The Suzuki drz 400E is a powerful and versatile motorcycle designed for off-road adventures. This manual provides detailed instructions for inspecting, servicing, and overhauling the motorcycle's main components. It covers everything from routine maintenance like oil changes and air filter cleaning to more complex tasks like engine rebuilds. Whether you're a seasoned mechanic or a beginner, this manual is your essential guide to keeping your Suzuki drz 400E running smoothly.
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DR-Z400/E
9 9 5 0 0 - 4 3 0 2 2 - 0 1 E
GROUP INDEX
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider.
7
8
5
6
3
4
1
2
9
10
11
© COPYRICHT SUZUKI MOTOR CORPORATION 1999
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 section to help you find the item and page you need.
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
1 Front axle
2 Odometer gearbox
3 Bearing (R)
4 Front wheel
5 Spacer
6 Bearing (L)
7 Dust seal
8 Brake disc
9 Spacer
0 Washer
A
Front axle nut
B
Brake disc mounting bolt
ITEM
A
B
N·m kgf-m
42 4.2
10 1.0
lb-ft
30.5
7.0
Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified torque.
SYMBOL DEFINITION
Apply THREAD LOCK “1342”.
99000-32050
Indicates service data.
Apply or use brake fluid.
Apply oil. Use engine oil unless otherwise 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)
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
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
1-2 GENERAL INFORMATION
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 messages 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.
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.
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 outdoors.
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 equivalent.
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 washers, 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
RIGHT SIDE
* Difference between photographs and the actual motorcycle depends on the markets.
LEFT SIDE
The frame serial number or V.I.N. (Vehicle Identification Number)
1
is stamped on the right side of the steering head pipe. The engine serial number
2
is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.
1
2
Use only unleaded gasoline of at least 90 pump octane ( ). Gasoline containing MTBE (Methyl Tertiary
2
Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 95 octane (Research Method) or higher. Unleaded gasoline is recommended.
GENERAL INFORMATION 1-5
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 recommended viscosity is SAE 10W/40. If an SAE 10W/40 oil is not available, select an alternative according to the right chart.
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.
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.
Use SUZUKI FORK OIL SS-05 or an equivalent fork oil.
Use SUZUKI REAR SUSPENSION OIL SS-25 or an equivalent suspension oil.
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 capabilities will be reduced. Always keep the antifreeze content above 50% even if the atmospheric temperature does not go below the freezing point.
1-6 GENERAL INFORMATION
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
NO LABEL or PLATE NAME
1 Engine starting label (DR-Z400E)
2 Noise label
3 ICES Canada label
4 Manual notice label
5 Warning safety label
6 Frame serial number plate
7 Compliance label
8 Fuel information label
6 7
2
3
1
GENERAL INFORMATION 1-7
E-01
APPLIED SPECIFICATION
E-03
-
-
-
-
E-28
-
-
-
8 4 5
1-8 GENERAL INFORMATION
Overall length .................................................. 2 235 mm (88.0 in)
Overall width .................................................... 825 mm (32.5 in)
Overall height .................................................. 1 245 mm (49.0 in)
Wheelbase ....................................................... 1 475 mm (58.1 in)
Ground clearance ............................................ 325 mm (12.8 in)
Seat height ....................................................... 945 mm (37.2 in)
Dry mass .......................................................... 113 kg (249 lbs) ..... DR-Z400
119 kg (262 lbs) ..... DR-Z400E
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 cm
3
(24.3 cu. in)
Compression ratio ............................................ 12.2 : 1
Carburetor ........................................................ KEIHIN FCR39
Air cleaner ........................................................ Polyurethane foam element
Starter system .................................................. Primary kick .............. DR-Z400
Electric ...................... DR-Z400E
Lubrication system ........................................... Dry sump
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 ......................................... 3.357 (47/14)
Gear ratios, Low ............................................... 2.285 (32/14)
2nd ................................................ 1.733 (26/15)
3nd ................................................ 1.375 (22/16)
4th ................................................. 1.090 (24/22)
Top ................................................ 0.863 (19/22)
Drive chain ....................................................... RK520KZO, 112 links
GENERAL INFORMATION 1-9
Front suspension ............................................. Telescopic, coil spring, oil damped, rebound damping force
18-way adjustable, compression damping force 14-way adjustable
Rear suspension .............................................. Link type, coil spring, oil damped, spring preload fully adjustable, rebound damping force 21-way adjustable, compression damping force 26-way adjustable
Front suspension stroke .................................. 288 mm (11.3 in)
Rear wheel travel ............................................. 295 mm (11.6 in)
Caster .............................................................. 27° 20´
Trail ................................................................... 112 mm (4.41 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 51M
Rear tire size .................................................... 110/100-18 64M
Ignition type ..................................................... Electronic ignition (CDI)
Ignition timing ................................................... 7° BTDC at 1 800 r/min
Spark plug ........................................................ NGK: CR8E
DENSO: U24ESR-N
Generator ......................................................... Three-phase A.C. generator
Main fuse ......................................................... 10 A ....... DR-Z400E
Headlight .......................................................... 12 V 55 W
Taillight ............................................................. LED
Fuel tank, including reserve ............................ 10.0 L (2.6 US gal, 2.2 Imp gal) 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 ..................................................... 720 ml (24.3 US oz, 25.4 Imp oz)
Engine coolant ................................................. 1 250 ml (1.3 US qt, 1.1 Imp qt)
1-10 GENERAL INFORMATION
The following are codes and their applicable country or area.
CODE
E-01
E-03
E-28
COUNTRY OR AREA
General
USA
Canada
PERIODIC MAINTENANCE
2-1
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 .................................................................................. 2-10
FUEL LINE ................................................................................................. 2-10
DECOMPRESSION LEVER (DR-Z400) .................................................... 2-10
ENGINE OIL AND OIL FILTER .................................................................. 2-11
ENGINE OIL HOSES ................................................................................. 2-12
THROTTLE CABLE PLAY ......................................................................... 2-13
ENGINE IDLE SPEED ............................................................................... 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
CHASSIS NUTS AND BOLTS ................................................................... 2-24
GENERAL LUBRICATION ........................................................................ 2-26
COMPRESSION PRESSURE CHECK (DR-Z400E) ...................................... 2-27
COMPRESSION TEST PROCEDURE ....................................................... 2-27
OIL PRESSURE CHECK ............................................................................... 2-28
OIL PRESSURE TEST PROCEDURE ....................................................... 2-28
2-2 PERIODIC MAINTENANCE
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 hours.
Item
Air cleaner
Fuel line
Decompression lever (DR-Z400)
Engine oil and oil filter
Engine oil hoses
Carburetor
Engine coolant
Radiator hose
Clutch
Drive chain
Brakes
Brakes fluid
Brake hoses
Tires
Spoke nipples
Steering
Front fork
Rear suspension
Chassis nuts and bolts
Interval
Exhaust pipe nut and bolt and muffler nut and bolts
Tappet clearance
Spark plug
Spark arrester
Initial
5 hours
Every
30 hours
Every
60 hours
Inspect each time the motorcycle is ridden and clean as necessary.
–
–
T
I
I
T
–
I
C
I
R
I
I
I
Replace every four years.
I
–
I
I
I
I
Replace every two years.
I
I
I
I
Clean, lubricate and inspect each time the
R
C
T
I
I
I
I
I
R
I
I motorcycle is ridden.
I
I
Replace every two years.
I
I
I I
Replace every four years.
I
Check the tire pressure and the tire for
damage each time the motorcycle is ridden.
Inspect each time the motorcycle is ridden.
I – I
I
I
T
–
–
T
I
I
T
This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart.
PERIODIC MAINTENANCE 2-3
Inspect each time the motorcycle is ridden and clean as necessary.
If the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in power output and an increase in fuel consumption. Check and clean the air cleaner element in the following manner.
Remove the left frame cover. (
Remove the air cleaner element.
6-2)
Separate the polyurethane foam element 1 and element frame 2 .
Fill a wash pan of a proper size with a nonflammable cleaning solvent. Immerse the air cleaner element in the cleaning solvent 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 element or it will tear.
Immerse the element in motor oil, and then squeeze out the excess oil leaving the element slightly wet.
A
Nonflammable cleaning solvent
B
Motor oil SAE #30 or SAE 10W-40
Inspect the air cleaner element for tears. A torn element must be replaced.
The surest way to accelerate engine wear is to operate 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 depends largely on this component!
Remove the drain plug 3 to allow any water to drain out.
2
1
3
2-4 PERIODIC MAINTENANCE
Tighten initially at five hours of operation and every
30 hours 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 mounting nut 5 to 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)
4
1
2
3
5
Inspect initially at five hours of operation and every
60 hours thereafter.
INSPECTION
Remove the fuel tank. ( 4-2)
Disconnect the spark plug cap and remove the spark plug.
( 2-9)
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 servicing.
Remove the generator cover cap 1 and valve timing inspection plug 2 .
PERIODIC MAINTENANCE 2-5
2
1
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.
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)
2-6 PERIODIC MAINTENANCE
ADJUSTMENT
The clearance is adjusted by replacing the existing tappet shim with a thicker or thinner shim.
Remove the intake or exhaust camshafts. ( 3-12)
Remove the tappet and shim by hand or with a magnet. (
3-22)
Check the numbers printed on the tappet shim. These numbers indicate the thickness of the tappet shim, as illustrated.
Select a replacement tappet shim that will provide the 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 1 at the valve stem end, with the numbers facing towards the tappet. Be sure to measure the shim with a micrometer to ensure that it is of the proper size.
Refer to the tappet shim selection table for details.
Install the camshafts as specified. ( 3-61 to 3-63)
After replacing the tappet shim and camshafts, rotate the crankshaft so that the tappet is depressed fully (this will squeeze out any oil trapped between the tappet shim and the tappet that could cause an incorrect measurement). After rotating the crankshaft, check the tappet clearance again to make sure that it is within specification.
When installing the cylinder head cover, apply SUZUKI BOND
“1207B” to the cam end caps of the cylinder head cover gasket.
For USA
99104-31140: SUZUKI BOND “1207B”
For the other countries
99000-31140: SUZUKI BOND “1207B”
Tighten the cylinder head cover bolts to specification in two stages.
Cylinder head cover bolt
Initial: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Final: 14 N·m (1.4 kgf-m, 10.0 lb-ft)
INTAKE SIDE
PERIODIC MAINTENANCE 2-7
2-8 PERIODIC MAINTENANCE
EXHAUST SIDE
Inspect every 30 hours of operation.
Replace every 60 hours of operation.
Remove the fuel tank. ( 4-2)
Disconnect the spark plug cap and remove the spark plug.
NGK
DENSO
Cold type
CR9E
CR10E
U27ESR-N
U31ESR-N
Standard
CR8E
U24ESR-N
Hot type
CR7E
U22ESR-N
CARBON DEPOSITS
Check to see if there are carbon deposits on the spark plug. If carbon is deposited, remove it using a spark plug cleaner machine or carefully use a tool with a pointed end.
SPARK PLUG GAP
Measure the spark plug gap using a thickness gauge. If the spark plug gap is out of specification, adjust the gap.
Spark plug gap
Standard: 0.7 – 0.8 mm (0.028 – 0.031 in)
09900-20803: Thickness gauge
ELECTRODE
Check the condition of the electrode.
If the electrode is extremely worn or burnt, replace the spark plug with a new one.
Also, replace the spark plug if it has a broken insulator, damaged threads, etc.
Check the thread size and reach when replacing the spark plug. If the reach is too short, carbon will be deposited on the screw portion of the spark plug hole and engine damage may result.
SPARK PLUG INSTALLATION
To avoid damaging the cylinder head threads; first, finger tighten the spark plug, and then tighten it to the specified torque using the spark plug wrench.
Insert the spark plug and finger tighten it to the cylinder head, and then tighten it to the specified torque.
Spark plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
PERIODIC MAINTENANCE 2-9
2-10 PERIODIC MAINTENANCE
Clean every 30 hours of operation.
Remove the spark arrester.
Remove the carbon deposits from spark arrester and muffler.
Inspect initially at five hours of operation and every
30 hours thereafter.
Replace every four years of operation.
Inspect the fuel hose for damage and fuel leakage. If any damages are found, replace the fuel hoses with new ones.
Inspect initially at five hours of operation and every
60 hours, thereafter.
Incorrect adjustment of the lever clearance may result in starting difficulties or engine damage. Check the lever clearance and if necessary, adjust as follows:
Adjust the tappet clearance. ( 2-5 to 2-8)
Loosen the locknuts 1 .
Turn the adjuster 2 to provide the specified lever clearance
A
.
Tighten the locknuts 1 .
Decompression cable play
A
:
0 – 0.1 mm (0 – 0.004 in)
2
1
A
Replace initially at five hours of operation and every
60 hours thereafter.
The oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be done together with the engine oil change.
ENGINE OIL REPLACEMENT
Place an oil pan below the engine, and then drain the oil by removing the engine oil drain plugs ( 1 , 2 ) and engine oil filler cap 3 .
Tighten the engine oil drain plugs ( 1 , 2 ) to the specified torque, and then pour the new oil through the oil filler hole.
When performing an oil change (without oil filter replacement), the engine will hold about 1.7 L (1.8 US qt, 1.5 Imp qt) of oil.
Use an engine oil that meets API service classifications SF or
SG and that has a viscosity rating of SAE 10W-40.
Engine oil drain plug
(on the crankcase)
1
: 21 N·m (2.1 kgf-m, 15.0 lb-ft)
(on the frame)
2
: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
When installing the engine oil drain plug
2
with gasket, face the taper of gasket to drain plug as shown.
Make sure that the engine is cooled.
Place the motorcycle on level ground and hold it vertically.
Install the oil filler cap 3 .
Start the engine and allow it to run for three minutes at idling speed.
Turn off the engine and wait about three minutes, and then check the oil level on the dipstick 4 . The oil level should be between the “L” (low) and “F” (full) level lines. If the oil level is lower than the “L” level line, add oil to the “F” level line.
PERIODIC MAINTENANCE 2-11
1
2
3
4
2-12 PERIODIC MAINTENANCE
OIL FILTER REPLACEMENT
Drain the engine oil as described in the engine oil replacement procedure.
Remove the oil filter cap 1 and oil filter 2 .
Replace the oil filter with a new one.
1
3
4
Make sure that the O-ring
5
behind the filter is in the correct position.
3
4
2
5
Replace the oil filter cap and tighten the nut securely.
Add new engine oil and check the oil level as described in the engine oil replacement procedure.
Engine oil capacity
Oil change: 1.7 L (1.8 US qt, 1.5 Imp qt)
Oil and filter change: 1.8 L (1.9 US qt, 1.6 Imp qt)
Engine overhaul: 1.9 L (2.0 US qt, 1.7 Imp qt)
When reassembling the oil filter, make sure that the oil filter is installed as shown above. If the filter is installed improperly, serious engine damage may result.
Inspect initially at five hours of operation and every
30 hours thereafter.
Inspect the engine oil hoses for damage and oil leakage. If any damages are found, replace the engine oil hoses with new ones.
PERIODIC MAINTENANCE 2-13
Inspect initially at five hours of operation and every
30 hours thereafter.
Remove the fuel tank. ( 4-2)
A twin throttle cable system is used in this motorcycle. Cable 1 is for pulling and cable 2 is for returning. To adjust the cable play, adjust the returning cable first and then adjust the pulling cable.
RETURNING CABLE PLAY
The returning cable should be adjusted to have a thread length
A of 3 mm (0.12 in) as shown in the illustration. If the adjustment is necessary, adjust the thread length in the following way:
Loosen the locknut 3 .
Turn the nut 4 to obtain the thread length
A
of 3 mm
(0.12 in).
Tighten the locknut 3 securely.
PULLING CABLE PLAY
The pulling cable should be adjusted to have a cable play
B
of
2 – 4 mm (0.08 – 0.16 in) as shown in the Fig. If the adjustment is necessary, adjust the cable play in the following way:
Loosen the locknuts ( 5 , 6 ).
Turn the adjuster 7 or 8 to obtain the cable play
B
of
2 – 4 mm (0.08 – 0.16 in).
Tighten the locknuts ( 5 , 6 ) securely.
After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically.
8 6
1
2
7
5
4
3
A
B
2-14 PERIODIC MAINTENANCE
Inspect initially at five hours of operation and every
30 hours thereafter.
Connect the multi circuit tester to the high-tension cord.
Start the engine and set the engine idle speed between 1 700 and 1 900 r/min by turning the throttle stop screw 1 .
Engine idle speed: 1 800 ± 100 r/min
09900-25008: Multi circuit tester set
1
Replace every two years of operation.
ENGINE COOLANT LEVEL CHECK
Remove the radiator cap 1 and check that the engine coolant level is at the bottom of the inlet hole.
If not, replenish the radiator with the specified coolant.
Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.
Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine coolant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water. If engine coolant is swallowed, induce vomiting and call a physician immediately.
1
ENGINE COOLANT REPLACEMENT
Remove the radiator cap 1 and drain plug 2 . Then drain the engine coolant.
Tighten the drain plug 2 .
Pour the specified engine coolant slowly into the radiator.
Engine coolant:
Use an antifreeze designed for aluminum radiators mixed with distilled water only.
Water/antifreeze mixture ratio: 50:50 – 40:60
AIR BLEEDING THE ENGINE COOLANT CIRCUIT
Bleed air from the air bleeder bolt 3 .
Tighten the air bleeder bolt 3 to the specified torque.
Air bleeder bolt: 6.0 N·m (0.6 kgf-m, 4.3 lb-ft)
Add engine coolant up to the radiator inlet.
Tighten the radiator cap securely.
After warming up and cooling down the engine, add the specified engine coolant.
Engine coolant capacity:
1 250 ml (1.3 US qt, 1.1 Imp qt)
PERIODIC MAINTENANCE 2-15
1
3
2
Inspect initially at five hours of operation and every
30 hours thereafter.
Inspect the radiator hoses for damage and engine coolant leakage. If any damages are found, replace the radiator hoses with new ones.
2-16 PERIODIC MAINTENANCE
Inspect initially at five hours of operation and every
30 hours thereafter.
Loosen the locknut 1 and turn the adjuster 2 fully in.
Loosen the locknut 3 and turn the adjuster 4 until the clutch lever play
A
is within specification.
Clutch lever play
A
: 10 – 15 mm (0.4 – 0.6 in)
Tighten the locknuts.
3
4
2
1
A
Clean, lubricate and inspect each time the motorcycle is ridden.
With the transmission in neutral, support the motorcycle using a jack or wooden block and turn the rear wheel slowly by hand.
Visually inspect the drive chain for the possible damages listed below.
Loose pins
Damaged rollers
Rusted links
Missing O-ring seals
Twisted or seized links
Kinked or binding links
Excessive wear
If any damages are found, replace the drive chain with a new one.
The standard drive chain is RK520KZO. SUZUKI recommends to use this standard drive chain as a replacement.
CHECKING AND ADJUSTING
Remove the cotter pin. (E-03, 28)
Remove the rear axle nut 1 .
Tense the drive chain fully by turning both drive chain adjusters 2 .
2
1
PERIODIC MAINTENANCE 2-17
Count out 21 pins (20-pitch) on the drive chain and measure the distance between the two points. If the distance exceeds the service limit, replace the drive chain with a new one.
09900-20103: Vernier calipers
Drive chain 20-pitch length
Service Limit: 319.4 mm (12.57 in)
Loosen or tighten both chain adjusters 1 until there is 40 –
50 mm (1.6 – 2.0 in) of slack at the middle of the chain between the engine and rear sprockets as shown. The reference marks 2 on both sides of the swingarm and the edge of each chain adjuster must be aligned to ensure that the front and rear wheels are correctly aligned.
Drive chain slack: 40 – 50 mm (1.6 – 2.0 in)
After adjusting the drive chain, tighten the rear axle nut 3 to the specified torque.
Rear axle nut:
100 N·m (10.0 kgf-m, 72.5 lb-ft) .. for E-03, 28
110 N·m (11.0 kgf-m, 79.5 lb-ft) .. for the other countries
1
3
2
CLEANING AND LUBRICATING
Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened.
Do not use trichlene, gasoline or any similar fluids.
These fluids have too great a dissolving power for this chain and, what is more important, they can damage the O-rings (or seals) confining the grease in the bushing to pin clearance. Remember, high durability comes from the presence of grease in that clearance.
After cleaning and drying the chain, oil it with a heavyweight engine oil.
2-18 PERIODIC MAINTENANCE
Inspect initially at five hours of operation and every
30 hours thereafter.
(
BRAKE PADS
The extent of brake pad wear can be checked by observing the grooved limit line 1 on the brake pad. When the wear exceeds the grooved limit line, replace the pads with new ones.
6-46 and 6-55)
Replace the brake pads as a set, otherwise braking performance will be adversely affected.
BRAKE PEDAL HEIGHT
Loosen the locknut
1
.
Adjust the brake pedal height by turning the push rod 2 until the pedal is 5 mm (0.2 in)
A
below the top face of the footrest.
Tighten the locknut 1 securely.
Brake pedal height: 5 mm (0.2 in)
1
2
1
1
A
Inspect initially at five hours of operation and every
30 hours thereafter.
Replace every two years of operation.
BRAKE FLUID LEVEL
Keep the motorcycle upright and place the handlebar straight.
Check the brake fluid level by observing the lower limit line on the front and rear brake fluid reservoir.
When the brake fluid level is below the lower limit line, add brake fluid that meets the following specification to the specified level.
Specification and classification: DOT 4
The brake system is filled with an glycol-based brake fluid, which is classified DOT 4. Do not use or mix other types of brake fluid, such as silicone-based and petroleum-based brake fluids when refilling the brake system, otherwise serious damage to the brake system will result.
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.
When storing brake fluid, make sure to seal the container completely and keep it out of the reach of children.
When replenishing brake fluid, make sure not to get any dust or other foreign materials in the fluid.
Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding.
AIR BLEEDING THE BRAKE FLUID CIRCUIT
Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by “sponginess” of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:
Fill the master cylinder reservoir to the top of the inspection window. Replace the reservoir cap to prevent dirt from entering.
Attach a hose to the air bleeder valve, and insert the free end of the hose into a receptacle.
PERIODIC MAINTENANCE 2-19
2-20 PERIODIC MAINTENANCE
FRONT BRAKE
Bleed air from the brake system.
Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it.
Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the air bleeder valve, pump and squeeze the lever, and open the valve. Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles.
Close the air bleeder valve, and disconnect the hose. Fill the reservoir with brake fluid to the top of the inspection window.
Air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.
REAR BRAKE
The only difference between bleeding the front and rear brake is that the rear master cylinder is actuated by a pedal.
Inspect initially at five hours of operation and every
30 hours thereafter.
Replace every four years of operation.
Check the brake hoses for leakage, cracks, wear and damage. If any damages are found, replace the brake hoses with new ones.
PERIODIC MAINTENANCE 2-21
Check tire pressure and the tire for damage each time the motorcycle is ridden.
TIRE TREAD CONDITION
Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specification.
09900-20805: Tire depth gauge
Tire tread depth
Service Limit: Front 4.0 mm (0.16 in)
Rear 4.0 mm (0.16 in)
2-22 PERIODIC MAINTENANCE
TIRE PRESSURE
If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows.
COLD INFLATION TIRE PRESSURE kPa kgf/cm
2
FRONT
REAR
100
100
1.0
1.0
psi
14
14
The standard tire fitted on this motorcycle is a 80/100-
21 51M for the front and a 110/100-18 64M for the rear.
The use of tires other than those specified may cause instability. It is highly recommended to use the specified tires.
Inspect each time the motorcycle is ridden.
Make sure that the nipples are tight. If necessary, tighten them with a spoke nipple wrench.
Spoke nipple: 3.0 N·m (0.3 kgf-m, 2.0 lb-ft)
Inspect initially at five hours of operation and every
60 hours thereafter.
The steering should be adjusted properly for smooth turning of the handlebar and safe operation. Overtight steering prevents smooth turning of the handlebar and too loose steering will cause poor stability. Check that there is no play in the front fork. Support the motorcycle so that the front wheel is off the ground. With the wheel facing straight ahead, grasp the lower fork tubes near
( the axle and pull forward. If play is found, adjust the steering.
6-23)
Inspect initially at five hours of operation and every
60 hours thereafter.
Inspect the front forks for oil leakage, scoring, or scratches on the outer surface of the inner tubes. If any damages are found, replace the front fork with a new one. ( 6-13 and 6-14)
Inspect initially at five hours of operation and every
60 hours thereafter.
Inspect the rear shock absorber for oil leakage and damage. If any damages are found, replace the rear shock absorber with a new one.
PERIODIC MAINTENANCE 2-23
2-24 PERIODIC MAINTENANCE
Tighten initially at five hours of operation and every 30 hours thereafter.
Check that all chassis nuts and bolts are tightened to their specified torque. (Refer to page 2-25 for the locations of following the nuts and bolts.)
ITEM N·m kgf-m lb-ft
1 Front axle nut
2 Front axle pinch bolt
42
18
42
1.8
30.5
13.0
3 Front fork damper rod bolt
4 Front fork lower clamp bolt
5 Front fork upper clamp bolt
6 Front fork cap bolt
80
32
30
23
8.0
3.2
3.0
2.3
58.0
23.0
21.5
16.5
7 Steering stem head nut
8 Handlebar clamp bolt
9 Front brake master cylinder mounting bolt
0 Front brake caliper mounting bolt
A Front brake pad mounting pin
B Brake hose union bolt (front & rear)
C Brake air bleeder valve (front & rear)
D Brake disc mounting bolt (front & rear)
90
23
10
26
18
23
7.5
10
9.0
2.3
1.0
2.6
1.8
2.3
0.75
1.0
65.0
16.5
7.0
19.0
13.0
16.5
5.5
7.0
E Swingarm pivot nut
F Rear brake pedal bolt
G Rear shock absorber mounting nut (upper & lower)
H Cushion rod mounting nut
I Cushion lever mounting nut (front)
J Cushion lever mounting nut (center)
K Rear axle nut E-03, 28
The other countries
L Rear brake pad mounting pin
M Rear brake master cylinder mounting bolt
N Rear brake master cylinder rod locknut
O Seat rail mounting nut (upper)
P Seat rail mounting bolt (lower)
Q Rear sprocket nut
R Side-stand bolt
S Side-stand nut
T Drive chain roller mounting bolt (upper & lower)
U Spoke nipple
77
29
55
100
100
100
100
110
18
10
18
35
35
30
50
55
40
3
7.7
2.9
5.5
10.0
10.0
10.0
10.0
11.0
1.8
1.0
1.8
3.5
3.5
3.0
5.0
5.5
4.0
0.3
13.0
7.0
13.0
25.5
25.5
21.5
36.0
40.0
29.0
2.0
55.5
21.0
40.0
72.5
72.5
72.5
72.5
79.5
D
U
1
3
2
0
C
A
B
9
B
E
T
P
R
H
G
J
I
Q
5
4
PERIODIC MAINTENANCE 2-25
8
6
7
D
U
L
K
B
C
M
N
P
F
O
G
S
T
2-26 PERIODIC MAINTENANCE
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
0
1
3
9
2 3
A
5
0
4
1 Odometer cable
2 Odometer gearbox
3 Wheel bearing
4 Sidestand pivot
5 Drive chain
6 Swingarm pivot
7 Cushion lever pivot
8 Cushion lever rod pivot
9 Brake pedal pivot
0 Brake lever holder
A Clutch lever holder
PERIODIC MAINTENANCE 2-27
The compression pressure reading of a cylinder is a good indicator of its internal condition.
The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.
Compression pressure
Standard: 1 000 kPa (10.0 kgf/cm 2 , 142 psi)
(Automatic decompression actuated)
Low compression pressure can indicate any of the following conditions:
Excessively worn cylinder walls
Worn piston or piston rings
Piston rings stuck in grooves
Poor valve seating
Ruptured or otherwise defective cylinder head gasket
Remove the related parts and test the compression pressure in the following manner.
Remove the spark plug. ( 2-9)
Install the compression gauge and adaptor in the spark plug hole. Make sure that the connection is tight.
Keep the throttle lever in the fully open position.
Press the starter button and crank the engine for a few seconds.
Record the maximum gauge reading as the cylinder compression.
09915-64510: Compression gauge set
09915-63310: Adaptor
2-28 PERIODIC MAINTENANCE
Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts.
Oil pressure:
Above 40 kPa (0.4 kgf/cm 2 , 5.7 psi)
Below 140 kPa (1.4 kgf/cm 2 , 19.9 psi) at 3 000 r/min, oil temp at 60°C
Low or high oil pressure can indicate any of the following conditions:
LOW OIL PRESSURE
Clogged oil filter
Oil leakage from the oil passage
Damaged O-ring
Defective oil pump
Combination of the above items
HIGH OIL PRESSURE
Engine oil viscosity is too high
Clogged oil passage
Combination of the above items
Connect a tachometer to the high-tension cord.
Remove the main oil gallery plug 1 .
Install the oil pressure gauge and adaptor into the main oil gallery.
Warm up the engine as follows:
Summer: 10 minutes at 2 000 r/min
Winter: 20 minutes at 2 000 r/min
After warming up the engine, increase the engine speed to
3 000 r/min (check the tachometer), and then read the oil pressure gauge.
09915-74510: Oil pressure gauge
09915-70610: Adapter
ENGINE 3-1
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE ........................ 3- 2
ENGINE REMOVAL AND REMOUNTING ........................................................................ 3- 3
ENGINE REMOVAL ...................................................................................................... 3- 3
ENGINE REMOUNTING ............................................................................................... 3- 8
ENGINE DISASSEMBLY ................................................................................................... 3-11
ENGINE COMPONENTS INSPECTION AND SERVICE ................................................. 3-22
CYLINDER HEAD ......................................................................................................... 3-22
CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBLY ...................................... 3-31
CYLINDER .................................................................................................................... 3-33
PISTON AND PISTON RING ........................................................................................ 3-33
CONROD ....................................................................................................................... 3-35
CRANKSHAFT ............................................................................................................. 3-36
STARTER CLUTCH (DR-Z400E) ................................................................................. 3-36
STARTER TORQUE LIMITER (DR-Z400E) ................................................................. 3-37
OIL PUMP ..................................................................................................................... 3-37
CLUTCH ........................................................................................................................ 3-37
GEARSHIFT FORK AND GEAR .................................................................................. 3-38
TRANSMISSION ........................................................................................................... 3-39
BEARINGS .................................................................................................................... 3-42
OIL SEALS .................................................................................................................... 3-45
ENGINE REASSEMBLY ..................................................................................................... 3-47
CRANKSHAFT .............................................................................................................. 3-47
GEARSHIFT CAM AND FORK .................................................................................... 3-48
CRANKCASE ................................................................................................................ 3-49
STARTER CLUTCH AND GENERATOR ROTOR ........................................................ 3-50
BALANCER SHAFT ..................................................................................................... 3-51
PRIMARY DRIVE GEAR ............................................................................................... 3-52
GEARSHIFT CAM DRIVEN GEAR ............................................................................... 3-52
GEARSHIFT SHAFT ..................................................................................................... 3-53
OIL PUMP ..................................................................................................................... 3-53
KICK STARTER (DR-Z400) .......................................................................................... 3-54
CAM CHAIN .................................................................................................................. 3-55
CLUTCH ........................................................................................................................ 3-55
RIGHT CRANKCASE COVER ...................................................................................... 3-57
CLUTCH COVER .......................................................................................................... 3-57
GENERATOR ROTOR COVER ..................................................................................... 3-57
STARTER DRIVE GEAR COVER (DR-Z400E) ............................................................ 3-58
PISTON RING ................................................................................................................ 3-58
PISTON AND CYLINDER ............................................................................................. 3-59
CYLINDER HEAD ......................................................................................................... 3-60
CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBLY ....................................... 3-61
CYLINDER HEAD COVER ............................................................................................ 3-63
CAM CHAIN TENSION ADJUSTER ............................................................................. 3-64
3-2 ENGINE
The parts listed below can be removed and installed without removing the engine from the frame. Refer to the page listed in each section for removal and installation instructions.
ENGINE LEFT SIDE
PARTS
Engine sprocket
Starter drive/driven gear (DR-Z400E)
Generator rotor
Starter clutch
REMOVAL
3-6
3-14
3-19
3-19
INSTALLATION
3-9
3-57, 3-58
3-50
3-50
ENGINE RIGHT SIDE
PARTS
Exhaust pipe/muffler
Oil filter
Kick lever (DR-Z400)
Clutch pressure plate, drive plates, and driven plates
Clutch sleeve hub
Primary driven gear assembly
Oil pump drive/driven gear
Oil pump
Gearshift shaft
Gearshift cam driven gear
Balancer drive/driven gear
Kick starter drive/driven gear (DR-Z400)
ENGINE CENTER
Carburetor
Starter motor (DR-Z400E)
PARTS
Cam chain tension adjuster
Cylinder head cover
Camshaft/automatic decompression assembly
Decompression lever assembly (DR-Z400)
Cylinder head
Cylinder
Piston
Cam chain
REMOVAL
3-5
3-14
3-4
3-16
3-16
3-17
3-18
3-18
3-18
3-19
3-19
3-17
REMOVAL
4-10
3-4
3-11
3-11
3-12
3-12
3-13
3-13
3-13
3-17
INSTALLATION
3-10
–
3-10
3-56
3-56
3-56
3-53
3-53
3-53
3-52
3-51
3-54
INSTALLATION
4-15
–
3-64
3-63
3-61
3-61
3-60
3-60
3-59
3-55
Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps.
Remove the seat and frame covers. ( 6-2)
Drain the engine oil. (
Drain the engine coolant. (
2-11)
2-15)
Remove the carburetor. ( 4-10)
Disconnect the battery lead wire and engine ground coupler. (DR-Z400E)
Remove the engine side covers.
Remove the engine plate.
Disconnect the generator couplers.
ENGINE 3-3
-
3-4 ENGINE
Remove the regulator/rectifier.
Remove the engine coolant overflow tank mounting bolt.
Disconnect the spark plug cap 1 , engine oil breather hose 2 , engine oil hose 3 , and engine oil tank 4 .
Remove the clutch release arm 5 .
Remove the starter motor 6 . (DR-Z400E)
6
2
1
3
Remove the kick lever. (DR-Z400)
Remove the exhaust pipe 1 and muffler 2 .
Disconnect the radiator hoses.
Disconnect the decompression cable. (DR-Z400)
Disconnect the engine oil pipe 3 and engine oil hose union bolt 4 .
3
ENGINE 3-5
1
2
1
3-6 ENGINE
Remove the gearshift lever.
Remove the engine sprocket cover.
Flatten the washer 1 and remove the engine sprocket nut
2 while pressing down on the rear brake pedal.
2
1
Remove the cotter pins and brake pedal.
Replace the removed cotter pins with new ones.
