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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