Suzuki drz 400E User manual

DR-Z400/E
99500-43022-01E

FOREWORD
This manual contains an introductory description on
the SUZUKI DR-Z400/DR-Z400E and procedures for
its inspection, service, and overhaul of its main com-
ponents.
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.
© COPYRICHT SUZUKI MOTOR CORPORATION 1999
GROUP INDEX
GENERAL INFORMATION
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)
2
1
3
4
5
6
7
8
9
10
11

HOW TO USE THIS MANUAL
TO LOCATE WHATYOU 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

SYMBOL
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
Use rear shock absorber oil.
99000-99001-S25

GENERAL INFORMATION 1-1
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 ............................................................................................ 1- 5
FRONT FORK OIL ...................................................................................... 1- 5
REAR SHOCK ABSORBER 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-Z400Y/DR-Z400EY (2000-MODEL)
FUEL, OIL, AND ENGINE COOLANT RECOMMENDATIONS
FUEL (FOR USA AND CANADA)
Use only unleaded gasoline of at least 90 pump octane ( ). Gasoline containing MTBE (Methyl Tertiary
Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion
inhibitor is permissible.
FUEL (FOR THE OTHER COUNTRIES)
Gasoline used should be graded 95 octane (Research Method) or higher. Unleaded gasoline is recom-
mended.
* 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
12

GENERAL INFORMATION 1-5
ENGINE OIL (FOR USA)
SUZUKI recommends the use of SUZUKI PERFORMANCE 4
MOTOR OIL or an oil which is rated SF or SG under the API
(American Petroleum Institute) service classification. The rec-
ommended viscosity is SAE 10W/40. If an SAE 10W/40 oil is
not available, select an alternative according to the right chart.
ENGINE OIL (FOR THE OTHER COUN-
TRIES)
Use a premium quality 4-stroke 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 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
serious 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.
REAR SHOCK ABSORBER OIL
Use SUZUKI REAR SUSPENSION OIL SS-25 or an equivalent suspension 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 radia-
tor.
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 ca-
pabilities will be reduced. Always keep the antifreeze content above 50% even if the atmo-
spheric temperature does not go below the freezing point.

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 position.
Break-in throttle position
Initial 10 hours: Less than 1/2 throttle
Up to 15 hours: Less than 3/4 throttle