Remove the engine sprocket.
Remove the engine from the frame.
ENGINE 3-7
3-8 ENGINE
Remount the engine in the reverse order of engine removal.
Install the engine mounting nuts and bolts.
Replace the engine mounting nuts with new ones.
Hold the bolthead with a wrench, and then tighten the engine mounting nuts to the specified torque.
A
B
I
A
A
B
H
G
C
B
ITEM
A
B
C
N·m kgf-m
40 4.0
66
77
6.6
7.7
lb-ft
29.0
47.5
55.5
LENGTH
Bolt
D
Bolt
E
Bolt
F
Bolt
G
Bolt
H
Bolt
I
F
90 mm (3.5 in)
100 mm (3.9 in)
115 mm (4.5 in)
50 mm (2.0 in)
50 mm (2.0 in)
245 mm (9.6 in)
D
D
E
ENGINE 3-9
Tighten the brake pedal bolt to the specified torque.
Brake pedal bolt: 29 N·m (2.9 kgf-m, 21.0 lb-ft)
Install the engine sprocket, with side
A of the sprocket facing toward the engine.
Tighten the engine sprocket nut to the specified torque.
Engine sprocket nut: 110 N·m (11.0 kgf-m, 79.5 lb-ft)
Bend the washer securely.
Tighten the engine oil hose union bolt to the specified torque.
Engine oil hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
A
3-10 ENGINE
Tighten the exhaust pipe nut 1 , exhaust pipe bolt 2 , muffler connection bolt 3 , muffler mounting bolt 4 and muffler mounting nut 5 to 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
4
2
5
Apply THREAD LOCK SUPER “1303” to the kick lever bolt, and then tighten it. (DR-Z400)
99000-32030: THREAD LOCK SUPER “1303”
Pour 1.9 L (2.0 US qt, 1.7 Imp qt) of an API service classified
SF or SG engine oil that has a viscosity rating of SAE 10W-40, into the oil filler hole, located in the frame, after overhauling it.
Start the engine and allow it to run for about three minutes at idle speed.
Turn off the engine and wait about three minutes, and then check the oil level on the dipstick.
Engine oil capacity
Oil change: 1.7 L (1.8 US qt, 1.5 Imp qt)
Oil and filter change: 1.8 L (1.9 US qt, 1.6 Imp qt)
Engine overhaul: 1.9 L (2.0 US qt, 1.7 Imp qt)
Adjust the following items to specification.
Throttle cable play .............................................
Engine idle speed ..............................................
Brake pedal ........................................................
2-13
2-14
2-18
Remove the cap bolt 1 and cam chain tension adjuster 2 .
Remove the top-dead-center (TDC) plug 3 and generator cover cap 4 .
3
4
ENGINE 3-11
2
1
Turn the generator rotor until the “T” line on the generator rotor is aligned with the center of the hole in the generator cover.
Remove the spark plug.
Remove the cylinder head cover bolts in diagonal stages, and then remove the cylinder head cover.
3-12 ENGINE
Remove the cam chain guide 1 and camshaft journal holders 2 .
1
Remove the dowel pins 3 , intake camshaft 4 and exhaust camshaft 5 .
2
3
4
5
3
Remove the decompression lever assembly. (DR-Z400)
Remove the cylinder head side bolt.
Remove the four cylinder head bolts in diagonal stages.
Remove the cylinder head bolts, and then remove the cylinder head.
Remove the cylinder head gasket 1 and dowel pins 2 .
2
ENGINE 3-13
1
Remove the cam chain guide 3 .
Remove the cylinder base nuts 4 , and then remove the cylinder.
Remove the cylinder gasket 5 and dowel pins 6 .
4
3
5
6
Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase.
Remove the piston pin circlip.
Draw out the piston pin and remove the piston.
3-14 ENGINE
Remove the generator rotor cover. (DR-Z400)
Remove the starter drive gear cover 1 and starter drive gear 2 . (DR-Z400E)
1 2
Remove the generator rotor cover. (DR-Z400E)
Remove the starter driven gear 3 , dowel pins 4 , and gasket 5 .
5
3
4
4
Remove the oil filter cap 6 and oil filter 7 .
6
7
ENGINE 3-15
Remove the water pump cover.
Remove the clutch cover.
Remove the right crankcase cover.
Remove the dowel pins 1 and gasket 2 .
1
2
Loosen the clutch spring set bolts working in diagonal stages, and then remove them when they are fully loosened.
1
3-16 ENGINE
Remove the clutch pressure plate, clutch drive plates, and clutch driven plates.
Remove the push rod, spring washer, and spring washer seat.
Flatten the clutch sleeve hub washer.
Hold the clutch sleeve hub using the special tool, and then remove the clutch sleeve hub nut.
09920-53740: Clutch sleeve hub holder
Remove the clutch sleeve hub and washer.
ENGINE 3-17
Remove the primary driven gear assembly and collar.
Remove the cam chain tensioner 1 and cam chain 2 .
1
2
Remove the retainer 3 , spacer 4 and kick starter driven gear 5 . (DR-Z400)
Remove the kick starter assembly 6 . (DR-Z400)
Remove the kick starter guide 7 . (DR-Z400)
6
4
3
5
7
Remove the retainer 8 and spacer 9 . (DR-Z400E)
8
9
3-18 ENGINE
Remove the oil pump idle gear 1 and oil pump driven gear 2 .
1
2
Remove the pin 3 and oil pump assembly.
Do not remove the circrip
A
, before separating the crankase to prevent the oil pump idle gear shaft from dropping into the crankcase.
A
3
Remove the gearshift shaft 4 by removing the circlip 5 .
Remove the gearshift arm stopper 6 .
6
5
4
Remove the gearshift pawl lifter 7 and gearshift cam driven gear 8 .
7
8
Remove the gearshift cam stopper arm.
Remove the gearshift cam driven gear bolt.
Hold the generator rotor using the special tool (DR-Z400) or a 26-mm offset wrench (DR-Z400E), and then remove the balancer driven gear nut.
09930-44913: Rotor holder
Remove the washer, balancer driven gear, and key.
Hold the generator rotor using the special tool (DR-Z400) or a 26-mm offset wrench (DR-Z400E), and then remove the primary drive gear nut.
09930-44913: Rotor holder
Remove the washer, primary drive gear, pin, key, and balancer drive gear.
The primary drive gear nut has left-hand threads.
Hold the generator rotor using the special tool (DR-Z400) or a 26-mm offset wrench (DR-Z400E), and then remove the generator rotor nut.
09930-44913: Rotor holder
Remove the generator rotor using the special tool.
09930-31921: Rotor remover
Do not hit the generator rotor with a hammer, otherwise the rotor may be damaged.
ENGINE 3-19
3-20 ENGINE
Remove the left crankcase securing bolts.
Remove the right crankcase securing bolts.
Separate the crankcase using the special tool.
09920-13120: Crankcase separating tool
Remove the dowel pins.
Remove the gear shift fork shafts 1 , gear shift forks 2 , and gear shift cam 3 .
2
1
2
1
3
Remove the countershaft assembly 1 and driveshaft assembly 2 .
2
ENGINE 3-21
1
Remove the balancer shaft.
Remove the crankshaft from the crankcase using the special tool.
09920-13120: Crankcase separating tool
Remove the oil sump filter.
3-22 ENGINE
DISASSEMBLY
Identify the position of each removed part. Organize the parts in their respective groups (i.e., exhaust or intake) so that they can be installed in their original positions.
Remove the intake pipe.
Remove the engine coolant hose housing.
Remove the tappets 1 and shims 2 by hand or by using a magnet.
1
1
Compress the valve springs, and then remove the valve cotters from the valve stem using the special tools.
09916-14510: Valve spring compressor
09916-14910: Attachment
09916-84511: Tweezers
Remove the valve spring retainer and valve springs.
Remove the valve from the other side.
2
2
Remove the oil seal with long-nose pliers.
Remove the valve spring seat.
CYLINDER HEAD DISTORTION
Decarbonize the combustion chamber.
Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge. Take clearance readings at several places. If any clearance reading exceeds the service limit, replace the cylinder head with a new one.
09900-20803: Thickness gauge
Cylinder head distortion
Service Limit: 0.05 mm (0.002 in)
VALVE STEM RUNOUT
Support the valve using V-blocks and measure the valve stem runout using the dial gauge, as shown. If the runout exceeds the service limit, replace the valve with a new one.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
Valve stem runout
Service Limit: 0.05 mm (0.002 in)
ENGINE 3-23
3-24 ENGINE
VALVE HEAD RADIAL RUNOUT
Support the valve using a V-block and measure the valve head radial runout using the dial gauge, as shown. If the runout exceeds the service limit, replace the valve with a new one.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
Valve head radial runout
Service Limit: 0.03 mm (0.001 in)
VALVE FACE WEAR
Visually inspect each valve face for wear or damage. If any abnormal wear is found, replace the respective valve with a new one. Measure the valve face thickness
T
. If the valve face thickness is not within the specified value, replace the valve with a new one.
09900-20101: Vernier calipers
Valve face thickness
T
Service Limit: 0.5 mm (0.02 in)
VALVE STEM DEFLECTION
Lift the valve about 10 mm (0.39 in) from the valve seat. Measure the valve stem deflection in two directions, “X” and “Y”, perpendicular to each other. Position the dial gauge as shown. If the deflection exceeds the service limit, determine whether the valve or the guide should be replaced with a new one.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
Valve stem deflection
Service Limit: 0.35 mm (0.014 in)
VALVE STEM WEAR
Measure the valve stem outside diameter using the micrometer.
If the outside diameter is not within the specified value, replace the valve with a new one. If the valve stem outside diameter is within specification, but the valve stem deflection is not, replace the valve guide with a new one. After replacing the valve or valve guide, check the deflection.
09900-20205: Micrometer (0 – 25 mm)
Valve stem O.D.
Standard:
IN: 4.975 – 4.990 mm (0.1959 – 0.1965 in)
EX: 4.955 – 4.970 mm (0.1951 – 0.1957 in)
X
Y
VALVE GUIDE SERVICING
Drive the valve guide out toward the camshaft side using the valve guide remover.
09916-44310: Valve guide remover/installer
Refinish the valve guide holes in the cylinder head using the valve guide reamer and handle.
09916-34580: Valve guide reamer (10.8 mm)
09916-34542: Reamer handle
Oil the stem hole of each valve guide and drive the guide into the guide hole using the valve guide installer and attachment.
09916-44310: Valve guide remover/installer
09916-53360: Valve guide installer attachment
Failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head.
After fitting the valve guides, refinish their guiding bores with the valve guide reamer. Be sure to clean and oil the guides after reaming.
09916-34570: Valve guide reamer (5.0 mm)
09916-34542: Reamer handle
ENGINE 3-25
3-26 ENGINE
VALVE SEAT WIDTH
Coat the valve seat uniformly with prussian blue. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.
09916-10911: Valve lapper set
The ring-like dye impression left on the valve face must be continuous, without any breaks. In addition, the width of the dye ring, which is the valve seat width, must be within the following specification.
Valve seat width
W
Standard: 0.9 – 1.1 mm (0.035 – 0.043 in)
If the valve seat is out of specification, re-cut the seat.
VALVE SEAT SERVICING
The valve seats for both the intake and exhaust valves are machined to three different angles. The seat contact surface is cut at 45°.
45°
15°
30°
60°
Intake
N-128
—
N-128
N-114
Exhaust
N-128
N-121
—
N-114
For USA
Valve seat cutter: N-114, N-121, and N-128
Solid pilot:
For the other countries
N-100-5.0
09916-21110: Valve seat cutter set
09916-22420: Cutter N-128
09916-22430: Cutter N-114
09916-20610: Cutter N-121
09916-24311: Solid pilot N-100-5.0
The valve seat contact area must be inspected after each cut.
intake
60˚
45˚
30˚
60˚ exhaust
45˚
15˚
When installing the solid pilot 1 , rotate it slightly.
1
ENGINE 3-27
Seat the pilot snugly. Install the 45° cutter 2 , attachment 3 , and T-handle 4 .
2
3
4
INITIAL SEAT CUT
Descale and clean up the seat using the 45° cutter. Rotate the cutter one or two turns.
Measure the valve seat width
W
after every cut.
If the valve seat is pitted or burned, use the 45° cutter to condition the seat some more.
W
45
°
3-28 ENGINE
TOP NARROWING CUT
If the contact area is too high on the valve, or if it is too wide, use the 30° cutter ( for the intake side ) and the 15° cutter (for the exhaust side) to lower and narrow the contact area.
FINAL SEAT CUT
If the contact area is too low or too narrow, use the 60° cutter to raise and widen the contact area. If the contact area is too high or too wide, use the 15° cutter to lower and narrow it to the correct width.
After the desired seat position and width is achieved, use the
60° cutter very lightly to clean up any burrs caused by the previous cutting operations.
DO NOT use a lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish but not a highly polished or shiny one.
This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation.
60˚ w w
30˚
W
15
°
VALVE SEAT SEALING CONDITION INSPECTION
With the valve and valve spring assembled, pour a small quantity of gasoline into the intake or exhaust port.
Check that no gasoline leaks through the valve seat. If leakage is found, correct the sealing surface.
Gasoline is highly flammable and explosive.
Keep heat, sparks, and flames away from gasoline.
VALVE SPRING
The force of the coil spring keeps the valve seat tight. A weakened spring results in reduced engine power output and accounts for the chattering noise coming from the valve mechanism.
Check the valve springs for proper strength by measuring their free length and also by the force required to compress them. If the spring length is less than the service limit or if the force required to compress the valve spring is not within specification, replace both the inner and outer springs as a set.
Valve spring free length (IN & EX)
Service Limit:
INNER: 32.6 mm (1.28 in)
OUTER:36.3 mm (1.43 in)
Valve spring tension (IN & EX)
Standard:
INNER: 5.6 – 6.4 kgf/27.4 mm (12.3 – 14.1 lbs/1.08 in)
OUTER:12.6 – 14.5 kgf/30.9 mm (27.7 – 32.0 lbs/1.22 in)
ENGINE 3-29
3-30 ENGINE
REASSEMBLY
Install each valve spring seat.
Apply molybdenum oil solution to each oil seal and press-fit them into position.
Do not reuse the oil seals.
Apply molybdenum oil solution to the valve as shown, and then insert them into the valve guides.
When inserting each valve into the valve guides, make sure not to damage the lip of the oil seal.
Install the valve spring with the smaller pitch
A
facing the cylinder head.
B
Larger pitch
C
Down
Install the valve spring retainer by pressing down the spring using the valve lifter. Fit the cotter halves to the stem end and release the lifter to allow the cotter 1 to wedge between the retainer and the valve stem. Make sure that the rounded lip 2 of the cotter fits snugly into the groove 3 in the stem end.
09916-14510: Valve spring compressor
09916-14910: Attachment
09916-84511: Tweezers
Be sure to install all of the parts in their original positions.
Do not attempt to disassemble the camshaft/automatic decompression assembly. It is not serviceable.
AUTOMATIC DECOMPRESSION
Move the automatic decompression weight by hand to inspect if it is operating smoothly. If the automatic decompression weight does not operate smoothly, replace it with a new one.
CAM WEAR
Worn-down cams are often the cause of mistimed valve operation resulting in reduced power output.
Measure the cam height
H
using the micrometer. If the cams are worn to the service limit, replace the camshaft with new a one.
09900-20202: Micrometer (25 – 50 mm)
Cam height
H
Service Limit:
IN: 36.610 mm (1.4413 in)
EX: 36.580 mm (1.4402 in)
ENGINE 3-31
3-32 ENGINE
CAMSHAFT JOURNAL WEAR
Measure the oil clearance, with the camshaft installed, using the plastigauge.
09900-22301: Plastigauge
09900-22302: Plastigauge
Camshaft journal oil clearance (IN & EX)
Service Limit: 0.150 mm (0.0059 in)
Tighten the camshaft journal holder bolts evenly and in diagonal stages to the specified torque.
Camshaft journal holder bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)
Remove the journal holders and read the width of the compressed plastigauge with the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge.
If the camshaft journal oil clearance exceeds the service limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. Replace the camshaft or the cylinder head and camshaft holder depending upon which one exceeds the specification.
09900-22403: Small bore gauge
Camshaft journal holder I.D. (IN & EX)
Standard: 22.012 – 22.025 mm (0.8666 – 0.8671 in)
09900-20205: Micrometer (0 – 25 mm)
Camshaft journal O.D. (IN & EX)
Standard: 21.972 – 21.993 mm (0.8653 – 0.8659 in)
CAMSHAFT RUNOUT
Support the valve using V-blocks and measure the camshaft runout using the dial gauge. If the runout exceeds the service limit, replace the camshaft with a new one.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
Camshaft runout
Service Limit: 0.10 mm (0.004 in)
CYLINDER DISTORTION
Check the gasket surface of the cylinder block for distortion using a straightedge and thickness gauge. Take clearance readings at several places. If any clearance reading exceeds the service limit, replace the cylinder block with a new one.
09900-20803: Thickness gauge
Cylinder distortion
Service Limit: 0.05 mm (0.002 in)
CYLINDER BORE
Inspect the cylinder wall for any scratches, nicks or other damage. Measure the cylinder bore diameter at six places.
09900-20508: Cylinder gauge set
Cylinder bore
Standard: 90.000 – 90.015 mm (3.5433 – 3.5439 in)
ENGINE 3-33
PISTON DIAMETER
Measure the piston diameter using the micrometer at 15 mm
(0.6 in) from the skirt end.
If the piston diameter is less than the service limit, replace the piston with a new one.
09900-20204: Micrometer (75 – 100 mm)
Piston diameter
Service Limit: 89.880 mm (3.5386 in)
3-34 ENGINE
PISTON-RING-TO-GROOVE CLEARANCE
Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. If any clearance reading exceeds the service limit, replace both the piston and piston rings.
09900-20803: Thickness gauge
09900-20205: Micrometer (0 – 25 mm)
Piston-ring-to-groove clearance
Service Limit:
1st: 0.18 mm (0.0071 in)
2nd: 0.15 mm (0.0059 in)
Piston ring groove width
Standard:
1st: 0.78 – 0.80 mm (0.0307 – 0.0315 in)
1.30 – 1.32 mm (0.0512 – 0.0520 in)
2nd: 0.81 – 0.83 mm (0.0319 – 0.0327 in)
Oil: 2.01 – 2.03 mm (0.0791 – 0.0799 in)
Piston ring thickness
Standard:
1st: 0.71 – 0.76 mm (0.0280 – 0.0299 in)
1.08 – 1.10 mm (0.0425 – 0.0433 in)
2nd: 0.77 – 0.79 mm (0.0303 – 0.0311 in)
PISTON RING FREE END GAP AND PISTON RING END GAP
Measure the piston ring free end gap using the vernier calipers, first, and then fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge.
If any measurement exceeds the service limit, replace the piston ring with a new one.
09900-20101: Vernier calipers
Piston ring free end gap
Service Limit:
1st: 5.5 mm (0.22 in)
2nd: 9.2 mm (0.36 in)
09900-20803: Thickness gauge
Piston ring end gap
Service Limit:
1st: 0.50 mm (0.020 in)
2nd: 0.50 mm (0.020 in)
PISTON PIN AND PIN BORE
Measure the piston pin bore diameter using the small bore gauge.
If the diameter exceeds the service limit, replace the piston with a new one.
09900-20602: Dial gauge (1/1000 mm)
09900-22403: Small bore gauge (18 – 35 mm)
Piston pin bore
Service Limit: 20.030 mm (0.7886 in)
Measure the piston pin outside diameter at three positions using the micrometer. If any measurement exceeds the service limit, replace the piston pin with a new one.
09900-20205: Micrometer (0 – 25 mm)
Piston pin O.D.
Service Limit: 19.980 mm (0.7866 in)
CONROD SMALL END I.D.
Measure the conrod small end inside diameter using the small bore gauge.
If the conrod small end inside diameter exceeds the service limit, replace the conrod with a new one.
09900-20605: Dial calipers
Conrod small end I.D.
Service Limit: 20.040 mm (0.7890 in)
CONROD DEFLECTION AND BIG END SIDE CLEARANCE
Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod. This method can also be used to check the extent of wear on the parts of the conrod’s big end.
09900-20701: Magnetic stand
09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block set (100 mm)
Conrod deflection
Service Limit: 3.0 mm (0.12 in)
Push the big end of the conrod to one side and measure the side clearance using a thickness gauge. If the clearance exceeds the service limit, replace the crankshaft assembly with a new one or bring the deflection and the side clearance within the service limit by replacing the worn parts (conrod, big end bearing, crank pin, etc.) with new ones.
09900-20803: Thickness gauge
Big end side clearance
Service Limit: 1.00 mm (0.039 in)
ENGINE 3-35
3-36 ENGINE
CRANKSHAFT RUNOUT
Support the crankshaft using V-blocks and measure the crankshaft runout using the dial gauge, as shown. If the runout exceeds the service limit, replace the crankshaft with a new one.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09910-21304: V-block set (100 mm)
Crankshaft runout
Service Limit: 0.08 mm (0.003 in)
Hold the rotor with a 26-mm offset wrench and remove the hexagon bolts.
Install the starter clutch in the proper direction as shown.
A
Apply engine oil to the starter clutch.
Apply THREAD LOCK SUPER “1303” to the hexagon bolts, and then tighten them to the specified torque while holding the rotor and using a 26-mm offset wrench.
99000-32030: THREAD LOCK SUPER “1303”
Starter clutch bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft)
Install the starter gear 1 to the starter clutch.
Check that the rotor 2 turns in the direction of the arrow 3 on the rotor while holding the starter gear, and that the rotor never turns in the opposite direction of the arrow.
3
1
2
Do not attempt to disassemble the starter torque limiter. It is unserviceable.
Check the slip torque of the starter torque limiter using the special tools and vise as shown, if the slip torque is not within the specified torque, replace the starter torque limiter with a new one.
09930-73170: Starter torque limiter holder
09930-73180: Starter torque limiter socket
Slip torque:
30 – 55 N·m (3.0 – 5.5 kgf-m, 21.5 – 40.0 lb-ft)
The oil pump case securing screw is applied with
SUZUKI THREAD LOCK SUPER “1303”. If an attempt is made to overhaul the oil pump assembly, the screw may be damaged. Only the oil pump unit is available as a replacement.
99000-32030: THREAD LOCK SUPER “1303”
CLUTCH DRIVE PLATES
Measure the thickness of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the service limit, replace the clutch plates as a set.
09900-20101: Vernier calipers
Drive plate thickness (No.1 & No.2)
Service Limit: 2.62 mm (0.103 in)
Drive plate claw width (No.1 & No.2)
Service Limit: 13.2 mm (0.520 in)
CLUTCH DRIVEN PLATES
Measure each clutch driven plate for distortion using the thickness gauge. If a clutch driven plate is not within the service limit, replace the clutch plates as a set.
09900-20803: Thickness gauge
Driven plate distortion
Service Limit: 0.10 mm (0.004 in)
ENGINE 3-37
3-38 ENGINE
CLUTCH SPRING FREE LENGTH
Measure the free length of each clutch spring using vernier calipers. If any spring is not within the service limit, replace all of the springs with new ones.
09900-20101: Vernier calipers
Clutch spring free length
Service Limit: 49.9 mm (1.96 in)
GEARSHIFT-FORK-TO-GEARSHIFT-FORK GROOVE
CLEARANCE
Clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting process.
Measure the gearshift fork clearance in the groove of its respective gear using the thickness gauge.
If the clearance exceeds specification, replace the fork, its respective gear, or both.
09900-20803: Thickness gauge
09900-20101: Vernier calipers
Gearshift-fork-to-gearshift-fork-groove clearance
Service Limit: 0.50 mm (0.020 in)
Shift fork groove width
Standard: 4.8 – 4.9 mm (0.189 – 0.193 in)
Shift fork thickness
Standard: 4.6 – 4.7 mm (0.181 – 0.185 in)
DISASSEMBLY
Disassemble the transmission gears as shown.
ENGINE 3-39
1 Countershaft
2 5th (top) drive gear
3 Circlip
4 3rd drive gear
5 Circlip
6 4th drive gear
7 2nd drive gear
8 Circlip
9 Bearing
0 Bearing
A Driveshaft
B Washer
C 2nd driven gear
D Spacer
E Bearing
F Oil seal
G 4th driven gear
H 3rd driven gear
I Washer
J Circlip
K 5th (top) driven gear
L Washer
M 1st (low) driven gear
N Spacer
O Washer
P Bearing
3-40 ENGINE
REASSEMBLY
Reassemble the transmission in the reverse order of disassembly. Pay special attention to the following points:
Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed.
When installing a new circlip, do not expand the end gap larger than required to slip the circlip over the shaft.
After installing a new circlip, make sure that it is completely seated in its groove and securely fitted.
When installing a new circlip, pay attention to the direction of the circlip. Fit it to the side where the thrust is, as shown. The rounded side should be against the gear surface.
A
Thrust
B
Sharp edge
1 Countershaft
2 Driveshaft
2
A
1
ENGINE 3-41
3-42 ENGINE
Wash the bearing with a cleaning solvent and lubricate it with motor oil before inspection. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defective and must be replaced with a new one as follows.
RIGHT COUNTERSHAFT BEARING
Remove the bearing retainer.
Remove the right countershaft bearing using the special tool.
09921-20220: Bearing remover set
Replace the removed bearing with a new one.
Install the right countershaft bearings using the special tool.
09913-70210: Bearing installer set
Apply a small quantity of THREAD LOCK “1342” or THREAD
LOCK SUPER “1322” to the bearing retainer screws, and tighten them securely.
For USA
99000-32050: THREAD LOCK “1342”
For the other countries
99000-32110: THREAD LOCK SUPER “1322”
LEFT COUNTERSHAFT BEARING
Remove the left countershaft bearing using the special tool.
09923-73210: Bearing remover
09930-30102: Sliding hammer
Replace the removed bearing with a new one.
Install the left countershaft bearing using the special tool.
09913-70210: Bearing installer set
DRIVESHAFT BEARINGS
Remove the right and left driveshaft bearings using the special tool.
09921-20220: Bearing remover set
Replace the removed bearings with new ones.
Install the right and left driveshaft bearings using the special tool.
09913-70210: Bearing installer set
CRANKSHAFT BEARINGS
Remove the bearing retainer.
Remove the right and left crankshaft bearings using the special tools.
09921-20220: Bearing remover set
Replace the removed bearings with new ones.
Install the right and left crankshaft bearing using the special tool.
09913-70210: Bearing installer set
RIGHT GEARSHIFT CAM BEARING
Remove the bearing retainer.
Remove the right gearshift cam bearing.
Replace the removed bearing with a new one.
Install the right gearshift cam bearing.
ENGINE 3-43
3-44 ENGINE
LEFT GEARSHIFT CAM BEARING
Remove the left gear shift cam bearing.
Replace the removed bearing with a new one.
Install the left gearshift cam bearing.
RIGHT BALANCER SHAFT BEARING
Remove the right balancer shaft bearing using the special tool.
09921-20220: Bearing remover set
Replace the removed bearing with a new one.
Install the right balancer shaft bearing using the special tool.
09913-70210: Bearing installer set
LEFT BALANCER SHAFT BEARING
Remove the left balancer shaft bearing using the special tools.
09921-20210: Bearing remover
09930-30102: Sliding hammer
Replace the removed bearing with a new one.
Install the left balancer shaft bearing using the special tool.
09913-70210: Bearing installer set
ENGINE 3-45
Damage to the lip of the oil seal may result in leakage of the air/ fuel mixture or engine oil. Inspect the oil seal for wear or damage. If any damages are found, replace the oil seal with a new one.
Install the oil seals into the crankcase, clutch housing case, and generator rotor cover. Pay attention to the following points:
Replace the removed oil seals with new ones.
Apply SUZUKI SUPER GREASE “A” to the lip of the oil seals.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
DRIVESHAFT OIL SEAL
Remove the collar 1 and retainer 2 .
Remove the driveshaft oil seal from the left crankcase using the special tool.
09913-50121: Oil seal remover
Replace the removed oil seal with a new one.
2
1
3-46 ENGINE
Install the driveshaft oil seal into the left crankcase slowly, using the special tool.
09913-70210: Bearing installer set
GEARSHIFT SHAFT OIL SEAL
Remove the gearshift shaft oil seal from the left crankcase, slowly using the special tool.
09913-50121: Oil seal remover
Replace the removed oil seal with a new one.
Install the gearshift shaft oil seal into the left crankcase slowly, using the special tool.
09913-70210: Bearing installer set
OIL CHECK VALVE
Remove the bushing 1 , oil check valve ball 2 and spring 3 from the right crankcase cover.
Install the spring 3 , oil check valve ball 2 and bushing 1 to the right crankcase cover 4 as shown.
The rubber part of bushing
1
must face to the outside.
Reassemble the engine in the reverse order of disassembly.
Pay special attention to the following points:
1 Bearing
2 Crankshaft (R)
3 Conrod
4 Bearing
5 Crank pin
6 Crankshaft (L)
7 Bearing
Determine the width between the webs referring to the figure when rebuilding the crankshaft.
Crank-web-to-web-width
Standard: 62.0 ± 0.1 mm (2.441 ± 0.004 in)
When mounting the crankshaft in the crankcase, it is necessary to pull its left end into the crankcase by using the special tools.
09910-32812: Crankshaft installer
09940-52861: Attachment
Never fit the crankshaft into the crankcase by striking it with a plastic hammer.
Always use the special tool, otherwise the accuracy of the crankshaft alignment will be affected.
ENGINE 3-47
3-48 ENGINE
1 Gearshift fork No.1
2 Gearshift fork No.2
3 Gearshift fork shaft
4 Bearing
5 Pin
6 Gearshift cam
7 Bearing
8 Gearshift fork No.3
9 Gearshift fork shaft
Install the gearshift forks into the gearshifting grooves in the correct position and direction.
Install the gearshift fork shafts.
Reassemble the crankcase in the reverse order of disassembly. Pay special attention to the following points:
Thoroughly remove the sealant material and oil stains on the mating surface of the right and left crankcases.
Before installing the sump filter, wash the sump filter with cleaning solvent, and then blow compressed air through it to dry it off.
Install the dowel pins to the left crankcase.
Apply engine oil to the conrod big end and to the transmission gears.
Apply SUZUKI BOND “1207B” or “1215” to the mating surface of the right crankcase and
A part of both crankcases as shown.
For USA
99104-31140: SUZUKI BOND “1207B”
For the other countries
99000-31110: SUZUKI BOND “1215”
ENGINE 3-49
A
3-50 ENGINE
Tighten the crankcase bolts to the specified torque.
Crankcase bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
After the crankcase bolts have been tightened, check if the crankshaft, countershaft, and driveshaft rotate smoothly. If a large resistance is felt to rotation, try to free the shafts by tapping them with a plastic mallet.
Remove the grease from the tapered portion of the crankshaft and the generator rotor.
Install the starter driven gear 1 and key 2 .
Tighten the generator rotor nut to the specified torque using the special tool (DR-Z400) or a 26-mm offset wrench (DR-
Z400E).
09930-44913: Rotor holder
Generator rotor nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
2
1
ENGINE 3-51
1 Washer
2 Balancer driven gear
3 Bearing
4 Pin
5 Balancer shaft
6 Bearing
A
Balancer shaft nut
ITEM
A
N·m
50
kgf-m lb-ft
5.0
36.0
When installing the balancer drive gear, align the pin 1 with the groove 2 .
2
1
When installing the balancer driven gear, align the pin 3 with the groove 4 .
Install the balancer driven gear by aligning the matching marks.
3
4
Hold the generator rotor using the special tool (DR-Z400) or a 26-mm offset wrench (DR-Z400E), and then tighten the balancer shaft nut to the specified torque.
09930-44913: Rotor holder
Balancer shaft nut: 50 N·m (5.0 kgf-m, 36.0 lb-ft)
3-52 ENGINE
Install the key 1 and primary drive gear 2 .
Hold the generator rotor using the special tool (DR-Z400) or a 26-mm offset wrench (DR-Z400E), and then tighten the primary drive gear nut to the specified torque.
09930-44913: Rotor holder
Primary drive gear nut: 110 N·m (11.0 kgf-m, 79.5 lb-ft)
Tighten the gearshift cam driven gear bolt to the specified torque.
Gearshift cam driven gear bolt:
24 N·m (2.4 kgf-m, 17.5 lb-ft)
Install each pawl lifter into the gearshift cam driven gear. The large shoulder
A
must face to the outside.
2
1
Apply a small quantity of THREAD LOCK “1342” or THREAD
LOCK SUPER “1322” to the pawl lifter screws, and then tighten them securely.
For USA
99000-32050: THREAD LOCK “1342”
For the other countries
99000-32110: THREAD LOCK SUPER “1322”
ENGINE 3-53
Tighten the gearshift arm stopper to the specified torque.
Gearshift arm stopper: 19 N·m (1.9 kgf-m, 13.5 lb-ft)
Before mounting the oil pump, apply engine oil to the sliding surfaces of the oil pump case, outer rotor, inner rotor, and shaft.
When installing the inner rotor, align the pin 1 with the groove 2 .
Apply a small quantity of THREAD LOCK “1342” or THREAD
LOCK SUPER “1322” to the threaded parts of the oil pump mounting screws, and then tighten them.
For USA
99000-32050: THREAD LOCK “1342”
For the other countries
99000-32110: THREAD LOCK SUPER “1322”
When installing the oil pump driven gear, align the pin 3 with the groove 4 .
1
2
4
3
3-54 ENGINE
1 Oil seal
2 Guide
3 Spring
4 Kick starter shaft
5 Kick starter drive gear
6 Washer
7 Circlip
8 Kick starter
9
Spring
0 Washer
A Bolt
B Kick starter guide
C
Kick starter stopper
When installing the kick starter drive gear onto the kick starter shaft, align the punch mark 1 on the kick starter with the line
3 on the kick starter shaft.
Install the kick starter shaft assembly and hook the end of the spring onto the crankcase boss.
2
1
Install the cam chain 1 on to the sprocket.
Tighten the cam chain tensioner mounting bolt 2 to the specified torque.
Cam chain tensioner mounting bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)
2
ENGINE 3-55
1
1 Clutch release camshaft
2 Bolt
3 Spring retainer
4 Spring
5 Pressure plate
6 Drive plate (7 pcs)
7 Driven plate (7 pcs)
8 Drive plate (1 pc)
9 Bearing
0 Push piece
A Washer
B Spring washer
C Spring washer seat
D Clutch sleeve hub
E Washer
F Primary driven gear assembly
G Spacer
H Push rod
A
Clutch sleeve hub nut
ITEM
A
N·m
70
kgf-m lb-ft
7.0
50.5
3-56 ENGINE
Hold the clutch sleeve hub using the special tool, and then tighten the clutch sleeve hub nut to the specified torque.
