tom faces of the tappet sh im,
* When installing the tappet shim, make sure that the side with
the numbers face towards the tappet.
[AC AUTION I
Install the camshafts as specified . ( c::7 3-61 to 3-63)
• After replacing the tappet shim and camshafts, rotate the
crankshaft so that the tappet
is depressed fully (this will
sq ueeze out any oil trapped between the tappet shim and the
tappet that could cause
an incorrect measurement). After ro-
tating the crankshaft,check the tappet clearance ogoin to moke
sure that it is within specification.
• When insta ll ing the cylinder head cover, apply SUZUKI BOND
"1207B" to the cam end caps of the cylinder head cover gas-
ket.
For USA
a 99104-31140: SUZUKI BOND "1207B"
For the other countries
a 99000-31140: SUZUKI BOND "1207B"
• Tighten the r.ylinrler he"rl
r.nVAr bolts to specification in two
stages.
~ Cylinder head cover bolt
Initial: 10 N·m (1 .0 kgf-m, 7.0 Ib-ft)
Final: 14 N·m (1 .4 kgf -m, 10.0 Ib-ft)
8 ¢ C! ==2:::J .8o : ::;:: mm
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I
SUFFIX
NO 230 235
MEASURED
PRESetv
TAPPET
SHIM SIZE
CLEARANCE
(mnj
230
2.35
(mm)
00lHl 0<
~
~
OOs-.<J,Ot
~
230
o lQ-O.2t
o 21-(l25
2 4<l
2._ 45
0.2&-0.30
2"
2,50
Q.31-<l.35 250
25'
0.36-0 40
25'
260
0.41 -0 45 260
",
0.46-0,5(1 2.65
270
0.51-055
2.70 2.75
0.56--06(1
27'
280
O.6 1 -o~ 2.80 2.85
0.66-0 .7 0 2.85
290
o 71-Cn 290 2.95
07&-080 2.95 3.00
0.81-0 8~
3.00 3.05
086-<)"
3.05 3.10
o 91-0 9~
3"
3.15
096-1 ()(I 3.15 3.20
1 01-1 O~
3.20 3.25
10&-1 10
325 330
I 11 -1 I~
330 335
1 16-1 2(
335 340
\ 21-1 2~
3<0 345
126-13t: 345
350
131 ·I~
350 350
13tH 4(
350
TAPPET SHIM SELECTION TABLE (INTAKE)
2<0 I '"
250 25' 260 26'
2.40
2.45 250 2.55 260 265
2.30 2.35
240
2.45 250
2.55
2.35 2.40
245 250
2.55
260
250
' 55
"" 2."
2.70 2.75
25'
260 265 2.70 2.75 2.60
"" ", 2.70
275 260
2.85
265 270
27'
280 285 290
270
27'
""
285 290 2.95
27'
2'"
285 290
2.95 3.00
280 285 290 295 300 305
285 290 295 300 305
3"
2.90 2.95 300 305 3.10 3.15
2.95
300 3.05 310
3"
320
300 305
3.10
31'
320 325
3.05 3.10 3.15 320 325 330
3.10 3.15 3.20
325 330
3.35
3"
320 325 330 335 3<0
3.20 3.25 3.30 3.35 340
34'
3.25 3.30 3.35 ""
34'
350
3.30 3.35
3.40
'"
350 350
335
3"
34'
350 350
340
34'
350
350
345 350
3.50
3.50 350
350
TAPPET SHIM SET NO . (12800-41810)1
I
270 275 280 285 290 295 300
30'
3"
'"
320 32' 330
""
3<0
3"
350
2.70 275
"0
285
290 1295
300 305
3"
'"
320 325 330 335
3.40
34'
350
2.60 2.65 2.70
27'
""
28'
290
29'
300
30'
'"
3.15
320
3.25 3.30 3.35
3<0
2.65 2.70 2.75 280
",
290 295
300
30'
3"
'"
320 325 330 335
,<0
3"
SPECIFIED CLEARANCEINO ADJUSTMENT REQUREO
2.60
",
2.90 2.95 300
2.85 2.90 2.95 3.00
30'
2.90 2.95 3.00 3.05 310
2.95
300
305
3"
315
3.00 3.05 3.10 3.1S 3.20
3.05 3.10 3.15 3.20 3.25
3.10 3.15
320
3.25
330
3.15 3.20 3.25
330
3.35
3.20 3.25 3.30 3.35 3.40
3.25 33"
33'
340 345
330 335 3<0
3 4'
350
3.35 3<0
34'
3.50 350
340 345 350
3.50
345 350 350
350 350
350
305
3"
",
320
32'
330 3.35 3.40 3.45 3.50 3.50
310 315 320
32'
330
33'
340
3.45 3.50 3.50
315
320
32'
330
",
340
34'
350
350
320 325 330
335 340
34'
350 350
3.25 330 3.35 340
3"
350 350
"'0
33'
3.40 345 350
3.50
335 3<0
34'
350 350
3. 40 3. 45 3.50
350
3.45 3.50 3.50
350 350
350
How to use this chart :
L Measure tappet clea ra nce when the engine IS cold.
II. Measure present shim size.
III. Match clearance in vertical column with present shim size In horizont.
column.
Ellample :
Tappet clearance is
Present shim size
Shim size to be used
0.23 rnm
2.70 rnm
2.80 rnm
z
~
~
m
Vl
1:1
m
"
m
:xl
5
1:1
(')
.:
~
z
-i
m
Z
l>
Z
n
m
..,
.:.,
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