09920-53740: Clutch sleeve hub holder
Clutch sleeve hub nut: 70 N·m (7.0 kgf-m, 50.5 lb-ft)
Bend the tongue of the washer securely.
Install the spring washer seat 1 and spring washer 2 onto the clutch sleeve hub correctly.
Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order.
Tighten the clutch spring set bolts securely in diagonal stages.
Install the dowel pins 1 and new gasket 2 .
Use a new gasket to prevent oil leakage.
Tighten the right crankcase cover bolts securely.
A
1
2
ENGINE 3-57
A
1
Tighten the clutch cover bolts securely.
A
A
Install the starter driven gear 1 (DR-Z400E), dowel pins 2 , and new gasket 3 .
Use a new gasket to prevent oil leakage.
3
2
Tighten the generator rotor cover bolts securely. (DR-Z400)
1
2
3-58 ENGINE
Tighten the generator rotor cover bolts securely. (DR-Z400E)
Tighten the starter drive gear cover screws securely.
Install the oil ring first, the 2nd ring second, and the 1st ring last.
1
2
1
2
First, install a spacer 1 into the oil ring groove, and then install the two side rails 2 . The spacer and side rails do not have a designated top and bottom. They can be installed in any position.
When installing the spacer, be careful not to allow its two ends to overlap in the groove.
È
INCORRECT
É
CORRECT
Position the piston ring gaps as shown. Before inserting the piston into its cylinder, check that the gaps are properly positioned.
A
Exhaust side
B
Intake side
3 2nd ring and lower side rail
4 Upper side rail
5 1st ring and spacer
Install the piston and cylinder in the reverse order of removal.
Apply molybdenum oil solution onto the piston pin.
Apply molybdenum oil solution to the small end of the conrod.
Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase, and then fit the piston pin circlip with long-nose pliers.
Use a new piston pin circlip to prevent circlip failure with a bent one.
Apply engine oil to the sliding surface of the piston and big end of the conrod.
ENGINE 3-59
3-60 ENGINE
Install the dowel pins 1 and new gasket 2 onto the crankcase.
Use a new gasket to prevent oil leakage.
Hold each piston ring with the piston ring sections positioned correctly and put it into the cylinder. Make sure that the piston rings are caught by the cylinder skirt.
1
1
Install the dowel pins 1 and new gasket 2 .
Use a new cylinder head gasket to prevent gas leakage.
1
2
1
2
With the head snugly seated on the cylinder, secure it by tightening the bolts in diagonal stages. Tighten the cylinder head bolts to the specified torque.
Cylinder head bolt
Initial: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
Final: 46 N·m (4.6 kgf-m, 33.5 lb-ft)
After tightening the cylinder head bolts to specification, tighten the cylinder head bolts 1 and cylinder nuts 2 to the specified torque.
Cylinder head bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Cylinder nut: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Tighten the cylinder head side bolt to the specified torque.
Cylinder head side bolt: 14 N·m (1.4 kgf-m, 10.0 lb-ft)
Install the decompression lever assembly to the cylinder head, and tighten its bolt 3 to the specified torque. (DR-Z400)
Decompression bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
3
1
2
ENGINE 3-61
Turn the generator rotor until the “T” line on the generator rotor is aligned with the center of the hole in the generator cover.
If the crankshaft is turned without drawing the cam chain upward, the cam chain will catch between crankcase and cam chain drive sprocket.
3-62 ENGINE
Place each camshaft into the correct position.
With the “T” line aligned with the center of the hole, hold the camshaft steady and lightly pull up the cam chain to remove any slack between the cam chain drive sprocket and exhaust camshaft sprocket.
The exhaust camshaft sprocket has an arrow marked “1” 1 . Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. Engage the cam chain with the exhaust camshaft sprocket.
The other arrow marked “2” 2 should now be pointing straight up. Starting from the roller pin that is directly above the arrow marked “2” 2 , count out 15 roller pins (from the exhaust camshaft side going towards the intake camshaft side).
Engage the 15th roller pin on the cam chain with the arrow marked “3” 3 on the intake sprocket. Refer to the following illustrations.
1st pin
2
3
15th pin
1
3
2
1
ENGINE 3-63
Install the dowel pins.
Place each camshaft journal holders and cam chain guide into the correct position.
Tighten the camshaft journal holder bolts to the specified torque.
Camshaft journal holder bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)
Thoroughly wipe off oil from the fitting surfaces of the cylinder head and cover.
Apply SUZUKI BOND “1207B” to the end caps of the cylinder head cover gasket as shown.
For USA
99104-31140: SUZUKI BOND “1207B”
For the other countries
99000-31140: SUZUKI BOND “1207B”
Apply engine oil to both sides of the washer 1 .
Lightly tighten the cylinder head cover bolts in diagonal stages, and then tighten them to the specified torque.
Cylinder head cover bolt
Initial: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Final: 14 N·m (1.4 kgf-m, 10.0 lb-ft)
Use a new washers
1
and cushion
2
.
1
2
3-64 ENGINE
Install the cam chain tension adjuster. Pay special attention to the following points:
Apply engine oil to the push rod.
Turn the adjusting screw clockwise with a flat-bladed screwdriver until the push rod is locked.
Fit a new gasket to the chain tension adjuster body.
Use a new gasket to prevent oil leakage.
Install the cam chain tension adjuster body to the cylinder, and then tighten the two Allen bolts to the specified torque.
Cam chain tension adjuster bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)
Turn the adjusting screw counterclockwise with a flat-bladed screwdriver to unlock.
Tighten the cam chain tensioner spring holder bolt to the specified torque.
Cam chain tensioner spring holder bolt:
8 N·m (0.8 kgf-m, 6.0 lb-ft)
FUEL AND LUBRICATION SYSTEM
4-1
CONTENTS
FUEL TANK .................................................................................................... 4- 2
REMOVAL .................................................................................................. 4- 2
REMOUNTING ........................................................................................... 4- 2
FUEL VALVE .................................................................................................. 4- 3
REMOVAL AND INSPECTION .................................................................. 4- 3
FUEL STRAINER ....................................................................................... 4- 3
REMOUNTING ........................................................................................... 4- 3
CARBURETOR .............................................................................................. 4- 4
CONSTRUCTION ...................................................................................... 4- 4
SPECIFICATIONS ...................................................................................... 4- 5
I.D. NO. LOCATION .................................................................................... 4- 5
SLOW SYSTEM .......................................................................................... 4- 6
COASTING ENRICHMENT SYSTEM ......................................................... 4- 6
MAIN SYSTEM ........................................................................................... 4- 7
ACCELERATOR PUMP SYSTEM .............................................................. 4- 8
STARTER SYSTEM .................................................................................... 4- 9
FLOAT SYSTEM ......................................................................................... 4- 9
REMOVAL .................................................................................................. 4-10
DISASSEMBLY .......................................................................................... 4-10
CLEANING................................................................................................. 4-13
INSPECTION ............................................................................................. 4-14
REASSEMBLY .......................................................................................... 4-14
REMOUNTING ........................................................................................... 4-15
LUBRICATION SYSTEM ............................................................................... 4-16
ENGINE LUBRICATION SYSTEM CHART .............................................. 4-16
4-2 FUEL AND LUBRICATION SYSTEM
Remove the seat and side covers. (
Turn the fuel valve to the “OFF” position.
6-2)
Disconnect the fuel hose.
Gasoline is highly flammable and explosive.
Keep heat, sparks, and flames away from gasoline.
Remove the fuel tank.
Remount the fuel tank in the reverse order of removal.
Remove the fuel tank. (
Drain the fuel completely.
Remove the fuel valve.
4-2)
Gasoline is highly flammable and explosive.
Keep heat, sparks, and flames away from gasoline.
Replace the removed O-ring with a new one to prevent fuel leakage.
Tighten the fuel valve mounting bolts to the specified torque.
Fuel valve mounting bolt: 4.4 N·m (0.44 kgf-m, 3.2 lb-ft)
FUEL AND LUBRICATION SYSTEM 4-3
If the fuel strainer is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel strainer with compressed air.
Remount the fuel valve in the reverse order of removal.
4-4 FUEL AND LUBRICATION SYSTEM
1 Top cap
2 Throttle valve lever
3 Throttle valve
4 Throttle lever assembly
5
Carburetor body
6 Intake joint
7 O-ring
8 Slow air jet
9
Main air jet
0 Air jet
A Throttle position sensor
B Starter plunger
C Hose
D
Coasting richer pump assembly
E Hose
F Hose
G Pilot screw
H
Starter jet
I Needle jet
J Pilot jet
K Main jet
L Needle valve
M
Valve seat
N Float pin
O Float
P Float chamber
Q
O-ring
R Throttle stop screw
S Accelerating pump assembly
FUEL AND LUBRICATION SYSTEM 4-5
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Main air jet
Jet needle
Needle jet
Slow jet
Slow air jet
Air jet
Pilot screw
Throttle cable play
(M.J.)
(M.A.J.)
(J.N.)
(N.J.)
(S.J.)
(S.A.J.)
(A.J.)
(P.S.)
SPECIFICATION
E-01
DR-Z400
KEIHIN FCR39H
39 mm (1.5 in)
E-03, 28
←
←
E-01
←
←
29F0
DR-Z400E
E-03, 28
←
←
1800 ± 100 r/min
9.0 ± 1.0 mm (0.35 ± 0.04 in)
29F1
←
←
29F3
←
←
29F4
←
←
#165
#200
OBDXP-4th
2.9 mm (0.11 in)
#45
#60
#90
1 1/2 turns out
2 – 4 mm (0.08 – 0.16 in)
#142
←
←
←
←
←
←
←
←
#165
←
←
←
←
←
←
←
←
#142
←
←
←
←
←
←
←
←
E-01: General E-03: USA E-28: Canada
Carburetor has an I.D. number 1 printed on its body.
1
4-6 FUEL AND LUBRICATION SYSTEM
This system supplies fuel during engine operation when the piston valve 1 is fully closed or slightly open.
The fuel from the float chamber 2 is metered by the pilot jet 3 where it mixes with air coming in through the pilot air jet 4 . This mixture, rich with fuel, then goes up through the pilot passage to the pilot screw 5 . A part of the mixture is discharged into the main bore from the bypass ports 6 . The remainder of the mixture is metered by the pilot screw 5 and sprayed into the main bore through the pilot outlet 7 .
The coasting enrichment system is included in the slow system. At normal operation, joining of the air from carburetor inlet side pilot air passage 8 which obtains the proper air/fuel mixture ratio. When the piston valve is closed suddenly, a high vacuum, which is generated in the main bore, is applied to the diaphragm 9 .
The valve 0 which interlocks with the diaphragm 9 closes the air passage 8 , and thus, produces an air/ fuel mixture that is rich with fuel. By controlling air flow in the pilot circuit, this system is able to keep combustion constant by varying the air/fuel mixture ratio.
FUEL AND LUBRICATION SYSTEM 4-7
As the piston valve 1 is opened, engine speed rises and vacuum in the venturi
A is increased.
The fuel in the float chamber 2 is metered by the main jet 3 . The metered fuel enters the needle jet 4 , mixes with the air admitted through the main air jet 5 , and then forms an emulsion.
The emulsified fuel then passes through the clearance between the needle jet 4 and jet needle 6 , and is discharged into the venturi
A
, in which it meets the main air stream being drawn by the engine.
Mixture proportioning is accomplished in the needle jet 4 . The clearance through which the emulsified fuel must flow depends ultimately on the throttle position.
4-8 FUEL AND LUBRICATION SYSTEM
This system works only when the rider opens the throttle grip quickly as the accelerator pump sends the necessary amount of fuel to the carburetor bore to correct the air/fuel mixture ratio. When the rider opens the throttle grip quickly, the intake air volume increases and air velocity at the bottom of the piston valve is slow and sucking volume of fuel is less.
The piston valve lever 1 pushes levers ( 2 , 3 ), and lever 4 turns and pushes rod 5 . The rod 5 pushes the plunger 6 . This plunger pushes out the fuel through the outlet pipe 7 , spraying fuel into the main bore.
FUEL AND LUBRICATION SYSTEM 4-9
Pulling the starter (enricher) knob causes fuel to be drawn into the starter circuit from the float chamber 1 .
The starter jet 2 meters this fuel, which then flows into the fuel passage 3 and mixes with the air coming from the float chamber. The mixture, rich in fuel, reaches starter plunger 4 and mixes again with the air coming through a passage 5 extending from behind the diaphragm.
The two successive mixtures of the fuel with the air provide the proper air/fuel mixture for starting. This occurs when the mixture is sprayed out through the starter outlet port 6 into the main bore.
The float 1 and needle valve 2 work in conjunction with one another. As the float moves up and down, so does the needle valve.
When there is a high fuel level in the float chamber 3 , the float rises and the needle valve pushes against the valve seat. When this occurs, no fuel enters the float chamber.
As the fuel level falls the float lowers and the needle valve unseats itself; admitting fuel into the float chamber.
In this manner, the needle valve admits and shuts off fuel to maintain the appropriate fuel level inside the float chamber.
4-10 FUEL AND LUBRICATION SYSTEM
Remove the fuel tank. ( 4-2)
Remove the left frame cover. ( 6-2)
Disconnect the throttle position sensor coupler.
Disconnect the throttle cables.
Disconnect the coasting richer pump hose.
Loosen the carburetor clamp screws, and then remove the carburetor assembly.
Remove the carburetor hoses.
First, remove the air valve mounting nut 1 , and then remove the air valve mounting bolt 2 and air valve assembly
3 . (DR-Z400)
FUEL AND LUBRICATION SYSTEM 4-11
1
2
3
Remove the throttle position sensor.
Remove the accelerating pump assembly.
Replace the removed O-ring with a new one to prevent fuel leakage.
Remove the coasting richer pump assembly.
Replace the removed O-ring with a new one to prevent fuel leakage.
Remove the starter plunger.
Remove the top cap.
4-12 FUEL AND LUBRICATION SYSTEM
Remove the throttle lever assembly.
Remove the throttle valve.
Remove the intake joint.
Replace the removed O-ring with a new one to prevent air leakage.
Remove the float chamber.
Replace the removed O-ring with a new one to prevent fuel leakage.
Remove the float pin 1 , float 2 , and needle valve 3 .
3
2
1
Remove the following parts.
1 Valve seat
2 Main jet
3 Slow jet
4 Pilot screw
5 Needle jet
6 Starter jet
7 Main air jet
8 Slow air jet
9 Air jet
4
FUEL AND LUBRICATION SYSTEM 4-13
3
8
4
1
2
6
5
9
7
Do not use wire to clean the passageways, valve seat, and jets. Use compressed air only.
Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions for proper use, handling and storage.
Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.
Clean all circuits of the carburetor thoroughly––not just the perceived problem area. Clean the circuits in the carburetor body with a spray-type cleaner. If necessary, soak each circuit in a dip-type cleaning solution to loosen dirt and varnish.
Dry the carburetor body using compressed air.
Do not use wire to clean the passageways, valve seat, and jets. If the components cannot be cleaned with a spray-type cleaner it may be necessary to soak the them in a dip-type cleaning solution. Always follow the chemical manufacturer’s instructions for proper use and cleaning of the carburetor components.
After cleaning, reassemble the carburetor with new O-rings.
Replace the removed O-rings with new ones.
4-14 FUEL AND LUBRICATION SYSTEM
Check the following items for any damage or clogging. If any damages are found, replace the damaged parts with new ones.
Pilot jet
Main jet
Float
Needle valve
O-ring
Throttle valve
Main air jet
Pilot air jet 1
Valve seat
Jet needle
Pilot air jet 2 Piston valve
Needle jet air bleeding hole Starter (enricher) jet
Diaphragm
Pilot outlet and bypass ports
NEEDLE VALVE INSPECTION
If foreign matter is caught between the valve seat and the needle valve, the gasoline will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve sticks, the gasoline will not flow into the float chamber.
Clean the float chamber and float parts with gasoline. If the needle valve is worn as shown, replace it and the valve seat a new one.
Clean the fuel passage of the mixing chamber using compressed air.
FLOAT HEIGHT ADJUSTMENT
To check the float height, turn the carburetor upside down.
Measure the float height
A
while the float arm is just contacting the needle valve using vernier calipers.
Bend the tongue as necessary to bring the float height
A
to the specified level.
A
109
09900-20101: Vernier calipers
Float height
A
: 9.0 ± 1.0 mm (0.35 ± 0.04 in)
THROTTLE POSITION SENSOR INSPECTION
Measure the resistance between the terminals as shown in the illustration.
Throttle position sensor resistance:
Approximately 5 k
Ω
Reassemble the carburetor in the reverse order of disassembly. Pay special attention to the following points:
PILOT SCREW
After cleaning, install the pilot screw 1 to the original setting by turning the screw in until it lightly seats, and then backing it out the same number of turns counted during disassembly.
Bl
B
Y
Ω
1 Pilot screw 2 Carburetor body
Replace the removed O-ring with a new one.
THROTTLE POSITION SENSOR INSTALLATION
Install the throttle position sensor as described below.
Measure the resistance
Ω
1
between the throttle position sensor terminals as shown in the illustration.
Throttle position sensor resistance
Ω
1
:
Approximately 5 k
Ω
FUEL AND LUBRICATION SYSTEM 4-15
Bl
Y
Ω
2
Ω
1
B
Measure the resistance
Ω
2
between the throttle position sensor terminals as shown in the illustration.
Fully open the throttle valve with the throttle lever.
Position the throttle position sensor until resistance
Ω
2
is 3.09
– 4.63 k
Ω
.
When the resistance
Ω
2
is within specification, tighten the throttle position sensor mounting screws.
Throttle position sensor resistance
Ω
2
:
3.09 – 4.63 k
Ω
Install the air valve assembly.
First tighten the bolt
3
and then tighten the nut
4
.
(DR-Z400)
4
3
Keep the clearance
A
(0.5 – 0.7 mm) between rink arm and carburetor body when pushing the throttle lever as shown.
A
: Clearance 0.5 – 0.7 mm
If the clearance is out of specification, adjust the clearance.
Remount the carburetor assembly in the reverse order of removal. After the carburetor assembly has been remounted onto the engine perform the following adjustments:
Throttle cable play ..................................................
Engine idle speed ..................................................
2-13
2-14
4-16 FUEL AND LUBRICATION SYSTEM
FRAME (OIL TANK)
CYLINDER WALL
POSITION
CONROD SMALL END
IN & EX CAM FACE
OIL SUMP FILTER
OIL HOSE
RIGHT CRANKCASE
CAM CHAIN
CAMSHAFT JOURNAL
PISTON PIN
PISTON JET
CYLINDER HEAD
CYLINDER
OIL JET
OIL PUMP
RIGHT CRANKCASE
CHECK
VALVE
OIL PIPE
OIL FILTER
BY-PASS
CONROD BIG END BEARING
CRANK PIN
RIGHT CRANKSHAFT
CRANKSHAFT RIGHT END
CLUTCH COVER
OIL PIPE
LEFT CRANKCASE
OIL HOSE
LEFT CRANKCASE
CLUTCH
PLATES
PRIMARY GEARS
COUNTERSHAFT
DRIVE GEARS
KICK IDEL
GEAR
(DR-Z400)
COUNTERSHAFT LEFT
END BEARING
DRIVESHAFT LEFT
END BEARING
DRIVESHFT
DRIVEN GEARS
OIL PUMP
(FOR RETURN)
OIL SUMP FILTER
COOLING SYSTEM 5-1
CONTENTS
COOLING SYSTEM ........................................................................................ 5- 2
DESCRIPTION ............................................................................................ 5- 2
CONSTRUCTION ....................................................................................... 5- 3
ENGINE COOLANT ........................................................................................ 5- 4
RADIATOR ...................................................................................................... 5- 5
INSPECTION .............................................................................................. 5- 5
REMOVAL ................................................................................................... 5- 6
REMOUNTING ............................................................................................ 5- 6
5-2 COOLING SYSTEM
The engine is cooled by a forced flow of engine coolant that circulates through jackets, which are formed in the cylinder and cylinder head, and through the radiator.
A high-capacity centrifugal pump is used for the water pump and a tube-and-fin type aluminum radiator, which is characterized by lightness in weight and good heat dissipation, is used.
Refer to the following illustration for the routing of the cooling system.
1 Impeller
2 Radiator cap
3 Right radiator
4 Left radiator
1 Radiator cap
2 Radiator (R)
3 Radiator (L)
4 Radiator inlet hose
5 Radiator outlet hose
6 Overflow hose
7 Overflow tank
A
Air bleeder bolt
ITEM
A
N·m kgf-m
6.0
0.6
lb-ft
4.3
1 Circlip
2 Water pump driven gear
3 Pin
4 Washer
5 Circlip
6 Bearing
7 O-ring
8 Oil seal
9 Mechanical seal
0 Impeller
A O-ring
B Water pump cover
C O-ring
COOLING SYSTEM 5-3
5-4 COOLING SYSTEM
At the time of manufacture, the cooling system is filled with a
50:50 mixture of distilled water and ethylene glycol antifreeze.
This mixture will provide optimum corrosion and heat protection, and will protect the cooling system from freezing at above
–31°C (–24°F).
If the motorcycle is to be exposed to temperatures below –31°C
(–24°F), the percentage of antifreeze should be increased to
55% or 60%, according to figure 2.
The characteristics of different antifreeze vary; therefore, be sure to use the specified antifreeze.
Engine coolant: Mix antifreeze designed for aluminum radiators with distilled water only.
Water/antifreeze mixture ratio: 50:50 – 40:60
Mix a high quality ethylene glycol based antifreeze with distilled water only. Do not mix an alcohol based antifreeze or different brands of antifreeze.
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 capabilities will be reduced. Always keep the antifreeze content above
50% even if the atmospheric temperature does not go below the freezing point.
Engine coolant capacity: 1 250 ml (1.3 US qt, 1.1 Imp qt)
Antifreeze density
50%
55%
60%
Freezing point
–31°C (–24°F)
–40°C (–40°F)
–55°C (–67°F)
Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.
The engine must be cool before servicing the cooling system.
Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine coolant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water. If engine coolant is swallowed, induce vomiting and call a physician immediately.
RADIATOR
Before removing the radiator and draining the engine coolant, check the following.
Check the cooling system for leaks with a radiator tester 1 .
Remove the radiator cap and connect the radiator tester to the filler. Pressurize the cooling system with 120 kPa (1.2 kgf/cm
2
,
17 psi) of pressure, and then check if it holds the pressure for 10 seconds. If the cooling system does not hold the pressure for at least 10 seconds, check the entire cooling system for leaks. If a leak is found, replace the damaged part.
Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.
When removing the radiator cap tester, put a rag on the filler to prevent the engine coolant from spraying out.
Do not exceed the radiator cap release pressure, or the radiator cap and subsequently the radiator, can be damaged.
Check the radiator cap 2 using a radiator tester 1 .
Attach the radiator cap to the radiator tester as shown. Slowly apply pressure to the radiator cap; do not exceed 95 – 125 kPa
(0.95 – 1.25 kgf/cm
2
, 13.5 – 17.8 psi). If the radiator cap does not hold the pressure for at least 10 seconds, replace it with a new one.
Radiator cap release pressure: 95 – 125 kPa
(0.95 – 1.25 kgf/cm
2
, 13.5 – 17.8 psi)
Check the radiator for dirt and other foreign materials. If any are found, clean the radiator using compressed air. Also, repair any bent or dented fins using a small screwdriver.
Check all the water hoses for cracks, flat spots, or loose connections. Replace any damaged hoses and properly tighten any loose connections.
COOLING SYSTEM 5-5
5-6 COOLING SYSTEM
Remove the side covers. (
Drain the engine coolant. (
6-2)
2-15)
Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.
The engine must be cool before servicing the cooling system.
Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine coolant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water. If engine coolant is swallowed, induce vomiting and call a physician immediately.
Disconnect the radiator hoses.
Remove the radiator.
Remount the radiator in the reverse order of removal. After remounting the radiator, be sure to add engine coolant. ( 2-15)
Drain the engine coolant. (
Drain the engine oil. (
2-15)
2-11)
Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.
The engine must be cool before servicing the cooling system.
Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine coolant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water. If engine coolant is swallowed, induce vomiting and call a physician immediately.
Disconnect the radiator hose 1 and right engine side cover 2 .
Remove the right crankcase cover.
Remove the water pump cover.
COOLING SYSTEM 5-7
1
92P50060
2
Remove the circlip 3 , water pump driven gear 4 and pin 5 .
4
3
5
Remove the E-ring 6 and impeller 7 .
6
7
5-8 COOLING SYSTEM
WATER PUMP BEARING
Inspect the inner race play of the water pump bearing by hand while it is in the water pump housing. Rotate the inner race by hand to inspect it for abnormal noise and smooth rotation. If abnormal noise occurs or if rough movement is noted, replace the water pump bearing with a new one.
Remove the water pump bearing using the special tool, as follows:
Insert the bearing remover attachment into the water pump bearing.
Install the wedge from the opposite side and lock it into the slit of the bearing remover attachment.
Drive out the water pump bearing by knocking the wedge bar.
09941-50111: Bearing remover
Replace the removed bearing with a new one.
MECHANICAL SEAL
Visually inspect the mechanical seal for damage. If any damages are found, replace the mechanical seal with a new one.
Remove the mechanical seal 1 .
Replace the removed mechanical seal with a new one.
Reassemble and remount the water pump in the reverse order of removal and disassembly. Pay attention to the following points:
Install the water pump bearings using the special tool.
09913-70210: Bearing installer set
COOLING SYSTEM 5-9
Apply SUZUKI SUPER GREASE “A” to the new O-rings.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
When installing the water pump driven gear align the pin 1 with the groove 2 .
After installing the water pump, be sure to add engine coolant. ( 2-15)
2
1
CHASSIS 6-1
EXTERIOR PARTS ...................................................................................................................................... 6- 2
REMOVAL .............................................................................................................................................. 6- 2
REMOUNTING ....................................................................................................................................... 6- 2
FRONT WHEEL ........................................................................................................................................... 6- 3
CONSTRUCTION .................................................................................................................................. 6- 3
REMOVAL AND DISASSEMBLY .......................................................................................................... 6- 5
INSPECTION ......................................................................................................................................... 6- 6
REASSEMBLY AND REMOUNTING .................................................................................................... 6- 8
FRONT FORK ............................................................................................................................................ 6-10
CONSTRUCTION ................................................................................................................................. 6-10
REMOVAL AND DISASSEMBLY ......................................................................................................... 6-11
INSPECTION ........................................................................................................................................ 6-13
REASSEMBLY AND REMOUNTING ................................................................................................... 6-14
SUSPENSION SETTING ...................................................................................................................... 6-17
STEERING ................................................................................................................................................. 6-18
CONSTRUCTION ................................................................................................................................. 6-18
REMOVAL AND DISASSEMBLY ......................................................................................................... 6-19
INSPECTION ........................................................................................................................................ 6-21
REASSEMBLY AND REMOUNTING ................................................................................................... 6-22
REAR WHEEL ............................................................................................................................................ 6-25
CONSTRUCTION ................................................................................................................................. 6-25
REMOVAL AND DISASSEMBLY ......................................................................................................... 6-27
INSPECTION ........................................................................................................................................ 6-28
REASSEMBLY AND REMOUNTING ................................................................................................... 6-28
REAR SUSPENSION ................................................................................................................................. 6-31
CONSTRUCTION ................................................................................................................................. 6-31
REAR SHOCK ABSORBER REMOVAL .............................................................................................. 6-33
REAR SHOCK ABSORBER INSPECTION AND DISASSEMBLY ...................................................... 6-35
REAR SHOCK ABSORBER DISPOSAL ............................................................................................. 6-35
OIL REPLACEMENT PROCEDURE .................................................................................................... 6-36
REAR SHOCK ABSORBER REASSEMBLY AND REMOUNTING ..................................................... 6-38
REAR SHOCK ABSORBER DAMPING FORCE ADJUSTMENT ....................................................... 6-39
REAR SWINGARM AND CUSHION LEVER REMOVAL ..................................................................... 6-40
INSPECTION AND DISASSEMBLY ..................................................................................................... 6-41
REASSEMBLY AND REMOUNTING ................................................................................................... 6-43
FINAL INSPECTION AND ADJUSTMENT .......................................................................................... 6-44
FRONT BRAKE .......................................................................................................................................... 6-45
CONSTRUCTION ................................................................................................................................. 6-45
BRAKE PAD REPLACEMENT ............................................................................................................. 6-46
BRAKE FLUID REPLACEMENT ......................................................................................................... 6-47
BRAKE CALIPER REMOVAL AND DISASSEMBLY ........................................................................... 6-47
BRAKE CALIPER INSPECTION .......................................................................................................... 6-48
BRAKE CALIPER REASSEMBLY AND REMOUNTING ..................................................................... 6-49
BRAKE DISC INSPECTION ................................................................................................................. 6-50
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...................................................................... 6-51
MASTER CYLINDER INSPECTION ..................................................................................................... 6-52
MASTER CYLINDER REASSEMBLY AND REMOUNTING ................................................................ 6-53
REAR BRAKE ............................................................................................................................................ 6-54
CONSTRUCTION ................................................................................................................................. 6-54
BRAKE PAD REPLACEMENT ............................................................................................................. 6-55
BRAKE FLUID REPLACEMENT ......................................................................................................... 6-56
BRAKE CALIPER REMOVAL AND DISASSEMBLY ........................................................................... 6-57
BRAKE CALIPER INSPECTION .......................................................................................................... 6-58
BRAKE CALIPER REASSEMBLY AND REMOUNTING ..................................................................... 6-58
BRAKE DISC INSPECTION ................................................................................................................. 6-59
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...................................................................... 6-60
MASTER CYLINDER INSPECTION ..................................................................................................... 6-61
MASTER CYLINDER REASSEMBLY AND REMOUNTING ................................................................ 6-61
6-2 CHASSIS
REMOVAL
SEAT
Remove the seat 1 .
SIDE COVERS
Remove the left and right side covers 1 .
1
1
1
FRAME COVERS
Remove the left frame cover 1 and right frame cover 2 .
1
2
BATTERY COVER
Remove the battery cover 1 .
1
REMOUNTING
Remount the seat, side covers, frame covers, and battery cover in the reverse order of removal.
CONSTRUCTION
CHASSIS 6-3
1 Front axle
2 Odometer gearbox
3 Bearing (R)
4 Front wheel
5 Spacer
6 Bearing (L)
7 Dust seal
8 Brake disc
9 Spacer
0 Washer
A
Front axle nut
B
Brake disc mounting bolt
ITEM
A
B
N·m kgf-m
42 4.2
10 1.0
lb-ft
30.5
7.0
6-4 CHASSIS
Left Right
Left Right Left
Spacer
Right
Clearance
CHASSIS 6-5
REMOVAL AND DISASSEMBLY
Disconnect the odometer cable.
Remove the front axle nut 1 and loosen the front axle pinch bolts 2 .
Support the motorcycle with a jack or wooden block and remove the front axle 3 and front wheel 4 .
Do not operate the brake lever during or after front wheel removal.
Remove the odometer gearbox 5 and spacer 6 .
5
3
4
2
2
1
6
Remove the brake disc.
6-6 CHASSIS
INSPECTION
ODOMETER GEARBOX DUST SEAL
Inspect the odometer gearbox dust seal for damage. If any damage is found, replace the odometer gearbox with a new one.
WHEEL HUB DUST SEAL
Inspect the wheel hub dust seal for damage. If any damage is found, replace the wheel hub dust seal with a new one.
Remove the wheel hub dust seal using the special tool.
09913-50121: Oil seal remover
Replace the removed dust seal with a new one.
WHEEL BEARINGS
Inspect the play of the wheel bearings by hand while they are in the wheel. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. If any abnormal noise occurs, or rough movement is noted, replace the wheel bearings with new ones.
Remove the wheel bearings as follows:
Remove the wheel hub dust seal. ( 6-6)
Insert the bearing remover attachment 1 into the wheel bearing.
Insert the wedge bar 2 from the opposite side and lock it into the slit of the bearing remover attachment.
Drive out the wheel bearing by striking the wedge bar.
09941-50111: Bearing remover
Replace the removed bearings with new ones.
2
1
FRONT WHEEL
Make sure that the wheel runout (axial and radial) does not exceed the service limit when checked as shown. An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel with a new one.
Wheel rim runout (axial and radial)
Service Limit: 2.0 mm (0.08 in)
FRONT AXLE
Measure the front axle runout using the dial gauge. If the runout exceeds the service limit, replace the front axle with a new one.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
Wheel axle runout
Service Limit: 0.25 mm (0.010 in)
TIRE ..............................................................
2-21 and 2-22
SPOKE NIPPLES ......................................................
2-22
CHASSIS 6-7
6-8 CHASSIS
REASSEMBLY AND REMOUNTING
Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay special attention to the following points:
WHEEL BEARINGS
Apply SUZUKI SUPER GREASE “A” to the wheel bearings.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
Install the wheel bearings using the special tool.
09924-84521: Bearing installer set
First, install the left wheel bearing, and then install the right wheel bearing. ( 6-4)
WHEEL HUB DUST SEAL
Apply SUZUKI SUPER GREASE “A” to the lip of dust seal.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
Install the wheel hub dust seal using the special tool.
09913-70210: Bearing installer set
BRAKE DISC
Make sure that the brake disc is clean and free of any grease.
Apply THREAD LOCK SUPER “1360” to the brake disc mounting bolts, and then tighten them to the specified torque.
99000-32130: THREAD LOCK SUPER “1360”
Brake disc mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
CHASSIS 6-9
ODOMETER GEARBOX
Apply SUZUKI SUPER GREASE “A” to the odometer gearbox dust seal.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
Align the grooves 1 on the odometer gearbox with the lugs 2 on the wheel hub.
1
2
FRONT WHEEL
Make sure that the front fork stopper 1 and the odometer gearbox stopper 2 are installed as shown.
2
1
Tighten the front axle nut 3 to the 20 N·m (2.0 kgf-m, 14.5 lb-ft) by holding the front axle using the special tools.
09940-34520: T handle
09940-34581: Attachment F
Tighten the front axle pinch bolts 4 to the specified torque.
Front axle pinch bolt: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
Tighten the front axle nut to the specified torque, after tightening the axle pinch bolts.
Front axle nut: 42 N·m (4.2 kgf-m, 30.5 lb-ft)
4
4
3
6-10 CHASSIS
CONSTRUCTION
1 Air valve
2 O-ring
3 Push rod
4 Needle
5 Spring
6 Washer
7 Spring
8 Damper rod ring
9 Damper
0 Dust seal
A Stopper ring
B Oil seal
C Oil seal retainer
D Inner tube antifriction metal
E Inner tube
F Outer tube antifriction metal
G Clamp
H Boot
I Clamp
J Oil lock piece
K Holder
L Outer tube
M O-ring
N End plate
O O-ring
P O-ring
A
Front fork cap bolt
B
Front fork inner rod locknut
C
Front fork damper rod bolt
ITEM
A
B
C
N·m kgf-m
23 2.3
22
80
2.2
8.0
lb-ft
16.5
16.0
58.0
CHASSIS 6-11
REMOVAL AND DISASSEMBLY
Remove the front wheel. ( 6-5)
Remove the front brake caliper. (
Remove the headlight assembly. (
6-47)
7-27)
Remove the brake hose clamp 1 and odometer cable guide 2 .
1
Remove the front fork after loosening the front fork upper clamp bolts 3 and lower clamp bolts 4 .
5
3
4
Remove the boot.
Replace the removed boot clamps with new ones.
5
2
Remove the cap bolt out of the inner tube and slowly pull down the inner tube.
Hold the piston rod locknut with a 17-mm wrench and special tool.
Remove the cap bolt, washer, and spring.
09940-94922: Front fork stopper plate
6-12 CHASSIS
Invert the fork and stroke it several times to drain out the fork oil.
Remove the push rod 1 , needle 2 , and return spring 3 .
Remove the dust seal 4 and stopper ring 5 .
4
5
3 2 1
Place the front fork in a vise with soft jaws.
Do not over tighten the vise or the outer tube will be damaged.
Remove the damper rod bolt using the special tool.
09940-54821: Front fork inner rod holder
CHASSIS 6-13
Remove the damper 1 .
1
Slowly pull out the inner tube.
Remove the oil seal 2 , oil seal retainer 3 , outer tube antifriction metal 4 inner tube antifriction metal 5 , and oil lock piece 6 .
The outer and inner tube’s antifriction metals must be replaced along with the oil seal and dust seal when assembling the front fork.
4 3 3
6
INSPECTION
FORK SPRING
Measure the fork spring free length. If the fork spring free length is shorter than the service limit, replace the fork spring with a new one.
Front fork spring free length
Service Limit: 500 mm (19.7 in)
6-14 CHASSIS
INNER AND OUTER TUBE
Inspect the inner tube sliding surface and outer tube sliding surface for any scuffing or damage. If any damages are found, replace the inner tube and outer tube with new ones.
DAMPER ROD RING
Inspect the damper rod ring for wear or damage. If any damages are found, replace the fork cylinder ring with a new one.
REASSEMBLY AND REMOUNTING
Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay special attention to the following points:
ANTIFRICTION METALS, OIL SEAL, AND DUST SEAL
Hold the inner tube vertically, clean the metal groove, and install the inner tube slide metal by hand.
Do not damage the Teflon coated surface of the inner tube antifriction metal when mounting the inner tube.
Apply fork oil to the inner tube and outer tube antifriction metals.
Apply front fork oil to the lip of oil seal lightly before installing it.
99000-99001-SS5: SUZUKI FORK OIL SS-05
Install the oil lock piece 1 , outer tube antifriction metal 2 , oil seal retainer 3 , and oil seal 4 onto the inner tube.
2 3
3
1
Insert the inner tube into the outer tube and install the oil seal using the special tool.
09940-52861: Front fork oil seal installer set
Install the oil seal stopper ring.
Make sure that the oil seal stopper ring is fitted securely.
DAMPER ROD BOLT
Tighten the front fork damper rod bolt to the specified torque using the special tool.
09940-54821: Front fork inner rod holder
Frant fork damper rod bolt: 80 N·m (8.0 kgf-m, 58.0 lb-ft)
Use a new O-ring to prevent oil leakage.
FORK OIL
Place the front fork vertically without the spring.
Pour the specified fork oil into the inner tube.
99000-99001-SS5: SUZUKI FORK OIL SS-05
Standard fork oil capacity (each leg):
720 ml (24.3 US oz, 25.4 Imp oz)
Move the inner tube and inner rod slowly several times.
Hold the front fork in a vertical position and adjust the fork oil level using the special tool.
09943-74111: Fork oil level gauge
Fork oil level
Standard: 122 mm (4.8 in)
CHASSIS 6-15
6-16 CHASSIS
PISTON ROD LOCKNUT AND FORK SPRING
Install the piston rod locknut to the lowest position.
Install the fork spring.
Install a washer 1 .
Pull up the piston rod using the special tool.
09940-52841: Front fork inner rod holder
Compress the spring and then insert the special tool between the locknut and washer.
Slowly turn the cap bolt by hand until it is seated on the locknut.
Tighten the locknut to the specified torque while holding the cap bolt.
09940-94922: Front fork stopper plate
Front fork inner rod locknut:
22 N·m (2.2 kgf-m, 16.0 lb-ft)
1
CHASSIS 6-17
When remounting the front fork, align the groove 1 of the inner tube with the upper surface 2 of the steering stem upper bracket.
A
Tighten the front fork lower clamp bolts 1 , front fork cap bolt 2 , and front fork upper clamp bolts 3 to the specified torque.
Front fork lower clamp bolt: 32 N·m (3.2 kgf-m, 23.0 lb-ft)
Front fork upper clamp bolt: 30 N·m (3.0 kgf-m, 21.5 lb-ft)
Front fork cap bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
2
1
3
1
FRONT WHEEL .........................................................
6-5
2
A
SUSPENSION SETTING
After installing the front fork, adjust the rebound damping force and compression damping force as follows.
Fully turn the damping force adjuster clockwise to the hard setting position, and then turn it out to the standard setting position.
Standard setting position
Rebound damping force adjuster
A
:
15 clicks out
Compression damping force adjuster
B
:
12 clicks out
A
B
6-18 CHASSIS
CONSTRUCTION
1 Handlebar
2 Washer
3 Handlebar clamp
4 Steering stem head bracket
5 Steering stem nut
6 Bearing
7 Steering stem
8 Bearing
A
Handlebar clamp bolt
B
Steering stem head nut
C
Front fork upper clamp bolt
D
Front fork lower clamp bolt
ITEM
A
B
C
D
N·m kgf-m
23 2.3
90
30
32
9.0
3.0
3.2
lb-ft
16.5
65.0
21.5
23.0
CHASSIS 6-19
REMOVAL AND DISASSEMBLY
Remove the front fork. ( 6-11)
Remove the master cylinder assembly. (
Remove the front brake hose guide bolts.
6-51)
Remove the odometer assembly.
Remove the clamps 1 and engine stop switch 2 .
1
2
Disconnect the main switch coupler 3 , starter button coupler 4 (DR-Z400E), and clutch lever position switch lead wires 5 (DR-Z400E).
Remove the throttle cables 6 and throttle grip 7 .
3 4
5
6
6-20 CHASSIS
- Disconnect the clutch cable.
Disconnect the decompression cable. (DR-Z400)
Remove the front fender.
Remove the handlebar 1 and ignition switch 2 (DR-Z400E).
2
1
Remove the steering stem head nut.
Remove the washer 1 and steering stem upper bracket 2 .
CHASSIS 6-21
1 2
Remove the steering stem nut using the special tools.
09940-14911: Steering nut socket wrench
09940-14960: Steering nut wrench socket
Remove the steering stem lower bracket.
Remove the steering stem upper bearing.
INSPECTION
Inspect the removed parts for the following abnormalities. If any damages are found, replace the respective part with a new one.
Steering race wear and brinelling.
Bearing wear or damage.
Abnormal bearing noise.
Distortion of steering stem or handlebar.
Remove the steering stem lower bearing using a chisel.
Replace the removed bearing with a new one.
6-22 CHASSIS
Drive out the steering stem upper and lower bearing races using the special tools.
09941-54911: Bearing outer race remover
09941-74910: Bearing installer
REASSEMBLY AND REMOUNTING
Reassemble and remount the steering stem in the reverse order of removal and disassembly. Pay attention to the following points.
BEARING RACES
Press in the upper and lower bearing races using the special tools.
09924-84510: Bearing installer set
09941-34513: Steering race installer
BEARINGS
Press in the steering stem lower bearing using the special tool.
09925-18010: Steering bearing installer
Apply SUZUKI SUPER GREASE “A” to the steering stem upper and lower bearings.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
STEERING STEM
Tighten the steering stem nut to the specified torque using the special tools.
09940-14911: Steering nut socket wrench
09940-14960: Steering nut wrench socket
Steering stem nut: 45 N·m (4.5 kgf-m, 32.5 lb-ft)
CHASSIS 6-23
Turn the steering stem lower bracket about five or six times to the left and right so that the bearings seat properly.
Loosen the steering stem nut 1/4-1/2 of a turn
A
.
Tighten the steering stem head nut to the specified torque.
Steering stem head nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft)
HANDLEBAR
When setting the handlebar clamp to the handlebar holder of the steering upper bracket, face the punched mark 1 on its clamp forward.
Set the handlebar to match its punched mark 2 to the mating face of the handlebar clamp.
First, tighten the handlebar clamp bolts 3 to the specified torque, and then tighten the handlebar clamp bolts 4 to the specified torque.
Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
CLUTCH CABLE AND THROTTLE CABLES
Apply SUZUKI SUPER GREASE “A” to the end of clutch cable and throttle cables.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
2
3
1
4
2
6-24 CHASSIS
FRONT WHEEL .........................................................
WIRE HARNESS, CABLE,
AND HOSE ROUTING ................................
6-5
8-12 to 8-18
After performing the adjustment and installing the handlebars, “rock” the front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly. Finally, check to make sure that the steering stem moves freely from left to right with its own weight. If play or stiffness is noticeable, readjust the steering stem nut.
CONSTRUCTION
CHASSIS 6-25
1
Cotter pin (For E-03, 28)
2 Washer
3 Chain adjuster
4 Brake disc
5 Spacer
6
Dust seal
7 Bearing
8 Rear wheel
9 Rear sprocket
0
Spacer
A Bearing
B Bearing
C Dust seal
D Spacer
E
Rear axle
A
Rear axle nut
B
Brake disc mounting bolt
C
Rear sprocket nut
ITEM N·m kgf-m
A
E-03, 28
100 10.0
B
C
Others
110
10
30
11.0
1.0
3.0
lb-ft
72.5
75.5
7.0
21.5
6-26 CHASSIS
Left
Right
Left
Right
Left
(Except E-03, 28)
Right
Spacer
Clearance
REMOVAL AND DISASSEMBLY
Remove the cotter pin. (E-03, 28)
Remove the rear axle nut.
Replace the removed cotter pin with a new one.
Support the motorcycle with a jack or wooden block and remove the rear axle 1 and rear wheel.
Do not operate the brake pedal during or after rear wheel removal.
1
Remove the spacers.
CHASSIS 6-27
Remove the rear sprocket.
Remove the brake disc.
6-28 CHASSIS
INSPECTION
REAR SPROCKET
Inspect the rear sprocket for wear and damage. If any damages are found, replace the sprocket and drive chain as a set.
È
Normal wear
É
Excessive wear
WHEEL HUB DUST SEALS ......................................
WHEEL BEARINGS .....................................
6-6
6-6 and 6-7
REAR WHEEL ...........................................................
REAR AXLE ...............................................................
6-7
6-7
REASSEMBLY AND REMOUNTING
Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay special attention to the following points:
WHEEL BEARINGS
Apply SUZUKI SUPER GREASE “A” to the wheel bearings.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
Install the wheel bearings using the special tool.
09941-34513: Bearing installer set
First, install the right wheel bearing, and then install the left wheel bearings. The sealed cover on the wheel bearing must face out. ( 6-26)
WHEEL HUB DUST SEALS
Apply SUZUKI SUPER GREASE “A” to the wheel hub dust seals.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
Install the wheel hub dust seals using the special tool.
09913-70210: Bearing installer set
After installing the right and left spacers to the rear wheel, inspect the lip of dust seals properly positioned.
BRAKE DISC
Make sure that the brake disc is clean and free of any grease.
Apply THREAD LOCK SUPER “1360” to the brake disc mounting bolts, and then tighten them to the specified torque.
99000-32130: THREAD LOCK SUPER “1360”
Brake disc mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
REAR SPROCKET
Tighten the rear sprocket nuts to the specified torque.
Rear sprocket nut: 30 N·m (3.0 kgf-m, 21.5 lb-ft)
A
CHASSIS 6-29
A
6-30 CHASSIS
REAR WHEEL
Adjust the drive chain slack after installing the rear wheel axle. ( 2-16 and 2-17)
Tighten the rear axle nut to the specified torque.
Rear axle nut:
100 N·m (10.0 kgf-m, 72.5 lb-ft).. for E-03, 28
110 N·m (11.0 kgf-m, 79.5 lb-ft).. for the other countries
CONSTRUCTION
CHASSIS 6-31
1 Rear shock absorber
2 Spring adjuster
3 Spring
4 Spring seat
5
Circlip
6 Cushion lever rod
7 Cushion lever
8 Swingarm pivot shaft
9
Swingarm
0 Chain guide
A Chain buffer
A
Rear shock absorber nut
B
Rear shock absorber compression adjuster assembly
C
Rear shock absorber spring adjuster lock ring
D
Cushion rod mounting nut
E
Cushion lever mounting nut
F
Cushion lever mounting nut
G
Swingarm pivot nut
ITEM
A
B
C
D
,
E
F
G
N·m kgf-m
55 5.5
30
90
3.0
9.0
100
100
77
10.0
10.0
7.7
lb-ft
40.0
21.5
65.0
72.5
72.5
55.5
6-32 CHASSIS
A
B
F
D
C
E
ITEM
A
B
C
D
E
F
N·m kgf-m
55 5.5
55
100
5.5
10.0
100
100
77
10.0
10.0
7.7
lb-ft
40.0
40.0
72.5
72.5
72.5
55.5
F
A
D
B
C
E
CHASSIS 6-33
REAR SHOCK ABSORBER REMOVAL
Remove the muffler. ( 3-5)
Remove the battery. (DR-Z400E) (
Remove the clamps.
7-30)
Disconnect the taillight coupler 1 , starter relay coupler 2
(DR-Z400E), and starter relay lead wires 3 (DR-Z400E).
1
2
3
Disconnect the air cleaner breather hose and loosen the carburetor clamp.
Remove the seat rail with air cleaner case assembly.
Support the motorcycle with a jack or wooden block and remove the rear shock absorber.
6-34 CHASSIS
Loosen the lockring 1 and turn the adjuster 2 using the special tool.
09910-60611: Universal clamp wrench
Remove the circlip 3 , spring seat 4 , and spring 5 .
2
1
5
4
3
REAR SHOCK ABSORBER INSPECTION
AND DISASSEMBLY
Inspect the rear shock absorber for damage and oil leakage. If any damages are found, replace the spring or rear shock absorber with a new one.
REAR SHOCK ABSORBER DISPOSAL
The rear shock absorber unit contains high-pressure nitrogen gas.
Mishandling can cause explosion.
Keep away from fire and heat. High gas pressure caused by heat can cause an explosion.
Release gas pressure before disposing.
GAS PRESSURE RELEASE
Remove the valve cap.
Press the valve with a screwdriver to bleed out the nitrogen gas.
Releasing high pressure gas from the rear shock absorber unit can be hazardous. Never perform any servicing until the nitrogen gas pressure has been released from the rear shock absorber unit.
When releasing the gas pressure, place a rag over the gas valve and use the tip of a screwdriver to press the valve. Do not use your finger to depress the gas valve, and be sure to direct the valve away from your face and body.
Be sure to always wear eye protection when performing this procedure.
CHASSIS 6-35
6-36 CHASSIS
OIL REPLACEMENT PROCEDURE
TOOLS AND EQUIPMENT
The following tools and equipment are required to perform oil replacement.
1
3
5
8
4
9
SERVICE
MANUAL
7
6
1 Screwdriver or small punch
2 Vise*
3 Drain pan
4 Specified shock oil (SS-25)
5 Rags
6
Nitrogen tank
7 Filler hose and nozzle
8 Regulator assembly
9 Service manual
* Not shown in the illustration
OIL REPLACEMENT
Remove the rear shock absorber unit from the frame (
6-33), and then clean and dry it.
Remove the spring from the rear shock absorber unit. (
6-34)
Remove the valve cap, and then press the valve with a screwdriver to bleed out nitrogen gas.
Releasing high pressure gas from the rear shock absorber unit can be hazardous. Never perform any servicing until the nitrogen gas pressure has been released from the rear shock absorber unit.
When releasing the gas pressure, place a rag over the gas valve and use the tip of a screwdriver to press the valve. Do not use your finger to depress the gas valve, and be sure to direct the valve away from your face and body.
Be sure to always wear eye protection when performing this procedure.
Remove the compression adjuster assembly 1 and the orifice 2 from the rear shock absorber.
1
2
Move the rod and drain the oil completely into a drain pan.
Push the valve core again to equalize atmospheric pressure.
Fill a drain pan with the specified rear suspension oil.
Place the rear shock absorber into the drain pan so that the drain hole is submerged in the oil, and then fill the rear shock absorber with the oil by stroking the rod.
99000-99001-S25:
SUZUKI REAR SUSPENSION OIL SS-25
Oil capacity:
Approximately 380 ml (12.8 US oz, 13.4 lmp oz)
When fitting the orifice in the compression adjuster hole, face the conical side to the valve side.
Tighten the compression adjuster assembly to the specified torque.
Replace the remove O-rings with new ones.
Compression adjuster assembly:
30 N·m (3.0 kgf-m, 21.5 lb-ft)
Fill the rear shock absorber unit with nitrogen gas.
Rear shock absorber gas pressure:
900 kPa (9.0 kgf/cm
2
, 128 psi)
Tighten the gas valve cap.
Use of flammable gas for pressuring the rear shock absorber unit can be hazardous. Flammable gas such as gas welding oxygen can create a fire hazard.
Use nitrogen gas. If nitrogen gas is not available, compressed air free from water can be substituted.
Applying too much pressure to the rear shock absorber unit may rupture the rear shock absorber unit.
Be sure to fill the rear shock absorber unit to the specified pressured.
CHASSIS 6-37
6-38 CHASSIS
Riding the motorcycle with abnormal gas pressure can damage the rear shock absorber unit. Low gas pressure can result in oil leakage. Abnormal gas pressure cannot provide normal performance of the rear shock absorber.
Be sure to fill the rear shock absorber unit to the specified pressure.
REAR SHOCK ABSORBER REASSEMBLY
AND REMOUNTING
Reassemble and remount the rear shock absorber in the reverse order of removal and disassembly. Pay special attention to the following points:
Install the spring, spring seat, and circlip.
Turn the adjuster 1 to obtain the spring length
A
of
258.0 mm (10.16 in).
Tighten the lock ring 2 to the specified torque.
Rear shock absorber lock ring:
90 N·m (9.0 kgf-m, 65.0 lb-ft)
2 1
A
SPRING SETTING TABLE
Standard
258.0 mm
(10.16 in)
Spring preset length
Soft
259.5 mm
(10.22 in)
Hard
247.5 mm
(9.74 in)
Do not set the spring less than 247.5 mm (9.74 in).
Tighten the rear shock absorber upper and lower mounting nut to the specified torque.
Rear shock absorber upper and lower mounting nut:
55 N·m (5.5 kgf-m, 40.0 lb-ft)
Apply THREAD LOCK SUPER “1303” to the seat rail lower mounting bolt 4 .
99000-32030: THREAD LOCK SUPER “1303”
Tighten the seat rail upper mounting nut 3 and lower mounting bolts 4 to the specified torque.
Seat rail upper mounting nut:
35 N·m (3.5 kgf-m, 25.5 lb-ft)
Seat rail lower mounting bolt:
35 N·m (3.5 kgf-m, 25.5 lb-ft)
4
CHASSIS 6-39
3
REAR SHOCK ABSORBER DAMPING
FORCE ADJUSTMENT
After installing the rear suspension, adjust the rebound damping force and compression damping force as follows.
Fully turn the damping adjuster clockwise to the hard setting position, and then turn it out to the standard setting position.
Standard setting position:
Compression damping force adjuster
A
:
Rebound damping force adjuster
B
:
12 clicks out
13 clicks out
B
A
6-40 CHASSIS
REAR SWINGARM AND CUSHION LEVER
REMOVAL
Remove the rear wheel. ( 6-27)
Remove the rear shock absorber. (
Remove the rear brake caliper. (
Remove the drive chain guide.
6-33 and 6-34)
6-57)
Disconnect the brake hose from the brake hose guide.
Remove the cushion lever mounting bolt and nut.
Remove the swingarm pivot shaft nut and pivot shaft.
Remove the rear suspension assembly.
Remove the chain buffer 1 and brake hose guide 2 .
1
2
Remove the cushion lever 1 and cushion lever rods 2 .
INSPECTION AND DISASSEMBLY
SPACERS
Remove the dust seals, washers and spacers from the swingarm and cushion lever.
Inspect the spacers for any flaws or other damage. If any damages are found, replace the spacers with new ones.
Replace the removed dust seals with new ones.
CHAIN BUFFER
Inspect the chain buffer for wear and damage. If any damages are found, replace the chain buffer with a new one.
SWINGARM NEEDLE BEARINGS
Insert the spacers into the needle bearings, move the spacer up and down and check for any play. If there is excessive play, replace the bearings with new ones.
Remove the swingarm needle bearings using the special tools.
09923-74510: Bearing remover
09930-30102: Sliding hammer
Replace the removed needle bearings with new ones.
CHASSIS 6-41
2
1
6-42 CHASSIS
SWINGARM
Inspect the swingarm for damage. If any damages are found, replace the swingarm with a new one.
CUSHION LEVER NEEDLE BEARINGS
Insert the spacers into the needle bearings, move the spacer up and down and check for any play. If there is excessive play, replace the bearings with new ones.
Remove the cushion lever needle bearings using the special tools.
09923-73210: Bearing remover
09930-30102: Sliding hammer
Replace the removed needle bearings with new ones.
CUSHION LEVER AND CUSHION LEVER RODS
Inspect the cushion lever and cushion lever rods for damage. If any damages are found, replace the cushion lever and cushion lever rods with new ones.
PIVOT SHAFT
Measure the pivot shaft runout using the dial gauge. If the runout exceeds the service limit, replace the pivot shaft.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
Swingarm pivot shaft runout
Service Limit: 0.3 mm (0.01 in)
CHASSIS 6-43
REASSEMBLY AND REMOUNTING
Reassemble and remount the rear suspension in the reverse order of removal and disassembly. Pay special attention to the following points:
SWINGARM NEEDLE BEARINGS
Apply SUZUKI SUPER GREASE “A” to the spacers, dust seals and needle bearings.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
Press the needle bearings into the swingarm pivot using the special tool.
09941-34513: Steering outer race installer
CUSHION LEVER NEEDLE BEARINGS
Apply SUZUKI SUPER GREASE “A” to the spacers and needle bearings.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
Press the needle bearings into the cushion lever using the special tool.
09941-34513: Steering outer race installer
92P60960
REAR SUSPENSION
Tighten the cushion lever rod mounting nuts 1 to the specified torque.
Cushion lever rod mounting nut:
100 N·m (10.0 kgf·m, 72.5 lb-ft)
92P60970
1
6-44 CHASSIS
Tighten the swingarm pivot shaft nut to the specified torque.
Pivot shaft nut: 77 N·m (7.7 kgf-m, 55.5 lb-ft)
Tighten the cushion lever mounting nut to the specified torque.
Cushion lever mounting nut:
100 N·m (10.0 kgf·m, 72.5 lb-ft)
FINAL INSPECTION AND ADJUSTMENT
After installing the rear wheel, adjust the following before riding.
Drive chain ...................................................
2-16 to 2-17
Tire pressure ..........................................................
2-22
CHASSIS 6-45
CONSTRUCTION
1 Cap
2 Diaphragm
3 Master cylinder
4 Piston set
5 Brake hose
6 Caliper holder
7 Caliper
8 Pad set
9 Piston
0 Piston and dust seal
A
Master cylinder mounting bolt
B
Brake hose union bolt
C
Air bleeder valve
D
Brake caliper mounting bolt
E
Brake pad mounting pin
F
Plug
G
Caliper axle
H
Caliper axle
ITEM
A
B
C
D
E
F
G
H
N·m kgf-m
10 1.0
23
7.5
2.3
0.75
26
18
2.5
23
13
2.6
1.8
0.25
2.3
1.3
lb-ft
7.0
16.5
5.5
19.0
13.0
1.8
16.5
9.5
The brake system is filled with an glycol-based brake fluid, which is classified DOT 4. Do not use or mix other types of brake fluid, such as silicone-based and petroleum-based brake fluids when refilling the brake system, otherwise serious damage to the brake system will result.
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.
When storing brake fluid, make sure to seal the container completely and keep it out of the reach of children.
When replenishing brake fluid, make sure not to get any dust or other foreign materials in the fluid.
When washing brake components, always use new brake fluid. Do not use cleaning solvent.
A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the brake disc with high-quality brake cleaner or a neutral detergent.
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber material, etc.
6-46 CHASSIS
BRAKE PAD REPLACEMENT
Remove the brake pad mounting pin.
Remove the brake pads.
Do not operate the brake lever during or after brake pad removal.
Replace the brake pads as a set, otherwise braking performance will be adversely affected.
Install the new brake pads.
Make sure that the brake pad is properly engaged with the guide plate as shown in the photograph.
Tighten the brake pad mounting pin to the specified torque.
Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
CHASSIS 6-47
BRAKE FLUID REPLACEMENT
Place the motorcycle on a level surface and keep the handlebar straight.
Remove the master cylinder reservoir cap and diaphragm.
Remove as much old brake fluid as possible.
Fill the reservoir with new brake fluid.
Specification and classification: DOT 4
Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle.
Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system.
Close the air bleeder valve and disconnect the clear hose. Fill the reservoir with new brake fluid to the upper end of the inspection window.
(
Bleed air from the brake system.
2-19 and 2-20)
BRAKE CALIPER REMOVAL AND
DISASSEMBLY
Disconnect the brake hose from the brake caliper by removing the brake hose union bolt 1 and allow the brake fluid to drain into a suitable receptacle.
Remove the brake caliper by removing the brake caliper mounting bolts 2 .
Never reuse the brake fluid left over from previous servicing or which has been stored for long period of time, otherwise serious damage to the brake system will result.
Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and oil leakage.
2
1
6-48 CHASSIS
Remove the brake pads. ( 6-46)
Remove the brake caliper holder.
Remove the spring.
Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using compressed air.
Do not use extremely high pressure air to remove the brake caliper pistons, otherwise damage to the pistons will result.
Remove the dust seals and piston seals.
Do not reuse the dust seals and piston seals to prevent fluid leakage.
BRAKE CALIPER INSPECTION
BRAKE CALIPER
Inspect each brake caliper cylinder wall for nicks, scratches or other damage. If any damages are found, replace the brake caliper with a new one.
BRAKE CALIPER PISTONS
Inspect the brake caliper pistons for any scratches or other damage. If any damages are found, replace the piston with a new one.
RUBBER PARTS
Replace the removed rubber parts with new ones.
BRAKE CALIPER REASSEMBLY AND
REMOUNTING
Reassemble and remount the brake caliper in the reverse order of removal and disassembly. Pay special attention to the following points:
Wash the caliper bores and pistons with the specified brake fluid. Thoroughly wash the dust seal grooves and piston seal grooves.
Specification and classification: DOT 4
Wash the brake caliper components with new brake fluid before reassembly.
Do not wipe the brake fluid off after washing the components.
When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.
Replace the removed piston seals and dust seals with new ones.
Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly.
PISTON SEALS
Install the piston seals 1 and dust seals 2 as shown.
BRAKE CALIPER HOLDER
Apply SUZUKI SILICON GREASE to the brake caliper holder.
99000-25100: SUZUKI SILICONE GREASE
CHASSIS 6-49
6-50 CHASSIS
Tighten the brake pad mounting pin 1 , brake caliper mounting bolts 2 , and brake hose union bolt 3 to the specified torque.
Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
Brake caliper mounting bolt:
Brake hose union bolt:
26 N·m (2.6 kgf-m, 19.0 lb-ft)
23 N·m (2.3 kgf-m, 16.5 lb-ft)
Bleed air from the system after reassembling the brake caliper. ( 2-19 and 2-20)
BRAKE DISC INSPECTION
Check the brake disc for cracks or damage and measure the thickness using the micrometer. If any damages are found or if the thickness is less than the service limit, replace the brake disc with a new one.
09900-20205: Micrometer (0 – 25 mm)
Brake disc thickness
Service Limit: 2.5 mm (0.098 in)
Measure the runout using the dial gauge. If the runout exceeds the service limit, replace the brake disc with a new one.
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
Brake disc runout
Service Limit: 0.3 mm (0.012 in)
If either measurement exceeds the service limit, replace the brake disc with a new one. ( 6-5)
2
1
3
MASTER CYLINDER REMOVAL AND
DISASSEMBLY
Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid. Remove the brake hose union bolt and disconnect the brake hose.
Immediately wipe off any brake fluid contacting any part of the motorcycle. The brake fluid reacts chemically with paint, plastics, rubber materials, etc., and will damage them severely.
Remove the master cylinder assembly.
Remove the brake lever cover 1 and brake lever 2 .
1
CHASSIS 6-51
2
Remove the reservoir cap 3 and diaphragm 4 .
Drain the brake fluid.
4
3
Pull the dust boot 5 out and remove the circlip 6 .
5
6
6-52 CHASSIS
Remove the piston assembly.
MASTER CYLINDER INSPECTION
MASTER CYLINDER
Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one.
PISTON AND RUBBER PARTS
Inspect the piston surface, primary/secondary cup, and dust boot for any scratches, wear or damage. If any damages are found, replace the piston set with a new one.
MASTER CYLINDER REASSEMBLY AND
REMOUNTING
Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay special attention to the following points:
Wash the master cylinder components with new brake fluid before reassembly.
Do not wipe the brake fluid off after washing the components.
When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.
Apply brake fluid to the master cylinder bore and all of the master cylinder components before reassembly.
Specification and classification: DOT 4
When remounting the master cylinder on the handlebar, align the master cylinder holder’s mating surface 1 with the punch mark 2 on the handlebar, and then tighten the upper clamp bolt first.
Master cylinder clamp bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
A
Master cylinder
B
Master cylinder upper clamp bolt
C
Handlebar
D
Clearance
CHASSIS 6-53
1
2
Tighten the brake hose union bolt to the specified torque.
Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Bleed air from the brake system after reassembling the master cylinder. ( 2-19 and 2-20)
6-54 CHASSIS
CONSTRUCTION
1 Cap
2 Diaphragm
3 Master cylinder
4 Piston set
5 Brake hose
6 Reservoir cover
7 Caliper cover
8 Caliper
9 Caliper holder
0 Piston and dust seal
A Piston
B Pad set
A
Master cylinder mounting bolt
B
Brake hose union bolt
C
Rear brake rod locknut
D
Plug
E
Brake pad mounting pin
F
Caliper axle
G
Air bleeder valve
H
Caliper axle
ITEM
A
B
C
D
E
F
G
H
N·m kgf-m
10 1.0
23
18
2.3
1.8
2.5
18
28
7.5
13
0.25
1.8
2.8
0.75
1.3
lb-ft
7.0
16.5
13.0
1.8
13.0
20.0
5.5
9.5
The brake system is filled with an glycol-based brake fluid, which is classified DOT 4. Do not use or mix other types of brake fluid, such as silicone-based and petroleum-based brake fluids when refilling the brake system, otherwise serious damage to the brake system will result.
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.
When storing brake fluid, make sure to seal the container completely and keep it out of the reach of children.
When replenishing brake fluid, make sure not to get any dust or other foreign materials in the fluid.
When washing brake components, always use new brake fluid. Do not use cleaning solvent.
A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the brake disc with high-quality brake cleaner or a neutral detergent.
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.
BRAKE PAD REPLACEMENT
Remove the brake pad mounting pin.
Remove the brake pads.
Do not operate the brake pedal during or after brake pad removal.
Replace the brake pads as a set, otherwise braking performance will be adversely affected.
Install the new brake pads.
Make sure that the brake pad is properly engaged with the guide plate as shown in the photograph.
Tighten the brake pad mounting pin to the specified torque.
Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
CHASSIS 6-55
6-56 CHASSIS
BRAKE FLUID REPLACEMENT
Remove the reservoir cover.
Remove the reservoir cap and diaphragm.
Replace the brake fluid. ( 6-46)
Specification and classification: DOT 4
(
Bleed air from the brake system.
2-19 and 2-20)
BRAKE CALIPER REMOVAL AND
DISASSEMBLY
Remove the rear wheel. ( 6-27)
Disconnect the brake hose from the brake caliper by removing the brake hose union bolt and allow the brake fluid to drain into a suitable receptacle.
Remove the brake caliper.
Never reuse the brake fluid left over from previous servicing or which has been stored for long period of time, otherwise serious damage to the brake system will result.
Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and oil leakage.
Remove the brake pads. ( 6-55)
Remove the brake caliper cover 1 and brake disc cover 2 .
2
Remove the brake caliper holder.
CHASSIS 6-57
1
Remove the spring.
6-58 CHASSIS
Place a rag over the brake caliper piston to prevent them from popping out and then force out the piston using compressed air.
Do not use extremely high pressure air to remove the brake caliper piston, otherwise damage to the piston will result.
Remove the dust seals and piston seals.
Do not reuse the dust seals and piston seals to prevent fluid leakage.
BRAKE CALIPER INSPECTION
BRAKE CALIPER ......................................................
BRAKE CALIPER PISTON ........................................
RUBBER PARTS .......................................................
6-48
6-48
6-49
BRAKE CALIPER REASSEMBLY AND
REMOUNTING
Reassemble and remount the brake caliper in the reverse order of removal and disassembly. Pay special attention to the following points:
Wash the caliper bores and pistons with the specified brake fluid. Thoroughly wash the dust seal grooves and piston seal grooves.
Specification and classification: DOT 4
Wash the brake caliper components with new brake fluid before reassembly.
Do not wipe the brake fluid off after washing the components.
When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.
Replace the removed piston seals and dust seals with new ones.
Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly.
PISTON SEAL
Install the piston seal 1 and dust seal 2 as shown.
BRAKE CALIPER HOLDER
Apply SUZUKI SILICON GREASE to the brake caliper holder.
99000-25100: SUZUKI SILICONE GREASE
Tighten the brake hose union bolt to the specified torque.
Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Bleed air from the system after remounting the rear wheel. ( 2-19 and 2-20)
CHASSIS 6-59
BRAKE DISC INSPECTION
BRAKE DISC .............................................................
6-50
6-60 CHASSIS
MASTER CYLINDER REMOVAL AND
DISASSEMBLY
Remove the reservoir cover. ( 6-56)
Remove the reservoir mounting bolt.
Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid. Remove the brake hose union bolt and disconnect the brake hose.
Immediately wipe off any brake fluid contacting any part of the motorcycle. The brake fluid reacts chemically with paint, plastics, rubber materials, etc., and will damage them severely.
Loosen the locknut 1 and remove the master cylinder assembly.
Remove the circlip 2 and reservoir assembly 3 .
1
2
3
Pull the dust boot 4 out and remove the circlip 5 .
4
5
Remove the push rod 1 and piston assembly 2 .
MASTER CYLINDER INSPECTION
MASTER CYLINDER .................................................
PISTON AND RUBBER PARTS ................................
6-52
6-52
MASTER CYLINDER REASSEMBLY AND
REMOUNTING
Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay special attention to the following points:
Wash the master cylinder components with new brake fluid before reassembly.
Do not wipe the brake fluid off after washing the components.
When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.
Apply brake fluid to the master cylinder bore and all of the master cylinder components before reassembly.
Specification and classification: DOT 4
CHASSIS 6-61
2
1
6-62 CHASSIS
Tighten the master cylinder mounting bolts 1 , brake rod locknut 2 , and brake hose union bolt 3 to the specified torque.
Master cylinder mounting bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)
Brake rod locknut:
Brake hose union bolt:
18 N·m (1.8 kgf-m, 13.0 lb-ft)
23 N·m (2.3 kgf-m, 16.5 lb-ft)
Bleed air from the brake system after reassembling the master cylinder. ( 2-19 and 2-20)
1
2
3
ELECTRICAL SYSTEM
7-1
CONTENTS
CAUTIONS IN SERVICING ............................................................................. 7- 2
CONNECTORS ........................................................................................... 7- 2
COUPLERS ................................................................................................ 7- 2
CLAMPS ..................................................................................................... 7- 2
FUSE (DR-Z400E) ...................................................................................... 7- 2
SEMICONDUCTOR EQUIPPED PARTS .................................................... 7- 2
BATTERY (DR-Z400E) ................................................................................ 7- 3
CONNECTING THE BATTERY (DR-Z400E) ............................................... 7- 3
WIRING PROCEDURE ............................................................................... 7- 3
USING THE MULTI CIRCUIT TESTER ....................................................... 7- 4
LOCATION OF ELECTRICAL COMPONENTS .............................................. 7- 5
CHARGING SYSTEM (DR-Z400E) ................................................................. 7- 7
DESCRIPTION ............................................................................................ 7- 7
TROUBLESHOOTING ................................................................................ 7- 8
INSPECTION .............................................................................................. 7- 9
STARTER SYSTEM (DR-Z400E) .................................................................... 7-12
DESCRIPTION ............................................................................................ 7-12
TROUBLESHOOTING ................................................................................ 7-12
STARTER MOTOR REMOVAL AND DISASSEMBLY ................................ 7-13
STARTER MOTOR INSPECTION ............................................................... 7-14
STARTER MOTOR REASSEMBLY AND REMOUNTING .......................... 7-15
STARTER RELAY INSPECTION ................................................................ 7-16
IGNITION SYSTEM (DR-Z400) ....................................................................... 7-17
DESCRIPTION ............................................................................................ 7-17
TROUBLESHOOTING ................................................................................ 7-17
INSPECTION .............................................................................................. 7-19
IGNITION SYSTEM (DR-Z400E) .................................................................... 7-22
DESCRIPTION ............................................................................................ 7-22
TROUBLESHOOTING ................................................................................ 7-22
INSPECTION .............................................................................................. 7-24
ODOMETER .................................................................................................... 7-26
REMOVAL ................................................................................................... 7-26
LAMPS ............................................................................................................ 7-27
HEADLIGHT ............................................................................................... 7-27
TAILLIGHT .................................................................................................. 7-28
SWITCHES ..................................................................................................... 7-29
BATTERY (DR-Z400E) .................................................................................... 7-30
REMOVAL ................................................................................................... 7-30
SPECIFICATIONS ....................................................................................... 7-30
SERVICING ................................................................................................. 7-30
RECHARGING OPERATION ...................................................................... 7-31
7-2 ELECTRICAL SYSTEM
When disconnecting a connector, be sure to hold the terminals; do not pull the lead wires.
When connecting a connector, push it in so it is firmly attached.
Inspect the connector for corrosion, contamination and any breakage in the cover.
With a lock-type coupler, be sure to release the lock before disconnecting it. When connecting a coupler, push it in until the lock clicks shut.
When disconnecting a coupler, be sure to hold the coupler; do not pull the lead wires.
Inspect each terminal on the coupler for looseness or bends.
Inspect each terminal for corrosion and contamination.
Refer to the “WIRE HARNESS, CABLE, AND HOSE ROUT-
ING” section for proper clamping procedures. ( 8-12 to
8-18)
Bend the clamp properly, as shown in the illustration.
When clamping the wire harness, do not allow it to hang down.
Do not use wire or any substitutes for the band-type clamp.
When a fuse blows, always investigate the cause, correct the problem, and then replace the fuse.
Do not use a fuse of a different capacity.
Do not use any substitutes for the fuse (e.g., wire).
Do not drop any part that contains a semiconductor (e.g., CDI unit, regulator/rectifier).
When inspecting the part, follow the inspection instructions carefully. Neglecting proper procedures may cause this part to be damaged.
The battery has been pre-filled with electrolyte so there is no need to add fluid at any time.
The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment).
During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, make sure that there are no fire or spark sources (e.g., short circuit) nearby when charging the battery.
Be sure to recharge the battery in a well-ventilated and open area.
Note that the charging system for the MF battery is different from that of a conventional battery. Do not replace the MF battery with a conventional battery.
When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the battery lead wire, first.
When connecting the battery lead wires, be sure to connect the + battery lead wire, first.
If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush.
After connecting the battery, apply a light coat of grease to the battery terminals.
Install the cover over the + battery terminal.
ELECTRICAL SYSTEM 7-3
Properly route the wire harness according to the “WIRE HAR-
NESS, CABLE, AND HOSE ROUTING” section. ( 8-12 to
8-18)
7-4 ELECTRICAL SYSTEM
Properly use the multi circuit tester + and probes. Improper use can cause damage to the motorcycle and tester.
If the voltage and current values are not known, begin measuring in the highest range.
When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged.
After using the tester, turn the switch to the “OFF” position.
Before using the multi circuit tester, read its instruction manual.
ELECTRICAL SYSTEM 7-5
3
4
1
2
6
1 CDI unit
2 Ignition coil
3 Ignition switch (DR-Z400E)
4 Starter button (DR-Z400E)
5 Starter relay (DR-Z400E)
6 Condenser (DR-Z400)
7-6 ELECTRICAL SYSTEM
8
D
9
0
7
B
A
C
7 Engine stop switch
8 Clutch lever position switch (DR-Z400E)
9 Starter motor (DR-Z400E)
0 Regulator/rectifier
A Fuse (DR-Z400E)
B Battery (DR-Z400E)
C Generator (DR-Z400E)
D Throttle position sensor
E Generator (DR-Z400)
E
ELECTRICAL SYSTEM 7-7
The charging system consists of a generator, regulator/rectifier, and battery. The AC current, which is generated by the generator, is converted by the regulator/rectifier into DC current. The regulator/rectifier is one unit with two functions. The regulator prevents overcharging of the battery by grounding the excessive AC current. The rectifier changes the AC current, which is produced by the generator, to the DC current.
All of these components work together to maintain a correct and constant voltage and to prevent the battery from overcharging.
7-8 ELECTRICAL SYSTEM
Battery runs down quickly.
Check accessories which use excessive amounts of electricity.
No accessories
Check the battery for current leakage.
( 7-9)
No current leaks
Measure the regulated voltage.
( 7-9 and 7-10)
Incorrect
Accessories are installed
Current leaks
Correct
• Remove accessories
• Short circuit of the wire
harness
• Loose or disconnected
wires
• Faulty battery
• Faulty battery
• Abnormal driving
condition
Check the continuity of the generator. ( 7-10)
Continuity
Inspect the generator no-load performance. ( 7-11)
Correct
Inspect the regulator/rectifier.
( 7-11)
Correct
Inspect the wires.
Others
Battery overcharges
Correct
No continuity
Incorrect
Incorrect
• Faulty stator coil or
disconnected lead
wires
• Faulty generator
• Faulty rectifier or
regulator/rectifier
Incorrect
• Faulty rectifier or regulator/rectifier
• Faulty battery
• Poor contact of generator lead wire coupler
• Short circuit of wire
harness
• Improper coupler
contact
• Faulty battery
BATTERY CURRENT LEAKAGE (DR-Z400E)
Turn the ignition switch to the “OFF” position.
Remove the battery cover. ( 6-2)
Disconnect the battery lead wire.
Measure the current between the battery terminal and the battery lead wire using the multi circuit tester. If the reading exceeds the specified value, leakage is evident.
09900-25008: Multi circuit tester set
Tester knob indication: Current ( , 20mA)
Battery current (leak): Under 1mA
Because the current leak might be large, turn the multi circuit tester to the high range, first to avoid damage to the tester.
Do not turn the ignition switch to the “ON” position when measuring the current.
When checking to find the excessive current leakage, remove the couplers and connectors, one by one, checking each part.
ELECTRICAL SYSTEM 7-9
REGULATED VOLTAGE (DR-Z400)
Start the engine and run the engine at 5 000 r/min.
Measure the DC voltage between the headlight terminals using the multi circuit tester. If the tester reads without the specified value, inspect the generator and regulator/rectifier. ( and 7-11)
7-10
09900-25008: Multi circuit tester set
Tester knob indication: Voltage ( )
Regulated voltage
Standard: 12.5 – 14.0 V at 5 000 r/min
_
B/W O
+
(DC V)
Tester
7-10 ELECTRICAL SYSTEM
REGULATED VOLTAGE (DR-Z400E)
Remove the battery cover. ( 6-2)
Start the engine and run the engine at 5 000 r/min.
Measure the DC voltage between the + and battery termi-
( nals using the multi circuit tester. If the voltage is not within the specified value, inspect the generator and regulator/rectifier.
7-10 and 7-11)
09900-25008: Multi circuit tester set
Tester knob indication: Voltage ( )
Charging output (regulated voltage)
Standard: 13.5 – 15.0 V at 5 000 r/min
STATOR COIL RESISTANCE
Remove the left frame cover. ( 6-2)
Disconnect the stator coil lead wire coupler.
Measure the resistance between the three lead wires using the multi circuit tester. If the resistance is not within the specified value, replace the stator coil with a new one.
Also, check that the generator core is insulated.
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
)
Stator coil resistance
Standard: 0.50 – 1.25
Ω
(Yellow – Yellow)
∞
Ω
(Yellow – Ground)
ELECTRICAL SYSTEM 7-11
AC GENERATOR NO-LOAD PERFORMANCE
Remove the left frame cover. ( 6-2)
Disconnect the stator coil lead wire coupler.
Start the engine and run it at 5 000 r/min.
Measure the AC voltage between the lead wires of the generator using the multi circuit tester. If the voltage is under the specified value, replace the AC generator with a new one.
09900-25008: Multi circuit tester set
Tester knob indication: Voltage (~)
AC generator no-load performance
Standard:
More than 55 V (AC) at 5 000 r/min (DR-Z400)
More than 75 V (AC) at 5 000 r/min (DR-Z400E)
REGULATOR/RECTIFIER
Remove the left frame cover. ( 6-2)
Disconnect the regulator/rectifier coupler.
Measure the voltage between the terminals using the multi circuit tester, as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.
09900-25008: Multi circuit tester set
Tester knob indication: Diode test ( )
Unit: V
O or R
B/W
Y
1
Y
2
Y
3
O or R
1.4 – 1.5
1.4 – 1.5
0.4 – 0.7
1.4 – 1.5
0.4 – 0.7
1.4 – 1.5
+ Tester probe
B/W
0.5 – 1.2
0.4 – 0.7
Y
1
0.4 – 0.7
1.4 – 1.5
1.4 – 1.5
1.4 – 1.5
Y
2
Y
3
0.4 – 0.7
0.4 – 0.7
1.4 – 1.5
1.4 – 1.5
1.4 – 1.5
1.4 – 1.5
1.4 – 1.5
1.4 – 1.5
O: Orange, R: Red, Y: Yellow, B/W: Black with White tracer
Y1
Y2
B/W
Y3
OorR
7-12 ELECTRICAL SYSTEM
The starter system consists of the following components: the starter motor, starter relay, clutch lever position switch, starter button, ignition switch, and battery. Pressing the starter button energizes the starter relay, causing the contact points to close, thus, completing the circuit from the starter motor to the battery.
The starter motor draws about 80 amperes to start the engine.
Starter motor will not run.
The transmission is in neutral. Turn the ignition switch to the “ON” position. Grasp the clutch lever. Listen for a click from the starter relay when the starter button is pushed.
Clicks
No click
Continued on next page
Check if the starter motor runs when its terminal is connected to the battery terminal (Do not use a thin wire because a large amount of current flows.)
Runs Does not run
• Faulty starter motor
• Faulty starter relay
• Loose or disconnected starter
motor lead wire
ELECTRICAL SYSTEM 7-13
Measure the starter relay voltage at the starter relay connectors (between Y/B and B/W ) when the starter button is pushed.
Voltage
Inspect the starter relay.
( 7-16)
Correct
No voltage
Incorrect
Others
Engine does not turn though the starter motor runs.
• Faulty starter clutch
• Faulty ignition switch
• Faulty starter button
• Faulty clutch lever position
switch
• Improper connector contact
• Open circuit in wire harness
• Faulty starter relay
• Improper starter relay contact
Remove the exhaust pipe. ( 3-5)
Remove the regulator/rectifier mounting bolt and clutch cable guide mounting bolt.
Disconnect the starter motor lead wire.
Remove the starter motor.
7-14 ELECTRICAL SYSTEM
Disassemble the starter motor, as shown.
ITEM
A
N·m kgf-m
5 0.5
lb-ft
3.5
CARBON BRUSHES
Inspect the carbon brushes for abnormal wear, cracks, or smoothness in the brush holder.
If any damages are found, replace the brush assembly with a new one.
COMMUTATOR
Inspect the commutator for discoloration, abnormal wear or undercut
A
.
If abnormal wear is found, replace the armature with a new one.
If the commutator surface is discolored, polish it with #400 sandpaper and wipe it using a clean, dry cloth.
If there is no undercut, scrape out the insulator 1 with a saw blade.
ARMATURE COIL INSPECTION
Check for continuity between each segment and between each segment and the armature shaft using the multi circuit tester.
If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test ( )
OIL SEAL
Check the seal lip for damage or leakage. If any damages are found, replace the housing end (inside) of the starter motor with a new one.
ELECTRICAL SYSTEM 7-15
Reassemble and remount the starter motor in the reverse order of removal and disassembly. Pay special attention to the following points:
Replace the removed O-rings with new ones to prevent oil leakage and moisture.
Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft.
99000-25140: SUZUKI MOLY PASTE
Align the match marks on the starter motor case with the match mark on the housing end.
Apply a small quantity of THREAD LOCK “1342” to the starter motor housing bolts.
99000-32050: THREAD LOCK “1342”
Apply SUZUKI SUPER GREASE “A” to the O-ring.
For USA
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
99000-25010: SUZUKI SUPER GREASE “A”
7-16 ELECTRICAL SYSTEM
Remove the right frame cover. ( 6-3)
Disconnect the starter motor lead wire, battery lead wire, and starter relay coupler at the starter relay.
Remove the starter relay.
Apply 12 V to the terminals and check for continuity between the positive and negative terminals using the multi circuit tester.
If the starter relay clicks and continuity is found, the relay is ok.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test ( )
Do not apply battery voltage to the starter relay for more than five seconds, since the relay coil may overheat and be damage.
Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one.
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
)
Starter relay resistance
Standard: 3 – 5
Ω
ELECTRICAL SYSTEM 7-17
In the capacitor discharged ignition system, the electrical energy generated by the generator charges the capacitor. This energy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil. A high voltage is induced in the secondary windings of the ignition coil, resulting in a strong spark between the spark plug gap.
Ignition coil
Condenser
Regulator/
Rectifier
Generator
DC-DC converter
Ignition power source circuit
Wave form arrangement circuit
CPU
Throttle position sensor
Engine stop switch
No spark or poor spark
Check the ignition system couplers for poor connections.
Correct
Continued on next page
* Make sure the transmission is in the neutral position.
Loose • Improper coupler
connection
7-18 ELECTRICAL SYSTEM
Measure the ignition coil primary peak voltage. ( 7-19)
NOTE: The ignition coil peak voltage inspection method is applicable only with the multi circuit tester and the peak volt adaptor.
Incorrect
Correct
Inspect the ignition coil. ( 7-20)
Correct
Measure the pickup coil and signal coil peak voltage and resistance. ( 7-20 and 7-21)
NOTE: The pickup coil and signal coil peak voltage inspection is applicable only with the multi circuit tester and the peak volt adaptor.
Correct
Incorrect
Incorrect
Inspect the spark plug.
( 2-9)
Correct Incorrect
• Faulty spark plug
• Improper spark plug
connection
• Faulty ignition coil
• Faulty pickup coil
• Faulty signal coil
• Faulty CDI unit
• Open circuit in wiring
harness.
• Improper ignition coupler
connection
IGNITION COIL PRIMARY PEAK VOLTAGE
Remove the fuel tank. ( 4-2)
Remove the spark plug cap and spark plug.
Connect a new spark plug to spark plug cap and ground it to the cylinder head.
Do not let the spark plug touch the cylinder head cover, otherwise the cylinder head cover may be damaged.
Measure ignition coil primary peak voltage using the multi circuit tester in the following procedure.
Connect the multi circuit tester with the peak voltage adaptor as follows.
Ignition coil:
Black/White terminal – Black/Yellow
( + probe) ( probe)
09900-25008: Multi circuit tester set
When using the multi circuit tester and peak volt adaptor, refer to the appropriate instruction manual.
Shift the transmission into neutral and set the engine stop switch to the “RUN” position.
Pull the decompression lever.
Kick the kick starter lever and allow the engine to crank for a few times, and then measure the ignition coil primary peak voltage.
Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage.
Tester knob indication: Voltage ( )
Ignition coil primary peak voltage: More than 150 V
While testing, do not touch the tester probes and spark plug to prevent receiving an electric shock.
If the voltage is lower than the standard values, inspect the ignition coil. ( 7-20)
CDI unit
ELECTRICAL SYSTEM 7-19
B/Y
B/W
New spark plug
Peak volt adaptor
7-20 ELECTRICAL SYSTEM
IGNITION COIL RESISTANCE
Remove the fuel tank. ( 4-2)
Disconnect the ignition coil lead wire, and then remove the ignition coil.
Measure the ignition coil resistance in both the primary and secondary windings using the multi circuit tester. If the resistance in both the primary and secondary windings is close to the specified values, the windings are in sound condition.
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
)
Ignition coil resistance
Primary: 0.1 – 1.0
Ω
(terminal – ground)
Secondary: 12 – 20 k
Ω
(terminal – spark plug cap)
PICKUP COIL AND SIGNAL COIL PEAK VOLTAGE
Remove the left frame cover. ( 6-2)
Disconnect the wire harness coupler 1 .
Measure the pickup coil and signal coil peak voltage in the following procedure.
Connect the multi circuit tester with the peak volt adaptor as follows.
Pickup coil: Blue ( + probe) – Green ( probe)
Signal coil: Black ( + probe) – White ( probe)
09900-25008: Multi circuit tester set
When using the multi circuit tester and peak volt adaptor, refer to the appropriate instruction manual.
Shift the transmission into neutral.
Kick the kick starter lever and allow the engine to turn for a few times, and then measure the pickup coil and signal coil peak voltage.
Repeat the above procedure a few times and measure the highest pickup coil and signal coil peak voltage.
Tester knob indication: Voltage ( )
Pickup coil peak voltage: More than 10.0 V
Signal coil peak voltage: More than 1.0 V
1
B
W
BI
G
Peak volt adaptor
+
-
Generator
Pickup coil
B
W
BI
G
Peak volt adaptor
+
-
Generator
Signal coil
PICKUP COIL AND SIGNAL COIL RESISTANCE
Remove the left frame cover. ( 6-2)
Disconnect the generator coupler 1 .
Measure the resistance between the lead wires using the multi circuit tester. If the resistance is not within the specified value, the pickup coil and signal coil must be replaced.
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
)
Pickup coil resistance: 390 – 600
Ω
(Blue – Green)
Signal coil resistance: 0.05 – 0.20
Ω
(Black – White)
ELECTRICAL SYSTEM 7-21
1
7-22 ELECTRICAL SYSTEM
In the capacitor discharged ignition system, the battery’s electrical energy charges the capacitor. This energy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil. A high voltage is induced in the secondary windings of the ignition coil, resulting in a strong spark between the spark plug gap.
Battery
Regulator
/rectifier
Ignition switch
Generator
DC-DC converter
Ignition power source circuit
Wave form arrangement circuit
CPU
Ignition coil
Throttle position sensor
Engine stop switch
No spark or poor spark
Check the ignition system couplers for poor connections.
Correct
* Make sure the transmission is in the neutral position.
Also, make sure the fuse is not blown and the battery is
fullycharged before diagnosing.
Loose • Improper coupler
connection
Measure the battery voltage between input lead wires (O/W and B/W) at the CDI unit with the ignition switch in the “ON” position and the engine stop switch in the “RUN” position.
Incorrect • Faulty ignition switch
• Faulty engine stop switch
• Broken wire harness or
poor connection of related
circuit couplers
Correct
Continued on next page
ELECTRICAL SYSTEM 7-23
Measure the ignition coil primary peak voltage. ( 7-24)
NOTE: The ignition coil peak voltage inspection method is applicable only with the multi circuit tester and the peak volt adaptor.
Correct
Correct
Inspect the ignition coil. ( 7-20)
Correct
Measure the pickup coil and signal coil peak voltage and resistance. ( 7-21 and 7-25)
NOTE: The pickup coil and signal coil peak voltage inspection is applicable only with the multi circuit tester and the peak volt adaptor.
Correct
Incorrect
Incorrect
Inspect the spark plug.
( 2-9)
Correct Incorrect
• Faulty spark plug
• Improper spark plug
connection
• Faulty ignition coil
• Faulty pickup coil
• Faulty signal coil
• Open circuit in wiring
harness.
• Improper ignition coupler
connection
7-24 ELECTRICAL SYSTEM
IGNITION COIL PRIMARY PEAK VOLTAGE
Remove the fuel tank. ( 4-2)
Remove the spark plug cap.
Connect a new spark plug to the spark plug cap and ground it to the cylinder head.
Do not let the spark plug touch the cylinder head cover, otherwise the cylinder head cover may be damaged.
Measure ignition coil primary peak voltage using the multi circuit tester in the following procedure.
Connect the multi circuit tester with the peak voltage adaptor as follows.
Ignition coil:
Black/White terminal – Black/Yellow
( + probe) ( probe)
09900-25008: Multi circuit tester set
When using the multi circuit tester and peak volt adaptor, refer to the appropriate instruction manual.
Shift the transmission into neutral, and then turn the ignition switch to the “ON” position.
Pull the clutch lever.
Press the starter button and allow the engine to crank for a few seconds, and then measure the ignition coil primary peak voltage.
Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage.
Tester knob indication: Voltage ( )
Ignition coil primary peak voltage: More than 150 V
CDI unit
Battery
B/Y
B/W
New spark plug
Peak volt adaptor
While testing, do not touch the tester probes and spark plug to prevent receiving an electric shock.
If the voltage is lower than the standard values, inspect the ignition coil. ( 7-20)
ELECTRICAL SYSTEM 7-25
PICKUP COIL AND SIGNAL COIL PEAK VOLTAGE
Remove the left frame cover. ( 6-2)
Disconnect the wire harness coupler 1 at the CDI unit.
Measure the pickup coil and signal coil peak voltage in the following procedure.
Connect the multi circuit tester with the peak volt adaptor as follows.
Pickup coil: Blue ( + probe) – Green ( probe)
Signal coil: Black ( + probe) – White ( probe)
09900-25008: Multi circuit tester set
When using the multi circuit tester and peak volt adaptor, refer to the appropriate instruction manual.
Shift the transmission into neutral, and then turn the ignition switch to the “ON” position.
Pull the clutch lever.
Press the starter button and allow the engine to crank for a few seconds, and then measure the pickup coil and signal coil peak voltage.
Repeat the above procedure a few times and measure the highest pickup coil and signal coil peak voltage.
Tester knob indication: Voltage ( )
Pickup coil peak voltage: More than 5.0 V
Signal coil peak voltage: More than 1.4 V
IGNITION COIL RESISTANCE ..................................
PICKUP COIL AND SIGNAL COIL RESISTANCE ...
7-20
7-21
1
B
W
BI
G
Peak volt adaptor
+
-
Generator
Pickup coil
B
W
BI
G
Peak volt adaptor
+
-
Generator
Signal coil
7-26 ELECTRICAL SYSTEM
Remove the headlight assembly. (
Disconnect the odometer cable.
7-27)
Remove the odometer assembly.
ELECTRICAL SYSTEM 7-27
Headlight bulb : 12V 55W
BULB REPLACEMENT
Disconnect the bands and screw.
Disconnect the headlight coupler and remove the headlight assembly.
7-28 ELECTRICAL SYSTEM
Remove the rubber cap.
Remove the bulb.
Install the new bulb in the reverse order of removal.
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
TAILLIGHT REPLACEMENT
Remove the seat. ( 6-2)
Disconnect the taillight coupler.
Remove the taillight assembly.
ELECTRICAL SYSTEM 7-29
Measure each switch for continuity using a multi circuit tester. If any abnormality is found, replace the respective switch assemblies with a new one.
09900-25008: Multi circuit tester set
IGNITION SWITCH (DR-Z400E)
Position
Color
R
ON
OFF
ENGINE STOP SWITCH
Position
Color
B/W
OFF
RUN
STARTER BUTTON (DR-Z400E)
Color
O
Position
O
B/Y
B/Y
PUSH
CLUTCH SWITCH (DR-Z400E)
Position
Color
Y/G
OFF
ON
WIRE COLOR
G : Green
Gr : Gray
O : Orange
R : Red
Y : Yellow
W : White
B/W : Black with White tracer
O/W : Orange with White tracer
Y/G : Yellow with Green tracer
Y/G
7-30 ELECTRICAL SYSTEM
Remove the battery cover. (
Remove the battery holder.
6-2)
Remove the battery.
-
Type designation
Capacity
GT7B-4
12 V, 23.4 kC (6.5 Ah)/10 HR
Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
Measure the battery voltage using the multi circuit tester or digital volt meter. If the voltage reading is less than the 12.6 V
(DC), recharge the battery with a MF battery charger.
When recharging the battery, remove the battery from the motorcycle.
Recharging time: 0.65 A for 5 to 10 hours.
Do not attempt boost charging under any circumstances.
After recharging, wait at least 30 minutes and then measure the battery voltage using the multi circuit tester. If the battery voltage is less than 12.6 V, recharge the battery again. If the battery voltage is still less than 12.6 V after recharging, replace the battery with a new one.
When a battery is left unused for a long time, its voltage needs to be regularly measured. When the motorcycle is not used for more than one month (especially during the winter season), measure the battery voltage at least once a month.
ELECTRICAL SYSTEM 7-31
SERVICING INFORMATION
8-1
CONTENTS
TROUBLESHOOTING .................................................................................... 8- 2
ENGINE ...................................................................................................... 8- 2
CARBURETOR ........................................................................................... 8- 5
CHASSIS .................................................................................................... 8- 6
BRAKES ..................................................................................................... 8- 7
ELECTRICAL .............................................................................................. 8- 8
BATTERY (DR-Z400E) ................................................................................ 8- 9
WIRING DIAGRAM ......................................................................................... 8-10
DR-Z400 ...................................................................................................... 8-10
DR-Z400E ................................................................................................... 8-11
WIRE HARNESS, CABLE, AND HOSE ROUTING ........................................ 8-12
WIRE ROUTING ......................................................................................... 8-12
CABLE ROUTING ...................................................................................... 8-14
FUEL HOSE AND FUEL TANK MOUNTING .............................................. 8-15
OIL RETURN TANK HOSE ROUTING........................................................ 8-16
COOLING SYSTEM HOSE ROUTING ....................................................... 8-17
FRONT BRAKE HOSE ROUTING .............................................................. 8-18
REAR BRAKE HOSE ROUTING ................................................................ 8-18
SPECIAL TOOLS ............................................................................................ 8-19
TIGHTENING TORQUE ................................................................................... 8-22
ENGINE ...................................................................................................... 8-22
CHASSIS .................................................................................................... 8-23
TIGHTENING TORQUE CHART ................................................................. 8-24
SERVICE DATA ............................................................................................... 8-25
8-2 SERVICING INFORMATION
Complaint
Engine will not start or is hard to start.
Engine stalls easily.
Symptom and possible causes
Compression too low
1. Worn cylinder.
2. Worn piston ring.
3. Worn valve guide or improper valve seating.
4. Loose spark plug.
5. Broken, cracked, or damaged piston.
6. Slow cranking starter motor. (DR-Z400E)
7. Mistimed valves.
8. Tappet clearance out of adjustment.
Spark plug not sparking
1. Damaged spark plug.
2. Damaged spark plug cap.
3. Fouled spark plug.
4. Wet spark plug.
5. Defective ignition coil.
6. Open or short in high-tension cord.
7. Defective generator.
8. Defective CDI unit.
No fuel reaching the carburetor
1. Clogged fuel tank vent hose.
2. Clogged or defective fuel valve.
3. Defective carburetor needle valve.
4. Clogged fuel hose.
5. Clogged fuel filter.
1. Fouled spark plug.
2. Defective generator.
3. Defective CDI unit.
4. Clogged or defective fuel valve.
5. Clogged carburetor jet.
6. Tappet clearance out of adjustment.
Remedy
Replace.
Replace.
Repair or replace.
Tighten.
Replace.
See electrical section.
Adjust.
Adjust.
Replace.
Replace.
Clean or replace.
Clean and dry or replace.
Replace.
Replace.
Replace.
Replace.
Clean or replace.
Clean or replace.
Replace.
Clean or replace.
Clean or replace.
Clean or replace.
Replace.
Replace.
Clean or replace.
Clean.
Adjust.
SERVICING INFORMATION 8-3
Complaint
Engine is noisy.
Symptom and possible causes
Excessive valve chatter
1. Excessive tappet clearance.
2. Weak or broken valve spring.
3. Worn camshaft.
4. Worn or burnt camshaft journal.
Noise seems to come from the piston
1. Worn piston.
2. Worn cylinder.
3. Carbon buildup in combustion chamber.
4. Worn piston pin or piston pin bore.
5. Worn piston ring or ring groove.
Noise seems to come from the cam chain
1. Stretched cam chain.
2. Worn cam chain sprocket.
Clutch slips.
Clutch drags.
Transmission will not shift.
Transmission will not shift back.
3. Improperly working cam chain tensioner.
Noise seems to come from the clutch
1. Worn countershaft spline.
2. Worn clutch hub spline.
3. Worn clutch plate teeth.
4. Distorted clutch plate.
5. Weak clutch damper.
6. Weak clutch spring.
Noise seems to come from the crankshaft
1. Rattling bearing.
2. Worn or burnt crank pin bearing.
3. Worn or burnt journal bearing.
4. Excessive thrust clearance.
Noise seems to come from the transmission
1. Worn or rubbing gear.
2. Worn countershaft spline.
3. Worn driveshaft spline.
4. Worn or rubbing primary gear.
5. Worn bearing.
1. Clutch cable out of adjustment.
2. Weak or broken clutch spring.
3. Worn or distorted clutch pressure plate.
4. Distorted clutch plate.
1. Clutch out of adjustment.
2. Some clutch springs are weak, while others are not.
3. Worn or distorted clutch pressure plate.
4. Distorted clutch plate.
1. Broken gearshift cam.
2. Distorted gearshift fork.
3. Worn gearshift pawl.
1. Broken gearshift shaft return spring.
2. Rubbing or stuck gearshift shaft.
3. Worn or distorted gearshift fork.
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Clean.
Replace.
Replace.
Remedy
Replace cam chain and sprockets.
Replace cam chain and sprockets.
Repair or replace.
Replace countershaft.
Replace clutch hub.
Replace clutch plate.
Replace.
Replace primary driven gear.
Replace.
Replace.
Replace.
Replace.
Replace thrust bearing.
Replace.
Replace countershaft.
Replace driveshaft.
Replace.
Replace.
Adjust.
Replace.
Replace.
Replace.
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Replace.
8-4 SERVICING INFORMATION
Complaint
Transmission jumps out of gear.
Engine idles poorly.
Engine runs poorly in high-speed range.
Exhaust smoke is dirty or thick.
Engine lacks power.
Symptom and possible causes
1. Worn gear.
2. Worn or distorted gearshift fork.
3. Weakened gearshift stopper spring.
4. Worn gearshift pawl.
1. Tappet clearance out of adjustment.
2. Improper valve seating.
3. Worn valve guide.
4. Worn camshaft.
5. Excessive spark plug gap.
6. Defective ignition coil.
7. Defective generator.
8. Defective CDI unit.
9. Incorrect float chamber fuel level.
10. Clogged carburetor jet.
1. Weak valve spring.
2. Worn camshaft.
3. Insufficient spark plug gap.
4. Mistimed valves.
5. Ignition not advanced sufficiently due to poorly working timing advance circuit.
6. Defective ignition coil.
7. Defective generator.
8. Defective CDI unit.
9. Low float chamber fuel level.
10. Dirty air cleaner element.
11. Clogged fuel hose, resulting in inadequate fuel supply to carburetor.
1. Excessive amount of engine oil.
2. Worn cylinder.
3. Worn piston ring.
4. Worn valve guide.
5. Scored or scuffed cylinder wall.
6. Worn valve stem.
7. Defective valve stem oil seal.
8. Worn oil ring side rail.
1. Insufficient tappet clearance.
2. Weak valve spring.
3. Mistimed valves.
4. Worn cylinder.
5. Worn piston ring.
6. Improper valve seating.
7. Fouled spark plug.
8. Incorrect spark plug.
9. Clogged carburetor jet.
10. Incorrect float chamber fuel level.
11. Dirty air cleaner element.
12. Air leakage from intake pipe.
13. Excessive amount of engine oil.
Remedy
Replace.
Replace.
Replace.
Replace.
Adjust.
Repair or replace.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Adjust float height.
Clean.
Replace.
Replace.
Regap or replace.
Adjust.
Replace CDI unit.
Replace.
Replace.
Replace.
Adjust float height.
Clean or replace.
Clean and prime.
Check level and drain.
Rebore or replace.
Replace.
Replace.
Replace.
Replace valve.
Replace.
Replace oil ring.
Adjust.
Replace.
Adjust.
Replace.
Replace.
Repair or replace.
Clean or replace.
Replace.
Clean.
Adjust float height.
Clean or replace.
Tighten or replace.
Check level and drain.
Complaint
Engine overheats.
Symptom and possible causes
1. Carbon buildup on piston crown.
2. Insufficient amount of engine oil.
3. Defective oil pump.
4. Clogged oil circuit.
5. Float chamber fuel level too low.
6. Air leakage from intake pipe.
7. Incorrect engine oil.
SERVICING INFORMATION 8-5
Remedy
Clean.
Check level and add.
Replace.
Clean.
Adjust float height.
Tighten or replace.
Change.
Complaint
Starting difficulty.
Idling or low-speed trouble.
Medium or highspeed trouble.
Overflow and fuel level fluctuations.
Symptom and possible causes
1. Clogged starter jet.
2. Clogged starter jet passage.
3. Air leaking from joint between starter body and carburetor.
4. Air leaking from carburetor joint or vacuum hose joint.
5. Improperly working starter (enricher) plunger.
1. Clogged or loose pilot jet.
2. Clogged or loose pilot air jet.
3. Air leaking from carburetor joint, vacuum pipe joint, or starter.
4. Clogged pilot outlet port.
5. Clogged bypass port.
6. Starter (enricher) plunger not fully closed.
1. Clogged main jet.
2. Clogged main air jet.
3. Clogged needle jet.
4. Improperly working throttle valve.
5. Clogged fuel filter.
1. Worn or damaged needle valve.
2. Broken needle valve spring.
3. Improperly working float.
4. Foreign matter on the needle valve.
5. Incorrect float chamber fuel level.
Remedy
Clean.
Clean.
Tighten, adjust, or replace gasket.
Tighten or replace defective part.
Adjust.
Clean or tighten.
Clean or tighten.
Tighten or replace defective part.
Clean.
Clean.
Adjust.
Clean.
Clean.
Clean.
Adjust.
Clean or replace.
Replace.
Replace.
Adjust or replace.
Clean or replace with needle valve seat.
Adjust float height.
8-6 SERVICING INFORMATION
Complaint
Steering is heavy.
Handlebar wobbles.
Front wheel wobbles.
Front suspension too soft.
Front suspension too stiff.
Front suspension too noisy.
Rear wheel wobbles.
Rear suspension too soft.
Rear suspension too stiff.
Rear suspension too noisy.
Symptom and possible causes
1. Overtightened steering stem nut.
2. Broken bearing in steering stem.
3. Distorted steering stem.
4. Low tire pressure.
1. Loss of balance between right and left front forks.
2. Distorted front fork.
3. Distorted front axle.
4. Twisted tire.
1. Distorted wheel rim.
2. Worn front wheel bearing.
3. Defective or incorrect tire.
4. Loose front axle nut.
5. Incorrect fork oil level.
1. Weak spring.
2. Insufficient fork oil.
3. Improper suspension setting.
1. Excessively viscous fork oil.
2. Excessive fork oil.
3. Improper suspension setting.
1. Insufficient fork oil.
2. Loose front suspension fastener.
1. Distorted wheel rim.
2. Worn rear wheel bearing.
3. Defective or incorrect tire.
4. Worn swingarm bearing.
5. Loose rear axle nut.
6. Loose rear suspension fastener.
1. Weak rear shock absorber spring.
2. Rear shock absorber leaks oil.
3. Improper suspension setting.
1. Improper suspension setting.
2. Bent rear shock absorber shaft.
3. Worn swingarm bearing and rear suspension related bearing.
1. Loose rear suspension fastener.
2. Worn swingarm bearing and rear suspension related bearing.
Remedy
Adjust.
Replace.
Replace.
Regulate.
Adjust or replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Tighten.
Adjust.
Replace.
Check level and add.
Adjust.
Replace.
Check level and drain.
Adjust.
Check level and add.
Tighten.
Replace.
Replace.
Replace.
Replace.
Tighten.
Tighten.
Replace.
Replace.
Adjust.
Adjust.
Replace.
Replace.
Tighten.
Replace.
SERVICING INFORMATION 8-7
Complaint
Brake power insufficient.
Brake squeaks.
Brake lever or pedal stroke excessive.
Brake fluid leaks.
Brake drags.
Symptom and possible causes
1. Leakage of brake fluid.
2. Worn brake pad.
3. Oil on brake pad surface.
4. Worn brake disc.
5. Air in hydraulic system.
1. Carbon adhesion on brake pad surface.
2. Tilted brake pad.
3. Damaged wheel bearing.
4. Worn brake pad.
5. Foreign material in brake fluid.
6. Clogged return port of master cylinder.
7. Loose front or rear axle nut.
1. Air in hydraulic system.
2. Insufficient brake fluid.
3. Incorrect brake fluid.
1. Loose connection joint.
2. Cracked hose.
3. Worn piston seal.
4. Worn secondary cup.
1. Rusty part.
2. Insufficient brake lever or brake pedal pivot lubrication.
Remedy
Repair or replace.
Replace.
Clean brake disc and brake pads.
Replace.
Bleed.
Clean surface with sandpaper.
Readjust brake pad position or replace.
Replace.
Replace.
Change brake fluid.
Disassemble and clean master cylinder.
Tighten.
Bleed.
Check level and add. Bleed any air.
Change.
Tighten.
Replace.
Replace.
Replace.
Clean and lubricate.
Lubricate.
8-8 SERVICING INFORMATION
Complaint
No sparking or poor sparking.
Spark plug is wet or quickly becomes fouled with carbon.
Spark plug quickly becomes fouled with oil or carbon.
Spark plug electrodes overheat or burn.
Generator does not charge.
Generator charges but charging rate is below the specifications.
Generator overcharges.
Unstable charging.
Starter button does not work. (DR-Z400E)
Symptom and possible causes
1. Defective ignition coil.
2. Defective spark plug.
3. Defective generator.
4. Defective CDI unit.
1. Excessively rich air/fuel mixture.
2. Excessively high idling speed.
3. Incorrect gasoline.
4. Dirty air cleaner element.
5. Incorrect spark plug (cold type).
1. Worn piston ring.
2. Worn piston.
3. Worn cylinder.
4. Excessive valve-stem-to-valve-guide clearance.
5. Worn valve stem oil seal.
1. Incorrect spark plug (hot type).
2. Overheated engine.
3. Loose spark plug.
4. Excessively lean air/fuel mixture.
1. Open or short in lead wires, or loose lead connections.
Remedy
Replace.
Replace.
Replace.
Replace.
Adjust carburetor.
Adjust carburetor.
Change.
Clean or replace.
Change to hot type spark plug.
Replace.
Replace.
Replace.
Replace.
Replace.
Change to cold type spark plug.
Tune-up.
Tighten.
Adjust carburetor.
Repair, replace, or connect properly.
Replace.
Replace.
Repair or tighten.
2. Shorted, grounded, or open generator coil.
3. Shorted or punctured regulator/rectifier.
1. Lead wires tend to get shorted or open-circuited or loosely connected at terminal.
2. Grounded or open-circuited stator coils or generator.
3. Defective regulator/rectifier.
4. Defective battery cell plates.
1. Internal short-circuit in the battery.
2. Damaged or defective regulator/rectifier.
3. Poorly grounded regulator/rectifier.
1. Lead wire insulation frayed due to vibration, resulting in intermittent shorting.
2. Internally shorted generator.
3. Defective regulator/rectifier.
1. Run down battery.
2. Defective switch contact.
3. Brushes do not seat properly on the commutator in the starter motor.
4. Defective starter relay.
5. Wiring connections loose or disconnected.
Replace.
Replace.
Replace battery.
Replace battery.
Replace.
Repair, replace, or connect properly.
Repair or replace.
Replace.
Replace.
Recharge or replace.
Replace.
Repair or replace.
Replace.
Tighten or repair.
SERVICING INFORMATION 8-9
Complaint
Sulfation or spots on surfaces of cell plates.
Battery runs down quickly.
Battery sulfation.
Symptom and possible causes
1. Cracked battery case.
2. Battery has been left in a run-down condition for a long time.
1. Incorrect charging method.
Replace.
Replace.
Remedy
2. Battery cell plates have lost much of their active material as a result of overcharging.
3. Internally shorted battery.
4. Excessively low battery voltage.
5. Battery is too old.
6. Dirty container top and sides.
1. Incorrect charging rate.
(When not in use, the battery should be checked at least once a month and properly charged if necessary, to avoid sulfation.)
2. The battery was left unused in a cold climate for too long.
Check generator, regulator/ rectifier circuit connections, and make necessary adjustment to obtain specified charging operation.
Replace battery and correct charging system.
Replace.
Charge.
Replace.
Clean.
Replace.
Replace the battery if badly sulfated.
8-10 SERVICING INFORMATION
B
Y
Bl
B/Y
B/W
B/W
O
W
B/Y
Bl
B
Y
G
W
Bl
W
B/W
B/Y
B/W
Bl
Y
B/W
B/W
B/W
O
Y
Y
Y
O
B/W
B/W
O
R
Y
Y
Y
B/W
Y
Y
Y
Bl
W
B
G
B
SERVICING INFORMATION 8-11
Y
B
Bl
Y/G
Y/G Y/G
Y/G
W
B/W
Bl
Y
B
G
W
Bl
B/W
W
O
B/Y
Bl
Y
B/W
B/Y
O
Y/G
O
B/Y
B/W
B/Y
B/W
B/W
Y/G R/W
B/W
O
R
R
B/W
R
Y
Y
R
Y
B/W
R
R
B/W
O
R
Gr
Y
Y
Y
Bl
G
B
W
R
Y
Y
Y
B/W
8-12 SERVICING INFORMATION
SERVICING INFORMATION 8-13
8-14 SERVICING INFORMATION
0 – 2 mm
(0 – 0.08 in)
SERVICING INFORMATION 8-15
8-16 SERVICING INFORMATION
1 Face the tip of clip to the front
2 Face the tip of clip to the bottom
SERVICING INFORMATION 8-17
8-18 SERVICING INFORMATION
SERVICING INFORMATION 8-19
09900-00401
Hexagon wrench set
09900-00410
Hexagon wrench set
09900-06104
Snap ring pliers
09900-06105
Snap ring pliers
09900-06108
Snap ring pliers
09900-09004
Impact driver set
09900-20101
Vernier calipers
09900-20103
Vernier calipers
09900-20202
Micrometer
(25 – 50 mm)
09900-20204
Micrometer
(75 – 100 mm)
09900-20205
Micrometer
(0 – 25 mm)
09900-20508
Cylinder gauge set
09900-20602
Dial gauge
(1/1000 mm)
09900-20605
Dial calipers
(1/100 mm,
10 – 34 mm)
09900-20606
Dial gauge
(1/100 mm)
09900-20701
Magnetic stand
09900-20803
Thickness gauge
09900-20805
Tire depth gauge
09900-21304
V-block set
(100 mm)
09900-22301
Plastigauge
09900-22302
Plastigauge
09900-22403
Small bore gauge
(18 – 35 mm)
09900-25008
Multi circuit tester set
09910-32812
Crankshaft installer
09910-60611
Universal clamp wrench
8-20 SERVICING INFORMATION
09913-50121
Oil seal remover
09913-70210
Bearing installer set
09915-63310
Adapter
09915-64510
Compression gauge set
09915-70610
Adapter
09915-74510
Oil pressure gauge set
09916-10911
Valve lapper set
09916-14510
Valve lifter
09916-14910
Attachment
09916-20610
Seat cutter
(N-121)
09916-21110
Valve seat
Cutter set
09916-22420
Valve seat cutter
(N-128)
09916-22430
Valve seat cutter
(N-114)
09916-24311
Solid pilot
(N-100-5.0)
09916-34542
Reamer handle
09916-34570
Valve guide reamer
(5.0 mm)
09916-34580
Valve guide reamer
(10.8 mm)
09916-44310
Valve guide remover
09916-53360
Valve guide installer attachment
09916-84511
Tweezers
09920-13120
Crankcase separating tool
09920-53740
Clutch sleeve hub holder
09921-20210
Bearing remover
09921-20220
Bearing remover set
09923-73210
Bearing remover
SERVICING INFORMATION 8-21
09923-74510
Bearing remover
09924-84510
Bearing installer set
09924-84521
Bearing installer set
09925-18010
Steering bearing installer
09930-30102
Sliding hammer
09930-31921
Rotor remover set
09930-44913
Rotor holder
09940-14911
Steering stem nut wrench
09940-14960
Steering stem nut wrench socket
09940-34520
T handle
09940-34581
Attachment F
09940-52841
Front fork inner rod holder
09940-52861
Front fork oil seal installer
09940-54821
Front fork assembly tool
09940-94922
Stopper plate
09941-34513
Bearing installer
09941-50111
Bearing remover
09941-54911
Bearing outer race remover
09941-74910
Bearing installer
09943-74111
Fork oil level gauge
8-22 SERVICING INFORMATION
Cylinder head cover bolt
ITEM
Spark plug
Cylinder head bolt
Cylinder head side bolt
Cylinder nut
Decompression shaft bolt (DR-Z400)
Decompression shaft lever nut (DR-Z400)
Camshaft journal holder bolt
Balancer shaft nut
Primary drive gear nut
Generator rotor nut
Clutch sleeve hub nut
Gearshift arm stopper
Gearshift cam driven gear bolt
Cam chain tension adjuster bolt
Cam chain tensioner mounting bolt
Cam chain tensioner spring holder bolt
Engine oil drain plug (on the crankcase)
Engine oil drain bolt (on the frame)
Engine oil lebel bolt
Crankcase bolt
Oil strainer (on the frame)
Oil hose union bolt
Radiator air bleeder bolt
TDC plug
Engine mounting nut
Engine mounting bracket nut
Exhaust pipe bolt and nut
Muffler connection bolt
Muffler mounting bolt
Engine sprocket nut
Intake pipe union
Fuel valve mounting bolt
M10
M6
40
23
20
23
23
6.0
23
66
18
6
11
23
10
10
8
21
110
8
4.4
23
10
50
110
100
70
19
24
10
14
10
10
N·m
14
11
46
16.5
4.3
16.5
47.5
29.0
16.5
14.5
16.5
7.0
7.0
6.0
15.0
13.0
4.5
8.0
16.5
79.5
6.0
3.2
16.5
7.0
36.0
79.5
72.5
50.5
13.5
17.5
lb-ft
10.0
8.0
33.5
7.0
10.0
7.0
7.0
4.0
2.3
2.0
2.3
2.3
0.6
2.3
6.6
1.8
0.6
1.1
2.3
1.0
1.0
0.8
2.1
11.0
0.8
0.44
2.3
1.0
5.0
11.0
10.0
7.0
1.9
2.4
kgf-m
1.4
1.1
4.6
1.0
1.4
1.0
1.0
ITEM
Handlebar clamp bolt
Front fork upper clamp bolt
Front fork lower clamp bolt
Steering stem head nut
Front fork cap bolt
Front fork damper rod bolt
Front fork inner rod locknut
Front brake master cylinder mounting bolt
Rear brake master cylinder mounting bolt
Brake hose union bolt (front & rear)
Front brake caliper mounting bolt
Brake pad mounting pin (front & rear)
Brake caliper plug (front & rear)
Brake air bleeder valve (front & rear)
Rear brake rod locknut
Rear brake pedal bolt
Brake disc mounting bolt (front & rear)
Front axle nut
Front axle pinch bolt
Seat rail mounting nut (upper)
Seat rail mounting bolt (lower)
Rear axle nut E-03, 28
The other countries
Rear sprocket nut
Drive chain roller mounting bolt (upper & lower)
Spoke nipple (front & rear)
Swingarm pivot nut
Rear shock absorber compression adjuster assembly
Rear shock absorber spring adjuster lock ring
Rear shock absorber mounting nut (upper & lower)
Cushion lever mounting nut (center)
Cushion lever mounting nut (front)
Cushion rod mounting nut
Side stand bolt
Side stand nut
30
90
55
100
30
40
3
77
35
35
100
110
29
10
42
18
100
100
50
55
18
2.5
7.5
18
10
10
23
26
90
23
80
22
N·m
23
30
32
SERVICING INFORMATION 8-23
3.0
4.0
0.3
7.7
3.0
9.0
5.5
10.0
2.9
1.0
4.2
1.8
3.5
3.5
10.0
11.0
10.0
10.0
5.0
5.5
1.0
1.0
2.3
2.6
1.8
0.25
0.75
1.8
kgf-m
2.3
3.0
3.2
9.0
2.3
8.0
2.2
21.5
29.0
2.0
55.5
21.5
65.0
40.0
72.5
21.0
7.0
30.5
13.0
25.5
25.5
72.5
79.5
72.5
72.5
36.0
40.0
7.0
7.0
16.5
19.0
13.0
1.8
5.5
13.0
lb-ft
16.5
21.5
23.0
65.0
16.5
58.0
16.0
8-24 SERVICING INFORMATION
For other nuts and bolts not listed in the preceding page, refer to this chart:
Bolt Diameter
A
(mm)
4
5
6
8
10
12
14
16
18
Conventional or “4” marked bolt
N·m kgf-m lb-ft
1.5
3
5.5
0.15
0.3
0.55
1.0
2.0
4.0
13
29
45
1.3
2.9
4.5
9.5
21.0
32.5
65
105
160
6.5
10.5
16.0
47.0
76.0
115.5
N·m
2.3
4.5
10
23
50
85
135
210
240
“7” marked bolt kgf-m
0.23
0.45
1.0
2.3
5.0
8.5
13.5
21.0
24.0
lb-ft
1.5
3.0
7.0
16.5
36.0
61.5
97.5
152.0
173.5
Conventional bolt “4” marked bolt “7” marked bolt
SERVICING INFORMATION 8-25
Valve diameter
ITEM
Tappet clearance (when cold)
Valve-guide-to-valve-stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve stem thickness
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
IN.
EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN.
EX.
INNER
OUTER
STANDARD
36
(1.42)
29
(1.14)
0.10 – 0.20
(0.0039 – 0.0079)
0.20 – 0.30
(0.0079 – 0.0118)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
—
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
—
—
0.9 – 1.1
(0.035 – 0.043)
—
—
—
56 – 64 N
(5.6 – 6.4 kgf, 12.3 – 14.1 lbs) at length 27.4 mm (1.08 in)
126 – 145 N
(12.6 – 14.5 kgf, 27.7 – 32.0 lbs) at length 30.9 mm (1.22 in)
Unit: mm (in)
LIMIT
—
—
—
—
—
—
0.35
(0.014)
—
—
—
0.05
(0.002)
0.5
(0.02)
—
0.03
(0.001)
32.6
(1.28)
36.3
(1.43)
—
—
8-26 SERVICING INFORMATION
ITEM
Cam height
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Cam chain pin (at arrow “3”)
Cylinder head distortion
Cylinder head cover distortion
Decompression cable play (DR-Z400)
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
36.910 – 36.960
(1.4531 – 1.4551)
36.880 – 36.930
(1.4520 – 1.4539)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8653 – 0.8659)
—
15th pin
—
—
0 – 0.1
(0 – 0.004)
ITEM
Compression pressure (DR-Z400E)
(Automatic decompression actuated)
STANDARD
1 000 kPa
(10.0 kgf/cm 2 , 142 psi)
Piston-to-cylinder clearance
Cylinder bore
Piston diameter
0.030 – 0.040
(0.0012 – 0.0016)
90.000 – 90.015
(3.5433 – 3.5439)
89.965 – 89.980
(3.5419 – 3.5425)
Measure 15 (0.6) from the skirt end
Cylinder distortion
—
Piston ring free end gap
1st
R
Approximately 6.9 (0.27)
2nd
Piston ring end gap
Piston-ring-to-piston-ring-groove clearance
1st & 2nd
1st
2nd
R Approximately 11.5 (0.45)
0.08 – 0.20
(0.003 – 0.008)
—
—
—
0.10
(0.004)
—
0.05
(0.002)
0.05
(0.002)
—
Unit: mm (in)
LIMIT
36.610
(1.4413)
36.580
(1.4402)
0.150
(0.0059)
—
Unit: mm (in)
LIMIT
—
0.120
(0.0047)
Nicks or scratches
89.880
(3.5386)
0.05
(0.002)
5.5
(0.22)
9.2
(0.36)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
ITEM
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
ITEM
Conrod small end I.D.
Crank-web-to-crank-web width
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crankshaft runout
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
1st
2nd
Oil
1st
2nd
SERVICING INFORMATION 8-27
STANDARD
0.78 – 0.80 (0.0307 – 0.0315)
1.30 – 1.32 (0.0512 – 0.0520)
0.81 – 0.83
(0.0319 – 0.0327)
2.01 – 2.03
(0.0791 – 0.0799)
0.71 – 0.76 (0.0280 – 0.0299)
1.08 – 1.10 (0.0425 – 0.0433)
0.77 – 0.79
(0.0303 – 0.0311)
20.002 – 20.008
(0.7875 – 0.7877)
19.995 – 20.000
(0.7872 – 0.7874)
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
62.0 ± 0.1
(2.441 ± 0.004)
—
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
—
STANDARD
2.220 (74/25
×
20/16
Above 40 kPa (0.4 kgf/cm
Below 140 kPa (1.4 kgf/cm at 3000 r/min
×
12/20)
2 , 5.7 psi)
2
, 19.9 psi)
LIMIT
—
—
—
—
—
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
LIMIT
20.040
(0.7890)
—
3.0
(0.12)
1.0
(0.04)
—
0.08
(0.003)
Unit: mm (in)
LIMIT
—
—
8-28 SERVICING INFORMATION
Clutch lever play
ITEM
Clutch drive plate thickness
(No. 1 & No. 2)
Clutch drive plate claw width
(No. 1 & No. 2)
Clutch drive plate distortion
Clutch spring free length
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
—
—
Unit: mm (in)
LIMIT
—
2.62
(0.103)
13.2
(0.520)
0.10
(0.004)
49.9
(1.96)
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Gearshift-fork-to-gearshift-fork-groove clearance
Gearshift fork groove width
Gearshift fork thickness
Drive chain
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
Type
Links
20-pitch length
STANDARD
2.960 (74/25)
3.357 (47/14)
2.285 (32/14)
1.733 (26/15)
1.375 (22/16)
1.090 (24/22)
0.863 (19/22)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
4.6 – 4.7
(0.181 – 0.185)
RK520KZO
112
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
0.5
(0.02)
—
—
—
—
319.4
(12.57)
Drive chain slack 40 – 50
(1.6 – 2.0)
—
SERVICING INFORMATION 8-29
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Main air jet
Jet needle
Needle jet
Slow jet
Slow air jet
Air jet
Pilot screw
Throttle cable play
(M.J.)
(M.A.J.)
(J.N.)
(N.J.)
(S.J.)
(S.A.J.)
(A.J.)
(P.S.)
SPECIFICATION
E-01
DR-Z400
KEIHIN FCR39H
39 mm (1.5 in)
E-03, 28
←
←
E-01
←
←
DR-Z400E
E-03, 28
←
←
29F0
1800 ± 100 r/min
9.0 ± 1.0 mm (0.35 ± 0.04 in)
29F1
←
←
29F3
←
←
29F4
←
←
#165
#200
OBDXP-4th
2.9 mm (0.11 in)
#45
#60
#90
1 1/2 turns out
2 – 4 mm (0.08 – 0.16 in)
#142
←
←
←
←
←
←
←
←
#165
←
←
←
←
←
←
←
←
#142
←
←
←
←
←
←
←
←
ITEM
Radiator cap valve opening pressure
STANDARD/SPECIFICATION
95 – 125 kPa
(0.95 – 1.25 kgf/cm
2
, 13.5 – 17.8 psi)
Engine coolant type Use an antifreeze/coolant compatible with aluminum radiators, mixed with distilled water only, at the ratio of 50:50
Engine coolant capacity 1 250 ml
(1.3 US qt, 1.1 lmp qt)
NOTE
8-30 SERVICING INFORMATION
ITEM
Rear brake pedal height
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diameter
Brake caliper cylinder bore
Brake caliper piston diameter
Brake fluid type
Wheel rim runout
Wheel rim size
Wheel axle runout
Front
Rear
STANDARD/SPECIFICATION
5
(0.2)
3.0 ± 0.2
(0.118 ± 0.008)
4.5 ± 0.2
(0.177 ± 0.008)
Front &
Rear
—
Front
Rear
Front
Rear
Front
Rear
Front
Rear
11.000 – 11.043
(0.4331 – 0.4348)
12.700 – 12.743
(0.5000 – 0.5017)
10.957 – 10.984
(0.4314 – 0.4324)
12.657 – 12.684
(0.4983 – 0.4994)
27.000 – 27.050
(1.0630 – 1.0650)
27.000 – 27.050
(1.0630 – 1.0650)
26.900 – 26.950
(1.0591 – 1.0610)
26.900 – 26.950
(1.0591 – 1.0610)
DOT 4
Axial —
Radial
Front
Rear
Front
Rear
—
1.60
×
21
2.15
×
18
—
—
Unit: mm (in)
LIMIT
—
2.5
(0.10)
4.0
(0.16)
0.30
(0.01)
—
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
—
—
0.25
(0.010)
0.25
(0.010)
SERVICING INFORMATION 8-31
ITEM
Cold inflation tire pressure (Solo riding)
Tire size
Tire tread depth
Front
Rear
Front
Rear
STANDARD/SPECIFICATION
100 kPa (1.0 kgf/cm 2 , 14 psi)
100 kPa (1.0 kgf/cm
2
, 14 psi)
80/100 – 21 51M
110/100 – 18 64M
Front —
Rear —
Front fork stroke
ITEM
Front fork spring free length
Front fork oil level (without spring)
Front fork oil type
STANDARD/SPECIFICATION
288
(11.3)
510.6
(20.1)
122
(4.8)
SUZUKI FORK OIL SS-05 or an equivalent fork oil
Front fork oil capacity (each leg)
Front fork damping force adjuster
Rear shock absorber gas pressure
Rear shock absorber oil type
Rear shock absorber oil capacity
Rear shock absorber spring pre-set length
Rear shock absorber damping force adjuster
Rear wheel travel
Rebound
Compression
720 ml
(24.3 US oz, 25.4 lmp oz)
15 clicks out
12 clicks out
900 kPa
(9.0 kgf/cm 2 , 128 psi)
SUZUKI REAR SUSPENSION OIL SS-25 or an equivalent suspension oil
Rebound
Compression
380 ml
(12.8 US oz, 13.4 lmp oz)
258.0
(10.2)
13 clicks out
12 clicks out
295
(11.6)
Swingarm pivot shaft runout
—
Unit: mm (in)
LIMIT
—
—
—
—
4.0
(0.16)
4.0
(0.16)
—
—
—
—
—
—
0.3
(0.01)
—
—
—
—
—
Unit: mm (in)
LIMIT
—
500
(19.7)
—
8-32 SERVICING INFORMATION
Spark plug
ITEM
Spark performance
Ignition coil resistance
Ignition coil primary peak voltage
Generator coil resistance
Pickup coil peak voltage
Signal coil peak voltage
Generator no-load voltage
(when engine is cold)
Regulated voltage
Generator maximum output
Starter relay resistance
Battery Type designation
Capacity
Type
SPECIFICATION
NGK: CR8E
DENSO: U24 ESR-N
Gap
0.7 – 0.8
(0.028 – 0.031)
Primary
Secondary
Over 8 (0.3) at 1 atm.
0.1 – 1.0
Ω
12 – 20 k
Ω
More than 150 V ( + :B/W, :B/Y)
Signal coil
Pickup coil
Charging coil
0.05 – 0.20
Ω
390 – 600
Ω
0.50 – 1.25
Ω
More than 10.0 V ( + :Bl, :G)
More than 5.0 V ( + :Bl, :G)
More than 1.0 V ( + :B, :W)
More than 1.4 V ( + :B, :W)
More than 55 V (AC) at 5 000 r/min (Y–Y)
More than 75V (AC) at 5 000 r/min (Y–Y)
12.5 – 14.0 V at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
150 W at 5 000 r/min
200 W at 5 000 r/min
3 – 5
Ω
GT7B-4
12 V 23.4 kC (6.5 Ah)/10 HR
Headlight
Taillight
ITEM SPECIFICATION
55
LED
Unit: mm (in)
NOTE
Terminal – Ground
Plug cap – Terminal
B – W
G – Bl
Y – Y
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400E
DR-Z400E
Unit: W
Fuel type
ITEM
Fuel tank including reserve
Engine oil type
Engine oil capacity reserve
SERVICING INFORMATION 8-33
SPECIFICATION
Use only unleaded gasoline of at least 90 pump octane ( ).
2
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 95 octane or higher. An unleaded gasoline is recommended.
10.0 L
(2.6 US gal, 2.2 lmp gal)
2.3 L
(0.6 US gal, 0.5 lmp gal)
SAE 10 W-40, API SF or SG
Change
Filter change
Overhaul
1 700 ml
(1.8 US qt, 1.5 Imp qt)
1 800 ml
(1.9 US qt, 1.6 Imp qt)
1 900 ml
(2.0 US qt, 1.7 Imp qt)
NOTE
E-03, 28
E-01
DR-Z400EY (E-24 MODEL)
DR-Z400EY (E-24 MODEL)
9-1
CONTENTS
SPECIFICATIONS .................................................................................... 9- 2
SERVICE DATA ........................................................................................ 9- 4
SIDE-STAND/IGNITION INTERLOCK SYSTEM ...................................... 9-12
SWITCHES ............................................................................................... 9-13
SPEEDOMETER ...................................................................................... 9-14
WIRING DIAGRAM ................................................................................... 9-17
WIRE, CABLE AND HOSE ROUTING ..................................................... 9-18
9
9-2 DR-Z400EY (E-24 MODEL)
Overall length ................................................... 2 310 mm (90.9 in)
Overall width ....................................................
825 mm (32.5 in)
Overall height ................................................... 1 245 mm (49.0 in)
Wheelbase ....................................................... 1 475 mm (58.1 in)
Ground clearance ............................................
315 mm (12.4 in)
Seat height .......................................................
935 mm (36.8 in)
Dry mass ..........................................................
127 kg (279 lbs)
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 cm
3
(24.3 cu. in)
Compression ratio ............................................ 12.2 : 1
Carburetor ........................................................ KEIHIN FCR39
Air cleaner ........................................................ Polyurethane foam element
Starter system .................................................. Electric
Lubrication system ........................................... Dry sump
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 ......................................... 3.357 (47/14)
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
DR-Z400EY (E-24 MODEL) 9-3
Front suspension ............................................. Telescopic, coil spring, oil damped, rebound damping force
18-way adjustable, compression damping force 14-way adjustable
Rear suspension .............................................. Link type, coil spring, oil damped, spring preload fully adjustable, rebound damping force 21-way adjustable, compression damping force 26-way adjustable
Front fork stroke ............................................... 288 mm (11.3 in)
Rear wheel travel ............................................. 295 mm (11.6 in)
Caster .............................................................. 27° 20´
Trail ................................................................... 112 mm (4.41 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
Ignition type ..................................................... Electronic ignition (CDI)
Ignition timing ................................................... 7° BTDC at 1 800 r/min
Spark plug ........................................................ NGK: CR8E
DENSO: U24ESR-N
Generator ......................................................... Three-phase A.C. generator
Battery ............................................................. 12 V 23.4 kC (6.5 Ah)/10 HR
Fuse ................................................................. * 20 A
Headlight .......................................................... * 12 V 60/55 W
Brake light/Taillight ........................................... * 12 V 21/5 W
Turn signal light ................................................ * 12 V 21 W
Speedometer light ............................................ * LED
Neutral indicator light ....................................... * 12 V 2 W
High beam indicator light ................................. * 12 V 2 W
Turn signal indicator light ................................. * 12 V 2 W
Fuel tank, including reserve ............................ 10.0 L (2.6 US gal, 2.2 Imp gal) 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 .....................................................
720 ml (24.3 US oz, 25.4 Imp oz)
Engine coolant ................................................. 1 250 ml (1.3 US qt, 1.1 Imp qt)
9-4 DR-Z400EY (E-24 MODEL)
ITEM
Valve diam.
Tappet clearance (when cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve head thickness
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension (IN. & EX.)
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
INNER
OUTER
STANDARD
36
(1.42)
29
(1.14)
0.10 – 0.20
(0.0039 – 0.0078)
0.20 – 0.30
(0.0078 – 0.0118)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
———
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
———
———
0.9 – 1.1
(0.035 – 0.043)
———
———
———
56 – 64 N
(5.6 – 6.4 kgf, 12.3 – 14.1 lbs) at length 27.4 mm (1.08 in)
126 – 145 N
(12.6 – 14.5 kgf, 27.7 – 32.0 lbs) at length 30.9 mm (1.22 in)
Unit: mm (in)
LIMIT
———
———
———
———
———
———
0.35
(0.014)
———
———
———
0.05
(0.002)
0.5
(0.02)
———
0.03
(0.001)
32.6
(1.28)
36.3
(1.43)
———
———
DR-Z400EY (E-24 MODEL) 9-5
ITEM
Cam height
IN.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Cam chain pin (at arrow “3”)
Cylinder head distortion
Cylinder head cover distortion
EX.
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
36.910 – 36.960
(1.4531 – 1.4551)
36.880 – 36.930
(1.4520 – 1.4539)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8653 – 0.8659)
———
15th pin
———
———
ITEM
Compression pressure
(Automatic de-comp. actuated)
Piston to cylinder clearance
Cylinder bore
Piston diam.
STANDARD
1 000 kPa
( 10.0 kgf/cm 2
142 psi
)
0.030 – 0.040
(0.0012 – 0.0016)
90.000 – 90.015
(3.5433 – 3.5439)
89.965 – 89.980
(3.5419 – 3.5425)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
———
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
1st R
2nd R
1st
2nd
1st
Approx.
6.9
(0.27)
Approx.
11.5
(0.45)
0.08 – 0.20
(0.003 – 0.008)
0.08 – 0.20
(0.003 – 0.008)
———
2nd
———
Unit: mm (in)
LIMIT
36.610
(1.4413)
36.580
(1.4402)
0.150
(0.0059)
———
———
0.10
(0.004)
———
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
———
0.120
(0.0047)
Nicks or
Scratches
89.880
(3.5386)
0.05
(0.002)
5.5
(0.22)
9.2
(0.36)
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
9-6 DR-Z400EY (E-24 MODEL)
ITEM
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
1st
2nd
Oil
1st
2nd
STANDARD
2.220 (74/25 × 20/16 × 12/20)
Above 40 kPa (0.4 kgf/cm
2
, 5.7 psi)
Below 140 kPa (1.4 kgf/cm 2 , 19.9 psi) at 3 000 r/min.
STANDARD
0.78 – 0.80
(0.0307 – 0.0315)
1.30 – 1.32
(0.0512 – 0.0520)
0.81 – 0.83
(0.0319 – 0.0327)
2.01 – 2.03
(0.0791 – 0.0799)
0.71 – 0.76
(0.0280 – 0.0299)
1.08 – 1.10
(0.0425 – 0.0433)
0.77 – 0.79
(0.0303 – 0.0311)
20.002 – 20.008
(0.7875 – 0.7877)
19.995 – 20.000
(0.7872 – 0.7874)
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
———
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
———
LIMIT
———
———
———
———
———
———
———
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
LIMIT
20.040
(0.7890)
3.0
(0.12)
1.0
(0.04)
———
———
0.08
(0.003)
LIMIT
———
———
DR-Z400EY (E-24 MODEL) 9-7
ITEM
Clutch cable play
Drive plate thickness
(No. 1 & No. 2)
Drive plate claw width
(No. 1 & No. 2)
Driven plate distortion
Clutch spring free length
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
———
———
Unit: mm (in)
LIMIT
———
2.62
(0.103)
13.2
(0.520)
0.10
(0.004)
49.9
(1.96)
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
No.1, No.2
& No.3
No.1, No.2
& No.3
Type
Links
20-pitch length
STANDARD
2.960 (74/25)
3.357 (47/14)
2.285 (32/14)
1.733 (26/15)
1.375 (22/16)
1.090 (24/22)
0.863 (19/22)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
4.6 – 4.7
(0.181 – 0.185)
RK520KZO
112
———
Drive chain slack 40 – 50
(1.6 – 2.0)
ITEM
Carburetor type
Bore size
I.D. No
Idle r/min.
Float height
Main jet
Jet needle
Needle jet
(M.J.)
(J.N.)
(N.J.)
SPECIFICATION
KEIHIN FCR39H
39 mm
(1.5 in)
* 29F6
1 800 ± 100 r/min
9.0 ± 1.0 mm
(0.35 ± 0.04 in)
#165
OBDXP-4th
2.9 mm
(0.11 in)
Unit: mm (in) Except ratio
LIMIT
———
———
———
———
———
———
———
0.5
(0.020)
———
———
———
———
319.4
(12.57)
———
9-8 DR-Z400EY (E-24 MODEL)
ITEM
Slow jet
Slow air jet
Air jet
Pilot screw
Throttle cable play
(pulling cable)
(S.J.)
(S.A.J.)
(A.J.)
(P.S.)
SPECIFICATION
#45
#60
#90
* 2¾ turns back
2 – 4 mm
(0.08 – 0.16 in)
ITEM
Radiator cap valve opening pressure
Engine coolant type
Engine coolant capacity
STANDARD/SPECIFICATION
95 – 125 kPa
(0.95 – 1.25 kgf/cm 2 , 13.5 – 17.8 psi)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50 : 50.
1 250 ml
(1.3/1.1 US/Imp qt)
ITEM
Brake lever play
Rear brake pedal height
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Front
Rear
STANDARD/SPECIFICATION
0.1 – 0.3
(0.004 – 0.010)
5
(0.2)
3.0 ± 0.2
(0.118 ± 0.008)
4.5 ± 0.2
(0.177 ± 0.008)
Front
Rear
Front
Rear
Front
Rear
Front
Rear
———
* 12.700 – 12.743
(0.5000 – 0.5017)
12.700 – 12.743
(0.5000 – 0.5017)
* 12.657 – 12.684
(0.4983 – 0.4994)
12.657 – 12.684
(0.4983 – 0.4994)
27.000 – 27.050
(1.0630 – 1.0650)
27.000 – 27.050
(1.0630 – 1.0650)
26.900 – 26.950
(1.0591 – 1.0610)
26.900 – 26.950
(1.0591 – 1.0610)
DOT 4
NOTE
———
———
———
———
———
———
———
Unit: mm (in)
LIMIT
———
———
2.5
(0.098)
4.0
(0.16)
0.30
(0.012)
———
———
ITEM
Wheel rim runout
Wheel axle runout
Axial
Radial
Front
Rear
Front
Rear
STANDARD
———
———
———
———
1.60 × 21
2.15 × 18
DR-Z400EY (E-24 MODEL) 9-9
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
———
———
Wheel rim size
ITEM
Cold inflation tire pressure
(Solo riding)
Tire size
Tire tread depth
Front
Rear
Front
Rear
STANDARD/SPECIFICATION
* 125 kPa (1.25 kgf/cm
2
, 18 psi)
* 125 kPa (1.25 kgf/cm 2 , 18 psi)
* 80/100-21 51P
* 120/90-18 65P
Front ———
Rear ———
ITEM
Front fork stroke
STANDARD/SPECIFICATION
288
(11.3)
Front fork spring free length
Front fork oil level
(without spring)
Front fork oil type
510.6
(20.1)
122
(4.8)
Front fork oil capacity
(each leg)
Front fork damping force adjuster Rebound
Compression
SUZUKI FORK OIL SS-05 or an equivalent fork oil
720 ml
(24.3/25.4 US/Imp oz)
15th clicks turn back
12th clicks turn back
Rear shock absorber gas pressure
Rear shock absorber oil type
Rear shock absorber oil capacity
Rear shock absorber spring pre-set length
Rear shock absorber damping force adjuster
900 kPa
(9.0 kgf/cm 2 , 128 psi)
SUZUKI REAR SUSPENSION OIL SS-25 or an equivalent suspension oil
Rebound
Compression
380 ml
(12.8/13.4 US/Imp oz)
258.0
(10.2)
13th clicks turn back
12th clicks turn back
LIMIT
———
———
———
———
4.0 mm
(0.16 in)
4.0 mm
(0.16 in)
———
———
———
———
———
———
———
———
———
Unit: mm (in)
LIMIT
———
500
(19.7)
———
———
9-10 DR-Z400EY (E-24 MODEL)
ITEM
Rear wheel travel
Swingarm pivot shaft runout
STANDARD/SPECIFICATION
295
(11.6)
———
Spark plug
ITEM
Spark performance
Ignition coil resistance
Ignition coil primary peak voltage
Type
Gap
Primary
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8 mm
(0.028 – 0.031 mm)
Over 8 mm (0.3 in) at 1 atm.
0.1 – 1.0
Ω
Secondary 12 – 20 k
Ω
More than 150 V
Generator coil resistance
Pick-up coil peak voltage
Signal coil peak voltage
Generator no-load voltage
(when engine is cold)
Regulated voltage
Generator Max. output
Starter relay resistance
Battery Type designation
Capacity
Fuse size
Charging
Signal coil
Pick-up coil
0.50 – 1.25
Ω
0.05 – 0.20
Ω
390 – 600
Ω
More than 5.0 V
More than 1.4 V
More than 75 V (AC) at 5 000 r/min.
13.5 – 15.0 V at 5 000 r/min.
200 W at 5 000 r/min.
3 – 5
Ω
GT7B-4
12 V 23.4 kC (6.5 Ah)/10 HR
* 20 A
Headlight
ITEM
Brake light/Taillight
Turn signal light
Speedometer light
Neutral indicator light
High beam indicator light
Turn signal indicator light
HI
LO
SPECIFICATION
* 60
* 55
* 21/5
* 21
* LED
* 2
* 2
* 2
LIMIT
———
0.3
(0.01)
NOTE
Terminal –
Ground
Plug cap –
Terminal
+
: B/W,
-
: B/Y
Y – Y
B – W
G – Bl
+
: Bl,
-
: G
+
: B,
-
: W
Y – Y
Unit: W
DR-Z400EY (E-24 MODEL) 9-11
ITEM
Fuel type
Fuel tank including reserve reserve
Engine oil type
Engine oil capacity
SPECIFICATION
Gasoline used should be graded 95 octane or higher. An unleaded gasoline is recommended.
Change
10.0 L
(2.6/2.2 US/lmp gal)
2.3 L
(0.6/0.5 US/lmp gal)
SAE 10W/40, API SF or SG
1 700 ml
(1.8/1.5 US/lmp qt)
Filter change
Overhaul
1 800 ml
(1.9/1.6 US/lmp qt)
1 900 ml
(2.0/1.7 US/lmp qt)
NOTE
9-12 DR-Z400EY (E-24 MODEL)
This side-stand/ignition interlock system is to prevent starting the motorcycle with the side-stand left down.
First check the insulation between
D
and
E
terminals with the tester. Then apply 12 V to terminals
D
and
C
(
+
to
D
and
-
to
C
) and check the continuity between
D
and
E
. If there is no continuity, replace the turn signal/side-stand relay with a new one.
[
09900-25008: Multi circuit tester set
<
Tester knob indication: Continuity test (
>
)
Side-stand relay
Diode
Turn signal relay
Measure the voltage between the terminals using the multi circuit tester. Refer to the following table.
Unit: V
C
,
B
A
+
Probe of tester to:
C
,
B
0.4 – 0.6
A
1.4 – 1.5
[
09900-25008: Multi circuit tester set
Tester knob indication: Diode test (
=
)
(
9-13
)
Disconnect the side-stand switch lead wire coupler and measure the voltage between Green and Black/White lead wires.
[
09900-25008: Multi circuit tester set
Tester knob indication: Diode test (
=
)
ON
(Up-right position)
OFF
(Down position)
Green Black/White
(
+
Probe) (
-
Probe)
0.4 – 0.6 V
1.4 – 1.5 V
DR-Z400EY (E-24 MODEL) 9-13
Measure each switch for continuity using a multi circuit tester. If any abnormality is found, replace the respective switch assemblies with a new one.
[
09900-25008: Multi circuit tester set
IGNITION SWITCH
Position
Color
ON
OFF
R O
STARTER BUTTON
Position
Color
PUSH
O/W Y/G
ENGINE STOP SWITCH
Color
Position
OFF (
¡
)
RUN (
)
O/Y
TURN SIGNAL SWITCH
Color
Position
L (
)
PUSH
R (
)
Lg Lbl
DIMMER SWITCH
Color
Position
HI (
)
LO (
)
Y/W
PASSING LIGHT SWITCH
Position
Color
PUSH
O/R
W
O/W
Y
B
Y
HORN BUTTON
Position
Color
PUSH
B/Bl
NEUTRAL SWITCH
Position
Color
ON
OFF
Bl
WIRE COLOR
B : Black
Bl : Blue
Lbl : Light blue
Lg : Light green
O : Orange
R : Red
W : White
Y : Yellow
B/Bl : Black with Blue tracer
B/R : Black with Red tracer
B/W : Black with White tracer
O/R : Orange with Red tracer
O/W: Orange with White tracer
O/Y : Orange with Yellow tracer
W/B : White with Black tracer
Y/G : Yellow with Green tracer
Y/W : Yellow with White tracer
B/W
Ground
FRONT BRAKE LIGHT SWITCH
Position
Color
ON
OFF
B
REAR BRAKE LIGHT SWITCH
Position
Color
ON
OFF
O
B/R
W/B
9-14 DR-Z400EY (E-24 MODEL)
N
TRIP
A
TRIP TIME
MODE
km/h
TRIP
TOTAL
B
TIME
CLOCK
TRIP
TIME/
TRIP
+ –
SET ADJUST
SELECT
1
Turn signal indicator light
2
Neutral indicator light
3
High beam indicator light
4
Engine coolant temperature indicator light
5
Tripmeter A
6
Speedometer
7
Clock/stopwatch/timer
8
Tripmeter B/odometer
9
ADJUST button
0
SET TIME/TRIP button
A
SET TRIP button
B
MODE TIME button
C
MODE TRIP button
INITIAL DISPLAY
When the ignition switch is set to ON, all indicators light up for one second.
CHANGING THE DISPLAY MODE
With each press of the MODE TRIP button, the display changes between tripmeter A, tripmeter B and the odometer as shown below.
TRIP TIME
MODE
Tripmeter A
TRIP
A
TOTAL
Odometer Tripmeter A
TRIP
A
TRIP
B
Tripmeter B Tripmeter A
TRIP
A
TRIP
B
Tripmeter B
DR-Z400EY (E-24 MODEL) 9-15
With each press of the MODE TIME button, the display changes between the clock, the stopwatch and the timer as shown below.
Clock Stopwatch Timer
TRIP TIME
TIME
CLOCK
TIME
CLOCK
TIME
CLOCK
MODE
"
To avoid riding with only one hand, do not operate the buttons while riding.
ODOMETER
Displays the total distance travelled
TRIP TIME
MODE
TOTAL
TRIPMETER
Displays the distance travelled since the tripmeter was last reset.
TRIP TIME
MODE
TRIP
A
TRIP
B
Switching between addition and subtraction modes
TRIP
TIME/
TRIP
SET
S u b t r a c t i o n mode
TRIP
A
TRIP
B
No sign indicates addition mode.
Make addition or subtraction calculations.
Press the SET TRIP button to reset the tripmeter.
TRIP
TIME/
TRIP
+ –
ADJUST
SET
Displays the distance with a calibration coefficient (70 – 130 %) applied
Hold down the SET TIME/TRIP button for three seconds.
TRIP
SET
TIME/
TRIP
Select the calibration coefficient.
+ –
ADJUST
TRIP
A
TRIP
B
Return to the normal display.
TRIP
TIME/
TRIP
SET
9-16 DR-Z400EY (E-24 MODEL)
CLOCK
Displays the time (hours, minutes and seconds) on a 24-hour clock
TRIP TIME
TIME
CLOCK
MODE
Setting the time
Hold down the MODE TIME button for three seconds.
sec.
min.
hour
TRIP TIME
No
Flashing
MODE
TIME
CLOCK
Select the correct time.
The setting that is flashing can be changed.
+ –
ADJUST
TRIP
TIME/
TRIP
SET
Return to the normal display.
TRIP TIME
MODE
STOPWATCH
This 24-hour stopwatch displays the minutes, seconds and
1/100 seconds up to one hour. After one hour, the hours, minutes and seconds are displayed.
TRIP TIME
TIME
MODE
Start
TRIP
TIME/
TRIP
TIME
SET
Stop
TRIP
TIME/
TRIP
SET
TIME
Hold down the button for three seconds to reset the stopwatch.
TIMER
This 24-hour timer (or countdown timer) displays the minutes, seconds and 1/100 seconds up to one hour. After one hour, the hours, minutes and seconds are displayed.
TRIP TIME
TIME
MODE
Set the timer.
TRIP
TIME/
TRIP
SET
The setting that is flashing can be changed.
TRIP
TIME/
TRIP
SET sec.
min.
hour
+ –
Select the time that the timer will countdown from.
TRIP
TIME/
TRIP
Stop
SET
ADJUST
Finish entering settings.
Hold down the button for three seconds to reset the timer.
TRIP
TIME/
TRIP
SET
TRIP
TIME/
TRIP
SET
TIME
Start
TRIP
TIME/
TRIP
SET
TIME
O O
R R
Gr Gr Gr
W/B W/B W/B
O O
Y/W
O/W
O O
O/B O/B O/B
Y/W Y/W
O/W O/W
O O
R R
O O
B/W B/W B/W
Y Y
B/W B/W B/W
O O
Bl/B Bl/B Bl/B
Lg Lg Lg
B B
W W
B/W B/W B/W
O O
R R
B/W B/W B/W
B B
B/Bl B/Bl B/Bl
B/O B/O B/O
B/R B/R B/R
B/Lg B/Lg B/Lg
O O
R R
Gr Gr Gr
B/W
B/W
B/W B/W
B/W B/W
B/Y B/Y B/Y
O/Y O/Y O/Y
O O
O O
O O
O/W
Y/G Y/G Y/G
B B
O/W O/W
O O
W/B W/B W/B
G G
B/W B/W B/W
B B
Y Y
Bl Bl Bl
W W
B/W B/W B/W
G G
O/W O/W O/W
O O
W/B W/B W/B
B B
G G
Y Y
Bl Bl Bl
W W
Bl Bl Bl
Bl Bl Bl
Y Y
B/W B/W B/W
G G
B/W B/W B/W
DR-Z400EY (E-24 MODEL) 9-17
B/W B/W B/W
R R
R R
B/W B/W B/W
Y/B Y/B Y/B
R R
B/W B/W B/W
R R
Bl/W Bl/W Bl/W
R/W R/W R/W
Y/B Y/B Y/B
Lbl Lb Lbl
O O
Y/G Y/G Y/G
G G
Y Y
Y Y
Y Y
R R
B/W B/W B/W
Bl/B Bl/B Bl/B
Bl Bl Bl
Bl L
O O
B/Bl B/Bl B/Bl
Y/G Y/G Y/G
Y/G Y/G Y/G
Y Y
Y/W Y/W Y/W
W W
Y Y
B/Bl B/Bl B/Bl
B/W B/W B/W
B/W B/W B/W
Lbl Lb Lbl
B B
Lg Lg Lg
O/B O/B O/B
Y/G Y/G Y/G
Bl L
Y Y
Y/W Y/W
B/Bl B/Bl
Y/W
B/Bl
B/W B/W B/W
Lbl Lb Lbl
B B
Lg Lg Lg
O/R O/R O/R
Y Y
Y Y
Y Y
R R
B/W B/W B/W
Y Y
Y Y
Y Y
Bl Bl Bl
G G
B B
W W
9-18 DR-Z400EY (E-24 MODEL)
battery terminal
Fuse
battery terminal
Clamp
Wire harness
battery lead wire
Clamp
Wire harness
battery lead wire
Side stand switch
Neutral switch
battery lead wire
Clamp
Clamp
Wire harness
Starter moter
Clamp
Engine stop switch
Throttle cable
Clutch cable
Clamp
Wire harness
Clamp
battery lead wire
Clamp
Turn signal light
Brake light/taillight
Starter motor terminal
1
Set
+
battery and
-
battery coupler between frame and fuse holder.
2
Push the couplers into the frame.
Front brake light switch
Clamp
DR-Z400EY (E-24 MODEL) 9-19
Clamp
Handlebar switch (R)
Clamp
Wire harness
Clamp
Handlebar switch (L)
Clutch switch
Clutch cable
Clamp
Wire harness
Engine stop switch
Throttle cable
Clamp
Generator
Regulator/rectifier
Side stand switch
Neutral switch
battery lead wire
Throttle position sensor
Generator
Regulator/rectifier
Side stand switch
Neutral switch
battery lead wire
Clamp
Side stand switch
Clamp
Clamp
Generator
Neutral switch
1
Front turn signal light (L) lead wire must be passed over the clutch cable.
2
Set the regulator/rectifier, and throttle position sensor couplers in this order, under the frame.
9-20 DR-Z400EY (E-24 MODEL)
DR-Z400EY (E-24 MODEL) 9-21
Speedometer assembly
A
5
–
10 mm
(0.2
–
0.
4
) in
Headlight bracket
Clamp
Speedometer cable
Speedometer gearbox stopper
Speedometer cable
Front fork stopper
9-22 DR-Z400EY (E-24 MODEL)
Green mark
Align the green mark on the brake hose with the lower end of the brake hose clamp.
1
After touching the brake hose union to the stopper, tighten the union bolt to the specified torque.
2
Set brake hose in front of throttle cables.
3
Set brake hose in front of clutch cable.
DR-Z400/EK1 (’01-MODEL) 10-1
DR-Z400/EK1 (’01-MODEL)
CONTENTS
SPECIFICATIONS .................................................................................. 10- 2
DR-Z400/E (For E-01, 03 and 28) ..................................................... 10- 2
DR-Z400E (For E-24) ........................................................................ 10- 4
SERVICE DATA ...................................................................................... 10- 6
DR-Z400/E (For E-01, 03 and 28) ..................................................... 10- 6
DR-Z400E (For E-24) ........................................................................ 10-14
BATTERY (DR-Z400E) ........................................................................... 10-22
10
10-2 DR-Z400/EK1 (’01-MODEL)
Overall length .........................................................
2 235 mm (88.0 in)
Overall width ..........................................................
825 mm (32.5 in)
Overall height .........................................................
1 245 mm (49.0 in)
Wheelbase .............................................................
1 475 mm (58.1 in)
Ground clearance ..................................................
325 mm (12.8 in)
Seat height .............................................................
Dry mass ................................................................
945 mm (37.2 in)
113 kg (249 lbs) ..... DR-Z400
119 kg (262 lbs) ..... DR-Z400E
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 cm 3 (24.3 cu. in)
Compression ratio ..................................................
12.2 : 1
Carburetor ..............................................................
KEIHIN FCR39
Air cleaner ..............................................................
Polyurethane foam element
Starter system ........................................................
Primary kick ..... DR-Z400
Electric ..... DR-Z400E
Lubrication system .................................................
Dry sump
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 ...............................................
3.357 (47/14)
Gear ratios, Low ....................................................
2.285 (32/14)
2nd ....................................................
1.733 (26/15)
3nd ....................................................
1.375 (22/16)
4nd ....................................................
1.090 (24/22)
Top .....................................................
0.863 (19/22)
Drive chain .............................................................
RK520KZO, 112 links
DR-Z400/EK1 (’01-MODEL) 10-3
Front suspension ...................................................
Telescopic, coil spring, oil damped, rebound damping force 18-way adjustable, compression damping force
14-way adjustable
Rear suspension ....................................................
Link type, coil spring, oil damped, spring preload fully adjustable, rebound damping force 21-way adjustable, compression damping force 26-way adjustable
Front suspension stroke ........................................
288 mm (11.3 in)
Rear wheel travel ...................................................
295 mm (11.6 in)
Caster ....................................................................
27° 20’
Trail .........................................................................
112 mm (4.41 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 51M
Rear tire size ..........................................................
110/100-18 64M
Ignition type ...........................................................
Electronic ignition (CDI)
Ignition timing .........................................................
7° BTDC at 1 800 r/min
Spark plug ..............................................................
NGK: CR8E
DENSO: U24ESR-N
Battery ................................................................... * 12 V 21.6 kC (6 Ah)/10HR ..... DR-Z400E
Generator ...............................................................
Three-phase A.C. generator
Fuse .......................................................................
10 A ..... DR-Z400E
Headlight ................................................................
12 V 55 W
Taillight ...................................................................
LED
Fuel tank, including reserve ...................................
10.0 L (2.6 US gal, 2.2 Imp gal) 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 ...........................................................
720 ml (24.3 US oz, 25.4 Imp oz)
Engine coolant .......................................................
1 250 ml (1.3 US qt, 1.1 Imp qt)
10-4 DR-Z400/EK1 (’01-MODEL)
Overall length .........................................................
2 310 mm (90.9 in)
Overall width ..........................................................
825 mm (32.5 in)
Overall height .........................................................
1 245 mm (49.0 in)
Wheelbase .............................................................
1 475 mm (58.1 in)
Ground clearance ..................................................
315 mm (12.4 in)
Seat height .............................................................
Dry mass ................................................................
935 mm (36.8 in)
127 kg (279 lbs)
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 cm 3 (24.3 cu. in)
Compression ratio ..................................................
12.2 : 1
Carburetor ..............................................................
KEIHIN FCR39
Air cleaner ..............................................................
Polyurethane foam element
Starter system ........................................................
Electric
Lubrication system .................................................
Dry sump
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 ...............................................
3.357 (47/14)
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
DR-Z400/EK1 (’01-MODEL) 10-5
Front suspension ...................................................
Telescopic, coil spring, oil damped, rebound damping force 18-way adjustable, compression damping force
14-way adjustable
Rear suspension ....................................................
Link type, coil spring, oil damped, spring preload fully adjustable, rebound damping force 21-way adjustable, compression damping force 26-way adjustable
Front fork stroke .....................................................
288 mm (11.3 in)
Rear wheel travel ...................................................
295 mm (11.6 in)
Caster ....................................................................
27° 20’
Trail .........................................................................
112 mm (4.41 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
Ignition type ...........................................................
Electronic ignition (CDI)
Ignition timing .........................................................
7° BTDC at 1 800 r/min
Spark plug ..............................................................
NGK: CR8E
DENSO: U24ESR-N
Generator ...............................................................
Three-phase A.C. generator
Battery ................................................................... * 12 V 21.6 kC (6 Ah)/10 HR
Fuse .......................................................................
20 A
Headlight ................................................................
12 V 60/55 W
Brake light/Taillight .................................................
12 V 21/5 W
Turn signal light ......................................................
12 V 21 W
Speedometer light ..................................................
LED
Neutral indicator light .............................................
12 V 2 W
High beam indicator light .......................................
12 V 2 W
Turn signal indicator light .......................................
12 V 2 W
Fuel tank, including reserve ..................................
10.0 L (2.6 US gal, 2.2 Imp gal) 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 ...........................................................
720 ml (24.3 US oz, 25.4 Imp oz)
Engine coolant .......................................................
1 250 ml (1.3 US qt, 1.1 Imp qt)
10-6 DR-Z400/EK1 (’01-MODEL)
ITEM
Valve diam.
IN.
EX.
Tappet clearance (when cold)
IN.
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve head thickness
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
Valve spring tension (IN. & EX.)
INNER
OUTER
STANDARD
36
(1.42)
29
(1.14)
0.10 – 0.20
(0.0039 – 0.0078)
0.20 – 0.30
(0.0078 – 0.0118)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
———
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
———
———
0.9 – 1.1
(0.035 – 0.043)
———
———
———
56 – 64 N
(5.6 – 6.4 kgf, 12.3 – 14.1 lbs) at length 27.4 mm (1.08 in)
126 – 145 N
(12.6 – 14.5 kgf, 27.7 – 32.0 lbs) at length 30.9 mm (1.22 in)
Unit: mm (in)
LIMIT
———
———
———
———
———
———
0.35
(0.014)
———
———
———
0.05
(0.002)
0.5
(0.02)
———
0.03
(0.001)
32.6
(1.28)
36.3
(1.43)
———
———
DR-Z400/EK1 (’01-MODEL) 10-7
ITEM
Cam height
IN.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Cam chain pin (at arrow “3”)
Cylinder head distortion
EX.
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
36.910 – 36.960
(1.4531 – 1.4551)
36.880 – 36.930
(1.4520 – 1.4539)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8653 – 0.8659)
———
15th pin
———
Cylinder head cover distortion
De-compression cable play
(DR-Z400)
———
0 – 0.1
(0 – 0.004)
ITEM
Compression pressure
(Automatic de-comp. actuated)
Except for DR-Z400
Piston to cylinder clearance
Cylinder bore
Piston diam.
STANDARD
1 000 kPa
( 10.0 kgf/cm 2
142 psi
)
0.030 – 0.040
(0.0012 – 0.0016)
90.000 – 90.015
(3.5433 – 3.5439)
89.965 – 89.980
(3.5419 – 3.5425)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
———
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
1st R
2nd R
1st
2nd
1st
Approx.
6.9
(0.27)
Approx.
11.5
(0.45)
0.08 – 0.20
(0.003 – 0.008)
0.08 – 0.20
(0.003 – 0.008)
———
2nd
———
Unit: mm (in)
LIMIT
———
0.120
(0.0047)
Nicks or
Scratches
89.880
(3.5386)
0.05
(0.002)
5.5
(0.22)
9.2
(0.36)
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
———
0.10
(0.004)
———
0.05
(0.002)
0.05
(0.002)
———
Unit: mm (in)
LIMIT
36.610
(1.4413)
36.580
(1.4402)
0.150
(0.0059)
———
10-8 DR-Z400/EK1 (’01-MODEL)
ITEM
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
1st
2nd
Oil
1st
2nd
STANDARD
2.220 (74/25 × 20/16 × 12/20)
Above 40 kPa (0.4 kgf/cm
2
, 5.7 psi)
Below 140 kPa (1.4 kgf/cm 2 , 19.9 psi) at 3 000 r/min.
STANDARD
0.78 – 0.80
(0.0307 – 0.0315)
1.30 – 1.32
(0.0512 – 0.0520)
0.81 – 0.83
(0.0319 – 0.0327)
2.01 – 2.03
(0.0791 – 0.0799)
0.71 – 0.76
(0.0280 – 0.0299)
1.08 – 1.10
(0.0425 – 0.0433)
0.77 – 0.79
(0.0303 – 0.0311)
20.002 – 20.008
(0.7875 – 0.7877)
19.995 – 20.000
(0.7872 – 0.7874)
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
———
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
———
LIMIT
———
———
———
———
———
———
———
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
LIMIT
20.040
(0.7890)
3.0
(0.12)
1.0
(0.04)
———
———
0.08
(0.003)
LIMIT
———
———
DR-Z400/EK1 (’01-MODEL) 10-9
ITEM
Clutch cable play
Drive plate thickness
(No. 1 & No. 2)
Drive plate claw width
(No. 1 & No. 2)
Driven plate distortion
Clutch spring free length
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
———
———
Unit: mm (in)
LIMIT
———
2.62
(0.103)
13.2
(0.520)
0.10
(0.004)
49.9
(1.96)
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
No.1, No.2
& No.3
No.1, No.2
& No.3
Type
Links
20-pitch length
STANDARD
2.960 (74/25)
3.357 (47/14)
2.285 (32/14)
1.733 (26/15)
1.375 (22/16)
1.090 (24/22)
0.863 (19/22)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
4.6 – 4.7
(0.181 – 0.185)
RK520KZO
112
———
Drive chain slack 40 – 50
(1.6 – 2.0)
ITEM
Carburetor type
Bore size
I.D. No
Idle r/min.
Float height
Unit: mm (in) Except ratio
LIMIT
———
———
———
———
———
———
———
0.5
(0.020)
———
———
———
———
319.4
(12.57)
———
SPECIFICATION
DR-Z400
E-03, 28 E-01 E-01
KEIHIN
FCR39H
39 mm
(1.5 in)
29F0
1 800 ± 100 r/min
9.0 ± 1.0 mm
(0.35 ± 0.04 in)
←
←
29F1
←
←
←
←
29F3
←
←
DR-Z400E
E-03, 28
←
←
29F4
←
←
10-10 DR-Z400/EK1 (’01-MODEL)
Main jet
Jet needle
Needle jet
ITEM
Slow jet
Slow air jet
Air jet
Pilot screw
Throttle cable play
(pulling cable)
ITEM
Rear brake pedal height
(A.J.)
(P.S.)
E-01
(M.J.) #165
(J.N.) OBDXP-4th
(N.J.) 2.9 mm
(0.11 in)
(S.J.)
(S.A.J.)
#45
#60
#90
SPECIFICATION
DR-Z400
E-03, 28
#142
←
1½ turns back
2 – 4 mm
(0.08 – 0.16 in)
←
←
←
←
←
←
E-01
#165
←
←
←
←
←
←
←
DR-Z400E
E-03, 28
#142
←
←
←
←
←
←
←
ITEM
Radiator cap valve opening pressure
Engine coolant type
Engine coolant capacity
STANDARD/SPECIFICATION
95 – 125 kPa
(0.95 – 1.25 kgf/cm 2 , 13.5 – 17.8 psi)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50 : 50.
1 250 ml
(1.3/1.1 US/Imp qt)
NOTE
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Front
Rear
STANDARD/SPECIFICATION
5
(0.2)
3.0 ± 0.2
(0.118 ± 0.008)
4.5 ± 0.2
(0.177 ± 0.008)
———
Front
Rear
Front
Rear
11.000 – 11.043
(0.4331 – 0.4348)
12.700 – 12.743
(0.5000 – 0.5017)
10.957 – 10.984
(0.4314 – 0.4324)
12.657 – 12.684
(0.4983 – 0.4994)
Unit: mm (in)
LIMIT
———
2.5
(0.098)
4.0
(0.16)
0.30
(0.012)
———
———
———
———
ITEM
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Wheel rim runout
Wheel axle runout
Axial
Radial
Front
Rear
Front
Rear
Front
Rear
Front
Rear
STANDARD
27.000 – 27.050
(1.0630 – 1.0650)
27.000 – 27.050
(1.0630 – 1.0650)
26.900 – 26.950
(1.0591 – 1.0610)
26.900 – 26.950
(1.0591 – 1.0610)
DOT 4
———
———
———
———
1.60 × 21
2.15 × 18
DR-Z400/EK1 (’01-MODEL) 10-11
LIMIT
———
———
———
———
———
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
———
———
Wheel rim size
ITEM
Cold inflation tire pressure
(Solo riding)
Tire size
Tire tread depth
Front
Rear
Front
Rear
STANDARD/SPECIFICATION
100 kPa (1.0 kgf/cm 2 , 14 psi)
100 kPa (1.0 kgf/cm 2 , 14 psi)
80/100-21 51M
110/100-18 64M
Front
———
Rear
———
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
(without spring)
Front fork oil type
STANDARD/SPECIFICATION
288
(11.3)
510.6
(20.1)
122
(4.8)
SUZUKI FORK OIL SS-05 or an equivalent fork oil
Front fork oil capacity
(each leg)
Front fork damping force adjuster Rebound
Compression
720 ml
(24.3/25.4 US/Imp oz)
15th clicks turn back
12th clicks turn back
LIMIT
———
———
———
———
4.0 mm
(0.16 in)
4.0 mm
(0.16 in)
Unit: mm (in)
LIMIT
———
500
(19.7)
———
———
———
———
———
10-12 DR-Z400/EK1 (’01-MODEL)
pressure
ITEM
Rear shock absorber gas
Rear shock absorber oil type
Rear shock absorber oil capacity
Rear shock absorber spring pre-set length
Rear shock absorber damping force adjuster
Rear wheel travel
Swingarm pivot shaft runout
STANDARD/SPECIFICATION
900 kPa
(9.0 kgf/cm
2
, 128 psi)
SUZUKI REAR SUSPENSION OIL SS-25 or an equivalent suspension oil
380 ml
(12.8/13.4 US/Imp oz)
Rebound
Compression
258.0
(10.2)
13th clicks turn back
12th clicks turn back
295
(11.6)
———
Spark plug
ITEM
Spark performance
Ignition coil resistance
Type
Gap
Primary
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8 mm
(0.028 – 0.031 mm)
Over 8 mm (0.3 in) at 1 atm.
0.1 – 1.0
Ω
Secondary 12 – 20 k
Ω
Ignition coil primary peak voltage
Generator coil resistance
Pick-up coil peak voltage
More than 150 V ( : B/W, : B/Y)
Charging
Signal coil
Pick-up coil
0.50 – 1.25
Ω
0.05 – 0.20
Ω
390 – 600
Ω
More than 10.0 V ( : Bl, : G)
Signal coil peak voltage
More than 5.0 V ( : Bl, : G)
More than 1.0 V ( : B, : W)
Generator no-load voltage
(when engine is cold)
Regulated voltage
Generator Max. output
Starter relay resistance
Battery
Fuse size
Type designation
Capacity
More than 1.4 V ( : B, : W)
More than 55 V (AC) at 5 000 r/min.
(Y – Y)
More than 75 V (AC) at 5 000 r/min.
(Y – Y)
12.5 – 14.0 V at 5 000 r/min.
13.5 – 15.0 V at 5 000 r/min.
150 W at 5 000 r/min.
200 W at 5 000 r/min.
3 – 5
Ω
* YT7B-BS
* 12 V 21.6 kC (6 Ah)/10 HR
10 A
Terminal –
Ground
Plug cap –
Terminal
Y – Y
B – W
G – Bl
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400E
DR-Z400E
DR-Z400E
LIMIT
———
———
———
———
———
———
———
0.3
(0.01)
NOTE
ITEM
Headlight
Taillight
ITEM
Fuel type
Fuel tank including reserve reserve
Engine oil type
Engine oil capacity
DR-Z400/EK1 (’01-MODEL) 10-13
Unit: W
SPECIFICATION
55
LED
SPECIFICATION
Use only unleaded gasoline of at least 90 pump octane ( ).
Gasoline containing MTBE (MethyI Tertiary ButyI
Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 95 octane or higher. An unleaded gasoline is recommended.
Change
Overhaul
10.0 L
(2.6/2.2 US/lmp gal)
2.3 L
(0.6/0.5 US/lmp gal)
SAE 10W/40, API SF or SG
Filter change
1 700 ml
(1.8/1.5 US/lmp qt)
1 800 ml
(1.9/1.6 US/lmp qt)
1 900 ml
(2.0/1.7 US/lmp qt)
NOTE
E-03, 28
E-01
10-14 DR-Z400/EK1 (’01-MODEL)
ITEM
Valve diam.
Tappet clearance (when cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve head thickness
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension (IN. & EX.)
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
INNER
OUTER
STANDARD
36
(1.42)
29
(1.14)
0.10 – 0.20
(0.0039 – 0.0078)
0.20 – 0.30
(0.0078 – 0.0118)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
———
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
———
———
0.9 – 1.1
(0.035 – 0.043)
———
———
———
56 – 64 N
(5.6 – 6.4 kgf, 12.3 – 14.1 lbs) at length 27.4 mm (1.08 in)
126 – 145 N
(12.6 – 14.5 kgf, 27.7 – 32.0 lbs) at length 30.9 mm (1.22 in)
Unit: mm (in)
LIMIT
———
———
———
———
———
———
0.35
(0.014)
———
———
———
0.05
(0.002)
0.5
(0.02)
———
0.03
(0.001)
32.6
(1.28)
36.3
(1.43)
———
———
DR-Z400/EK1 (’01-MODEL) 10-15
ITEM
Cam height
IN.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Cam chain pin (at arrow “3”)
Cylinder head distortion
Cylinder head cover distortion
EX.
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
36.910 – 36.960
(1.4531 – 1.4551)
36.880 – 36.930
(1.4520 – 1.4539)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8653 – 0.8659)
———
15th pin
———
———
ITEM
Compression pressure
(Automatic de-comp. actuated)
Piston to cylinder clearance
Cylinder bore
Piston diam.
STANDARD
1 000 kPa
(
10.0 kgf/cm
142 psi
2 )
0.030 – 0.040
(0.0012 – 0.0016)
90.000 – 90.015
(3.5433 – 3.5439)
89.965 – 89.980
(3.5419 – 3.5425)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
———
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
1st R
2nd R
1st
2nd
1st
Approx.
6.9
(0.27)
Approx.
11.5
(0.45)
0.08 – 0.20
(0.003 – 0.008)
0.08 – 0.20
(0.003 – 0.008)
———
2nd
———
Unit: mm (in)
LIMIT
36.610
(1.4413)
36.580
(1.4402)
0.150
(0.0059)
———
———
0.10
(0.004)
———
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
———
0.120
(0.0047)
Nicks or
Scratches
89.880
(3.5386)
0.05
(0.002)
5.5
(0.22)
9.2
(0.36)
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
10-16 DR-Z400/EK1 (’01-MODEL)
ITEM
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
1st
2nd
Oil
1st
2nd
STANDARD
2.220 (74/25 × 20/16 × 12/20)
Above 40 kPa (0.4 kgf/cm
2
, 5.7 psi)
Below 140 kPa (1.4 kgf/cm 2 , 19.9 psi) at 3 000 r/min.
STANDARD
0.78 – 0.80
(0.0307 – 0.0315)
1.30 – 1.32
(0.0512 – 0.0520)
0.81 – 0.83
(0.0319 – 0.0327)
2.01 – 2.03
(0.0791 – 0.0799)
0.71 – 0.76
(0.0280 – 0.0299)
1.08 – 1.10
(0.0425 – 0.0433)
0.77 – 0.79
(0.0303 – 0.0311)
20.002 – 20.008
(0.7875 – 0.7877)
19.995 – 20.000
(0.7872 – 0.7874)
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
———
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
———
LIMIT
———
———
———
———
———
———
———
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
LIMIT
20.040
(0.7890)
3.0
(0.12)
1.0
(0.04)
———
———
0.08
(0.003)
LIMIT
———
———
DR-Z400/EK1 (’01-MODEL) 10-17
ITEM
Clutch cable play
Drive plate thickness
(No. 1 & No. 2)
Drive plate claw width
(No. 1 & No. 2)
Driven plate distortion
Clutch spring free length
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
———
———
Unit: mm (in)
LIMIT
———
2.62
(0.103)
13.2
(0.520)
0.10
(0.004)
49.9
(1.96)
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
No.1, No.2
& No.3
No.1, No.2
& No.3
Type
Links
20-pitch length
STANDARD
2.960 (74/25)
3.357 (47/14)
2.285 (32/14)
1.733 (26/15)
1.375 (22/16)
1.090 (24/22)
0.863 (19/22)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
4.6 – 4.7
(0.181 – 0.185)
RK520KZO
112
———
Drive chain slack 40 – 50
(1.6 – 2.0)
ITEM
Carburetor type
Bore size
I.D. No
Idle r/min.
Float height
Main jet
Jet needle
Needle jet
(M.J.)
(J.N.)
(N.J.)
SPECIFICATION
KEIHIN FCR39H
39 mm
(1.5 in)
29F6
1 800 ± 100 r/min
9.0 ± 1.0 mm
(0.35 ± 0.04 in)
#165
OBDXP-4th
2.9 mm
(0.11 in)
Unit: mm (in) Except ratio
LIMIT
———
———
———
———
———
———
———
0.5
(0.020)
———
———
———
———
319.4
(12.57)
———
10-18 DR-Z400/EK1 (’01-MODEL)
ITEM
Slow jet
Slow air jet
Air jet
Pilot screw
Throttle cable play
(pulling cable)
(S.J.)
(S.A.J.)
(A.J.)
(P.S.)
SPECIFICATION
#45
#60
#90
2¾ turns back
2 – 4 mm
(0.08 – 0.16 in)
ITEM
Radiator cap valve opening pressure
Engine coolant type
Engine coolant capacity
STANDARD/SPECIFICATION
95 – 125 kPa
(0.95 – 1.25 kgf/cm 2 , 13.5 – 17.8 psi)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50 : 50.
1 250 ml
(1.3/1.1 US/Imp qt)
ITEM
Brake lever play
Rear brake pedal height
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Front
Rear
STANDARD/SPECIFICATION
0.1 – 0.3
(0.004 – 0.010)
5
(0.2)
3.5 ± 0.2
(0.138 ± 0.008)
4.5 ± 0.2
(0.177 ± 0.008)
Front
Rear
Front
Rear
Front
Rear
Front
Rear
———
12.700 – 12.743
(0.5000 – 0.5017)
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
12.657 – 12.684
(0.4983 – 0.4994)
27.000 – 27.050
(1.0630 – 1.0650)
27.000 – 27.050
(1.0630 – 1.0650)
26.900 – 26.950
(1.0591 – 1.0610)
26.900 – 26.950
(1.0591 – 1.0610)
DOT 4
NOTE
———
———
———
———
———
———
———
Unit: mm (in)
LIMIT
———
———
3.0
(0.118)
4.0
(0.16)
0.30
(0.012)
———
———
ITEM
Wheel rim runout
Wheel axle runout
Axial
Radial
Front
Rear
Front
Rear
STANDARD
———
———
———
———
1.60 × 21
2.15 × 18
DR-Z400/EK1 (’01-MODEL) 10-19
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
———
———
Wheel rim size
ITEM
Cold inflation tire pressure
(Solo riding)
Tire size
Tire tread depth
Front
Rear
Front
Rear
STANDARD/SPECIFICATION
125 kPa (1.25 kgf/cm 2 , 18 psi)
125 kPa (1.25 kgf/cm
2
, 18 psi)
80/100-21 51P
120/90-18 65P
Front ———
Rear ———
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
(without spring)
Front fork oil type
STANDARD/SPECIFICATION
288
(11.3)
510.6
(20.1)
122
(4.8)
SUZUKI FORK OIL SS-05 or an equivalent fork oil
720 ml
(24.3/25.4 US/Imp oz)
Front fork oil capacity
(each leg)
Front fork damping force adjuster Rebound
Compression
Rear shock absorber gas pressure
Rear shock absorber oil type
15th clicks turn back
12th clicks turn back
900 kPa
(9.0 kgf/cm
2
, 128 psi)
SUZUKI REAR SUSPENSION OIL SS-25 or an equivalent suspension oil
Rear shock absorber oil capacity
Rear shock absorber spring pre-set length
380 ml
(12.8/13.4 US/Imp oz)
258.0
(10.2)
Rear shock absorber damping force adjuster
Rebound
Compression
13th clicks turn back
12th clicks turn back
LIMIT
———
———
———
———
4.0 mm
(0.16 in)
4.0 mm
(0.16 in)
———
———
———
———
———
———
———
———
———
Unit: mm (in)
LIMIT
———
500
(19.7)
———
———
10-20 DR-Z400/EK1 (’01-MODEL)
ITEM
Rear wheel travel
Swingarm pivot shaft runout
STANDARD/SPECIFICATION
295
(11.6)
———
Spark plug
ITEM
Spark performance
Ignition coil resistance
Type
Gap
Primary
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8 mm
(0.028 – 0.031 mm)
Over 8 mm (0.3 in) at 1 atm.
0.1 – 1.0
Ω
Secondary 12 – 20 k
Ω
Ignition coil primary peak voltage
More than 150 V
Generator coil resistance
Pick-up coil peak voltage
Signal coil peak voltage
Generator no-load voltage
(when engine is cold)
Regulated voltage
Generator Max. output
Starter relay resistance
Battery Type designation
Capacity
Fuse size
Charging
Signal coil
Pick-up coil
0.50 – 1.25
Ω
0.05 – 0.20
Ω
390 – 600
Ω
More than 5.0 V
More than 1.4 V
More than 75 V (AC) at 5 000 r/min.
13.5 – 15.0 V at 5 000 r/min.
200 W at 5 000 r/min.
3 – 5
Ω
* YT7B-BS
* 12 V 21.6 kC (6 Ah)/10 HR
20 A
Headlight
ITEM
Brake light/Taillight
Turn signal light
Speedometer light
Neutral indicator light
High beam indicator light
Turn signal indicator light
HI
LO
SPECIFICATION
60
55
21/5
21
LED
2
2
2
LIMIT
———
0.3
(0.01)
NOTE
Terminal –
Ground
Plug cap –
Terminal
: B/W,
: B/Y
Y – Y
B – W
G – Bl
: Bl, : G
: B, : W
Y – Y
Unit: W
DR-Z400/EK1 (’01-MODEL) 10-21
ITEM
Fuel type
Fuel tank including reserve reserve
Engine oil type
Engine oil capacity
SPECIFICATION
Gasoline used should be graded 95 octane or higher. An unleaded gasoline is recommended.
Overhaul
10.0 L
(2.6/2.2 US/lmp gal)
2.3 L
(0.6/0.5 US/lmp gal)
Change
SAE 10W/40, API SF or SG
Filter change
1 700 ml
(1.8/1.5 US/lmp qt)
1 800 ml
(1.9/1.6 US/lmp qt)
1 900 ml
(2.0/1.7 US/lmp qt)
NOTE
10-22 DR-Z400/EK1 (’01-MODEL)
Type designation
Capacity
YT7B-BS
12V, 21.6 kC (6 Ah)/10HR
Filling electrolyte
• Remove the aluminum tape
1
sealing the battery electrolyte filler holes.
• Remove the caps
2
.
2
3
• Insert the nozzles of the electrolyte container into the battery’s electrolyte filler holes, holding the container firmly so that it does not fall. Take precaution not to allow any of the fluid to spill.
• Make sure air bubbles are coming up each electrolyte container, and leave in this position for about more than 20 minutes.
• After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery.
Wait for around 20 minutes.
• Insert the caps into the filler holes, pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery’s top cover.
* Never use anything except the specified battery.
* Once install the caps to the battery; do not remove the caps.
* Do not tap the caps with a hammer when installing them.
DR-Z400/EK1 (’01-MODEL) 10-23
CORRECT
• Using multi circuit tester, measure the battery voltage. The tester should indicate more than 12.5 – 12.6 V (DC) as shown in the
Fig. If the battery voltage is lower than the specification, charge the battery with a battery charger. (Refer to the recharging operation)
Do not remove the caps on the battery top while charging.
Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpaper.
INCORRECT
10-24 DR-Z400/EK1 (’01-MODEL)
• Using the multi circuit tester, check the battery voltage. If the voltage reading is less than the 12.0 V (DC), recharge the battery with a battery charger.
* When recharging the battery, remove the battery from the motorcycle.
* Do not remove the caps on the battery top while recharging.
Recharging time: 0.7 A for 5 to 10 hours or 3 A for one hour
Be careful not to permit the charging current to exceed
3 A at any time.
• After recharging, wait for more than 30 minutes and check the battery voltage with a multi circuit tester.
• If the battery voltage is less than the 12.5 V, recharge the battery again.
• If battery voltage is still less than 12.5 V, after recharging, replace the battery with a new one.
• When the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery discharge.
DR-Z400/EK2 (’02-MODEL)
DR-Z400/EK2 (’02-MODEL) 11-1
CONTENTS
SPECIFICATIONS ............................................................................... 11- 2
DR-Z400/E (E-01, 03 and 28) ........................................................... 11- 2
DR-Z400E (E-24) .............................................................................. 11- 4
PERIODIC MAINTENANCE SCHEDULE (For E-24) ......................... 11- 6
SERVICE DATA ................................................................................... 11- 7
DR-Z400/E (E-01, 03 and 28) ........................................................... 11- 7
DR-Z400E (E-24) .............................................................................. 11-15
REAR SHOCK ABSORBER ............................................................... 11-23
OIL REPLACEMENT PROCEDURE ............................................... 11-23
REASSEMBLY AND REMOUNTING .............................................. 11-25
DAMPING FORCE ADJUSTMENT ................................................. 11-26
WIRING DIAGRAM .............................................................................. 11-27
COOLING SYSTEM HOSE ROUTING ................................................ 11-29
11
11-2 DR-Z400/EK2 (’02-MODEL)
Overall length .........................................................
2 235 mm (88.0 in)
Overall width ..........................................................
825 mm (32.5 in)
Overall height .........................................................
1 235 mm (48.6 in)
Wheelbase .............................................................
1 475 mm (58.1 in)
Ground clearance ..................................................
325 mm (12.8 in)
Seat height .............................................................
Dry mass ................................................................
945 mm (37.2 in)
113 kg (249 lbs) ..... DR-Z400
119 kg (262 lbs) ..... DR-Z400E
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 cm
3
(24.3 cu. in)
Compression ratio ..................................................
12.2 : 1
Carburetor ..............................................................
KEIHIN FCR39
Air cleaner ..............................................................
Polyurethane foam element
Starter system ........................................................
Primary kick ..... DR-Z400
Electric ..... DR-Z400E
Lubrication system .................................................
Dry sump
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 ...............................................
3.357 (47/14)
Gear ratios, Low ....................................................
2.285 (32/14)
2nd ....................................................
1.733 (26/15)
3nd ....................................................
1.375 (22/16)
4nd ....................................................
1.090 (24/22)
Top .....................................................
0.863 (19/22)
Drive chain .............................................................
RK520KZO, 112 links
DR-Z400/EK2 (’02-MODEL) 11-3
Front suspension ...................................................
Telescopic, coil spring, oil damped
Rear suspension ....................................................
Link type, coil spring, oil damped
Front suspension stroke ........................................
288 mm (11.3 in)
Rear wheel travel ...................................................
295 mm (11.6 in)
Caster ....................................................................
27° 20’
Trail .........................................................................
112 mm (4.41 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 51M
Rear tire size ..........................................................
110/100-18 64M
Ignition type ...........................................................
Electronic ignition (CDI)
Ignition timing .........................................................
7° BTDC at 1 800 r/min
Spark plug ..............................................................
NGK: CR8E
DENSO: U24ESR-N
Battery ...................................................................
12 V 21.6 kC (6 Ah)/10HR ..... DR-Z400E
Generator ...............................................................
Three-phase A.C. generator
Fuse .......................................................................
10 A ..... DR-Z400E
Headlight ................................................................ * 12 V 35 W
Taillight ...................................................................
LED
Fuel tank, including reserve ...................................
10.0 L (2.6 US gal, 2.2 Imp gal) 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 ...........................................................
720 ml (24.3 US oz, 25.4 Imp oz)
Engine coolant .......................................................
1 250 ml (1.3 US qt, 1.1 Imp qt)
11-4 DR-Z400/EK2 (’02-MODEL)
Overall length .........................................................
2 310 mm (90.9 in)
Overall width ..........................................................
825 mm (32.5 in)
Overall height .........................................................
1 235 mm (48.6 in)
Wheelbase .............................................................
1 475 mm (58.1 in)
Ground clearance ..................................................
315 mm (12.4 in)
Seat height .............................................................
Dry mass ................................................................
935 mm (36.8 in)
127 kg (279 lbs)
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 cm
3
(24.3 cu. in)
Compression ratio ..................................................
12.2 : 1
Carburetor ..............................................................
KEIHIN FCR39
Air cleaner ..............................................................
Polyurethane foam element
Starter system ........................................................
Electric
Lubrication system .................................................
Dry sump
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 ...............................................
3.357 (47/14)
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
DR-Z400/EK2 (’02-MODEL) 11-5
Front suspension ...................................................
Telescopic, coil spring, oil damped
Rear suspension ....................................................
Link type, coil spring, oil damped
Front fork stroke .....................................................
288 mm (11.3 in)
Rear wheel travel ...................................................
295 mm (11.6 in)
Caster ....................................................................
27° 20’
Trail .........................................................................
112 mm (4.41 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 or 80/100-21 M/C 51P
Rear tire size ..........................................................
120/90-18 65P or 120/90-18 M/C 65P
Ignition type ...........................................................
Electronic ignition (CDI)
Ignition timing .........................................................
7° BTDC at 1 800 r/min
Spark plug ..............................................................
NGK: CR8E
DENSO: U24ESR-N
Generator ...............................................................
Three-phase A.C. generator
Battery ...................................................................
12 V 21.6 kC (6 Ah)/10 HR
Fuse .......................................................................
20 A
Headlight ................................................................
12 V 60/55 W
Brake light/Taillight .................................................
12 V 21/5 W
Turn signal light ......................................................
12 V 21 W
Speedometer light ..................................................
LED
Neutral indicator light .............................................
12 V 2 W
High beam indicator light .......................................
12 V 2 W
Turn signal indicator light .......................................
12 V 2 W
Fuel tank, including reserve ..................................
10.0 L (2.6 US gal, 2.2 Imp gal) 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 ...........................................................
720 ml (24.3 US oz, 25.4 Imp oz)
Engine coolant .......................................................
1 250 ml (1.3 US qt, 1.1 Imp qt)
11-6 DR-Z400/EK2 (’02-MODEL)
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.
Interval
Item
Air cleaner element km miles months
Exhaust pipe bolts and muffler bolts
Valve clearance
Spark plugs
Fuel hose
Engine oil
Engine oil filter
Idle speed
Throttle cable play
Engine coolant
Radiator hose
Clutch
Drive chain
Brakes
Brake hose
Brake fluid
Tires
Spoke nipples
Steering
Front forks
Rear suspension
Chassis bolts and nuts
1 000
600
1
–
6 000
4 000
6
I
12 000
7 500
12
I
18 000
11 000
18
R
Inspect each time the motorcycles is ridden in off-road and clean as necessary
24 000
15 000
24
I
–
–
T
–
–
–
I
I
T
–
R
I
–
–
I
I
T
I
I
R
R
R
I
I
–
–
I
–
I
R
Replace every 4 years.
R R
I
–
I
I
Replace every 2 years.
R
I
I
I
I
I
I
I
I
I I I
Clean, lubricate and inspect each time the motorcycle is ridden in off-road
R
–
I
I
I
I
I
I
– I
I
I
I
I
I
– I
Replace every 4 years.
I I I
– I
Replace every 2 years.
I I I
Inspect each time the motorcycle is ridden in off-road
I I I I I
–
–
Inspect each time the motorcycle is ridden in off-road
I – I – I
–
–
I
I
–
– I
I
T T T T
I
I
T
DR-Z400/EK2 (’02-MODEL) 11-7
ITEM
Valve diam.
IN.
Tappet clearance (when cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve head thickness
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN. & EX.
INNER
OUTER
Valve spring tension (IN. & EX.)
INNER
OUTER
STANDARD
36
(1.42)
29
(1.14)
0.10 – 0.20
(0.0039 – 0.0078)
0.20 – 0.30
(0.0078 – 0.0118)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
———
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
———
———
0.9 – 1.1
(0.035 – 0.043)
———
———
———
56 – 64 N
(5.6 – 6.4 kgf, 12.3 – 14.1 lbs) at length 27.4 mm (1.08 in)
126 – 145 N
(12.6 – 14.5 kgf, 27.7 – 32.0 lbs) at length 30.9 mm (1.22 in)
———
Unit: mm (in)
LIMIT
———
———
———
———
———
0.05
(0.002)
0.5
(0.02)
———
0.03
(0.001)
32.6
(1.28)
36.3
(1.43)
———
———
———
———
0.35
(0.014)
———
11-8 DR-Z400/EK2 (’02-MODEL)
ITEM
Cam height
IN.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Cam chain pin (at arrow “3”)
Cylinder head distortion
EX.
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
36.910 – 36.960
(1.4531 – 1.4551)
36.880 – 36.930
(1.4520 – 1.4539)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8653 – 0.8659)
———
15th pin
———
Cylinder head cover distortion
De-compression cable play
(DR-Z400)
———
0 – 0.1
(0 – 0.004)
ITEM
Compression pressure
(Automatic de-comp. actuated)
Except for DR-Z400
Piston to cylinder clearance
Cylinder bore
Piston diam.
STANDARD
(
1 000 kPa
10.0 kgf/cm
142 psi
2
)
0.030 – 0.040
(0.0012 – 0.0016)
90.000 – 90.015
(3.5433 – 3.5439)
89.965 – 89.980
(3.5419 – 3.5425)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
———
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
1st R
2nd R
1st
2nd
1st
Approx.
6.9
(0.27)
Approx.
11.5
(0.45)
0.08 – 0.20
(0.003 – 0.008)
0.08 – 0.20
(0.003 – 0.008)
———
2nd ———
Unit: mm (in)
LIMIT
———
0.120
(0.0047)
Nicks or
Scratches
89.880
(3.5386)
0.05
(0.002)
5.5
(0.22)
9.2
(0.36)
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
———
0.10
(0.004)
———
0.05
(0.002)
0.05
(0.002)
———
Unit: mm (in)
LIMIT
36.610
(1.4413)
36.580
(1.4402)
0.150
(0.0059)
———
ITEM
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
1st
2nd
Oil
1st
2nd
STANDARD
2.220 (74/25 × 20/16 × 12/20)
Above 40 kPa (0.4 kgf/cm
2
, 5.7 psi)
Below 140 kPa (1.4 kgf/cm 2 , 19.9 psi) at 3 000 r/min.
STANDARD
0.78 – 0.80
(0.0307 – 0.0315)
1.30 – 1.32
(0.0512 – 0.0520)
0.81 – 0.83
(0.0319 – 0.0327)
2.01 – 2.03
(0.0791 – 0.0799)
0.71 – 0.76
(0.0280 – 0.0299)
1.08 – 1.10
(0.0425 – 0.0433)
0.77 – 0.79
(0.0303 – 0.0311)
20.002 – 20.008
(0.7875 – 0.7877)
19.995 – 20.000
(0.7872 – 0.7874)
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
———
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
———
DR-Z400/EK2 (’02-MODEL) 11-9
LIMIT
———
———
———
———
———
———
———
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
LIMIT
20.040
(0.7890)
3.0
(0.12)
1.0
(0.04)
———
———
0.08
(0.003)
LIMIT
———
———
11-10 DR-Z400/EK2 (’02-MODEL)
ITEM
Clutch cable play
Drive plate thickness
(No. 1 & No. 2)
Drive plate claw width
(No. 1 & No. 2)
Driven plate distortion
Clutch spring free length
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
———
———
Unit: mm (in)
LIMIT
———
2.62
(0.103)
13.2
(0.520)
0.10
(0.004)
49.9
(1.96)
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
No.1, No.2
& No.3
No.1, No.2
& No.3
Type
Links
20-pitch length
STANDARD
2.960 (74/25)
3.357 (47/14)
2.285 (32/14)
1.733 (26/15)
1.375 (22/16)
1.090 (24/22)
0.863 (19/22)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
4.6 – 4.7
(0.181 – 0.185)
RK520KZO
112
———
Drive chain slack 40 – 50
(1.6 – 2.0)
ITEM
Carburetor type
Bore size
I.D. No
Idle r/min.
Float height
Unit: mm (in) Except ratio
LIMIT
———
———
———
———
———
———
———
0.5
(0.020)
———
———
———
———
319.4
(12.57)
———
SPECIFICATION
E-01
KEIHIN
FCR39H
DR-Z400
E-03, 28
←
39 mm
(1.5 in)
29F0
1 800 ± 100 r/min
←
29F1
←
9.0 ± 1.0 mm
(0.35 ± 0.04 in)
←
E-01
←
←
29F3
←
←
DR-Z400E
E-03, 28
←
←
29F4
←
←
DR-Z400/EK2 (’02-MODEL) 11-11
Main jet
Jet needle
Needle jet
ITEM
Slow jet
Slow air jet
Air jet
Pilot screw
Throttle cable play
(pulling cable)
ITEM
Rear brake pedal height
(A.J.)
(P.S.)
E-01
(M.J.) #165
(J.N.) OBDXP-4th
(N.J.) 2.9 mm
(0.11 in)
(S.J.)
(S.A.J.)
#45
#60
#90
SPECIFICATION
DR-Z400
E-03, 28
#142
←
1½ turns back
2 – 4 mm
(0.08 – 0.16 in)
←
←
←
←
←
←
E-01
#165
←
←
←
←
←
←
←
DR-Z400E
E-03, 28
#142
←
←
←
←
←
←
←
ITEM
Radiator cap valve opening pressure
Engine coolant type
Engine coolant capacity
STANDARD/SPECIFICATION
95 – 125 kPa
(0.95 – 1.25 kgf/cm 2 , 13.5 – 17.8 psi)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50 : 50.
1 250 ml
(1.3/1.1 US/Imp qt)
NOTE
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Front
Rear
STANDARD/SPECIFICATION
5
(0.2)
3.0 ± 0.2
(0.118 ± 0.008)
4.5 ± 0.2
(0.177 ± 0.008)
———
Front
Rear
Front
Rear
11.000 – 11.043
(0.4331 – 0.4348)
12.700 – 12.743
(0.5000 – 0.5017)
10.957 – 10.984
(0.4314 – 0.4324)
12.657 – 12.684
(0.4983 – 0.4994)
Unit: mm (in)
LIMIT
———
2.5
(0.098)
4.0
(0.16)
0.30
(0.012)
———
———
———
———
11-12 DR-Z400/EK2 (’02-MODEL)
ITEM
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Wheel rim runout
Wheel axle runout
Front
Rear
Front
Rear
Axial
Radial
Front
Rear
Front
Rear
STANDARD
27.000 – 27.050
(1.0630 – 1.0650)
27.000 – 27.050
(1.0630 – 1.0650)
26.900 – 26.950
(1.0591 – 1.0610)
26.900 – 26.950
(1.0591 – 1.0610)
DOT 4
———
———
———
———
1.60 × 21
2.15 × 18
Wheel rim size
ITEM
Cold inflation tire pressure
(Solo riding)
Tire size
Tire tread depth
Front
Rear
Front
Rear
STANDARD/SPECIFICATION
100 kPa (1.0 kgf/cm
2
, 14 psi)
100 kPa (1.0 kgf/cm 2 , 14 psi)
80/100-21 51M
110/100-18 64M
Front
———
Rear ———
ITEM
Front fork stroke
STANDARD/SPECIFICATION
288
(11.3)
Front fork spring free length 510.6
(20.1)
Front fork oil level
(without spring)
Front fork oil type
122
(4.8)
SUZUKI FORK OIL SS-05 or an equivalent fork oil
Front fork oil capacity
(each leg)
Front fork damping force adjuster Rebound
Compression
720 ml
(24.3/25.4 US/Imp oz)
15th clicks turn back
12th clicks turn back
LIMIT
———
———
———
———
4.0 mm
(0.16 in)
4.0 mm
(0.16 in)
Unit: mm (in)
LIMIT
———
500
(19.7)
———
———
———
———
———
LIMIT
———
———
———
———
———
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
———
———
ITEM
Rear shock absorber gas pressure
Rear shock absorber oil type
Rear shock absorber oil capacity
Rear shock absorber spring pre-set length
Rear shock absorber damping force adjuster
Rear wheel travel
Swingarm pivot shaft runout
STANDARD/SPECIFICATION
900 kPa
(9.0 kgf/cm 2 , 128 psi)
SUZUKI REAR SUSPENSION OIL SS-25 or an equivalent suspension oil
Rebound
380 ml
(12.8/13.4 US/Imp oz)
258.0
(10.2)
13th clicks turn back
Compression
*High speed 1¼ turns out
*Low speed 10th clicks turn back
295
(11.6)
———
Spark plug
ITEM
Spark performance
Ignition coil resistance
Type
Gap
Primary
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8 mm
(0.028 – 0.031 mm)
Over 8 mm (0.3 in) at 1 atm.
0.1 – 1.0
Ω
Secondary 12 – 20 k
Ω
Ignition coil primary peak voltage
Generator coil resistance
Pick-up coil peak voltage
More than 150 V ( : B/W, : B/Y)
Charging
Signal coil
Pick-up coil
0.50 – 1.25
Ω
0.05 – 0.20
Ω
390 – 600
Ω
More than 10.0 V ( : Bl, : G)
Signal coil peak voltage
More than 5.0 V ( : Bl, : G)
More than 1.0 V ( : B, : W)
Generator no-load voltage
(when engine is cold)
Regulated voltage
Generator Max. output
Starter relay resistance
Battery Type designation
Capacity
More than 1.4 V ( : B, : W)
More than 55 V (AC) at 5 000 r/min.
(Y – Y)
More than 75 V (AC) at 5 000 r/min.
(Y – Y)
12.5 – 14.0 V at 5 000 r/min.
13.5 – 15.0 V at 5 000 r/min.
150 W at 5 000 r/min.
200 W at 5 000 r/min.
3 – 5
Ω
YT7B-BS
12 V 21.6 kC (6 Ah)/10 HR
DR-Z400/EK2 (’02-MODEL) 11-13
LIMIT
———
———
———
———
———
———
———
———
0.3
(0.01)
NOTE
Terminal –
Ground
Plug cap –
Terminal
Y – Y
B – W
G – Bl
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400E
DR-Z400E
11-14 DR-Z400/EK2 (’02-MODEL)
ITEM
Headlight
Taillight
ITEM
Fuel type
Fuel tank including reserve reserve
Engine oil type
Engine oil capacity
Unit: W
SPECIFICATION
*35
LED
SPECIFICATION
Use only unleaded gasoline of at least 90 pump octane ( ).
Gasoline containing MTBE (MethyI Tertiary ButyI
Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 95 octane or higher. An unleaded gasoline is recommended.
Overhaul
10.0 L
(2.6/2.2 US/lmp gal)
2.3 L
(0.6/0.5 US/lmp gal)
Change
SAE 10W/40, API SF or SG
Filter change
1 700 ml
(1.8/1.5 US/lmp qt)
1 800 ml
(1.9/1.6 US/lmp qt)
1 900 ml
(2.0/1.7 US/lmp qt)
NOTE
E-03, 28
E-01
DR-Z400/EK2 (’02-MODEL) 11-15
ITEM
Valve diam.
Tappet clearance (when cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve head thickness
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension (IN. & EX.)
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN. & EX.
INNER
OUTER
STANDARD
36
(1.42)
29
(1.14)
0.10 – 0.20
(0.0039 – 0.0078)
0.20 – 0.30
(0.0078 – 0.0118)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
———
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
———
———
0.9 – 1.1
(0.035 – 0.043)
———
———
———
56 – 64 N
(5.6 – 6.4 kgf, 12.3 – 14.1 lbs) at length 27.4 mm (1.08 in)
126 – 145 N
(12.6 – 14.5 kgf, 27.7 – 32.0 lbs) at length 30.9 mm (1.22 in)
———
———
0.35
(0.014)
———
———
———
0.05
(0.002)
0.5
(0.02)
———
0.03
(0.001)
32.6
(1.28)
36.3
(1.43)
———
Unit: mm (in)
LIMIT
———
———
———
———
———
11-16 DR-Z400/EK2 (’02-MODEL)
ITEM
Cam height
IN.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Cam chain pin (at arrow “3”)
Cylinder head distortion
Cylinder head cover distortion
EX.
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
36.910 – 36.960
(1.4531 – 1.4551)
36.880 – 36.930
(1.4520 – 1.4539)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8653 – 0.8659)
———
15th pin
———
———
ITEM
Compression pressure
(Automatic de-comp. actuated)
Piston to cylinder clearance
Cylinder bore
Piston diam.
STANDARD
1 000 kPa
( 10.0 kgf/cm 2
142 psi
)
0.030 – 0.040
(0.0012 – 0.0016)
90.000 – 90.015
(3.5433 – 3.5439)
89.965 – 89.980
(3.5419 – 3.5425)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
———
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
1st R
2nd R
1st
2nd
1st
Approx.
6.9
(0.27)
Approx.
11.5
(0.45)
0.08 – 0.20
(0.003 – 0.008)
0.08 – 0.20
(0.003 – 0.008)
———
2nd
———
Unit: mm (in)
LIMIT
36.610
(1.4413)
36.580
(1.4402)
0.150
(0.0059)
———
———
0.10
(0.004)
———
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
———
0.120
(0.0047)
Nicks or
Scratches
89.880
(3.5386)
0.05
(0.002)
5.5
(0.22)
9.2
(0.36)
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
ITEM
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
1st
2nd
Oil
1st
2nd
STANDARD
2.220 (74/25 × 20/16 × 12/20)
Above 40 kPa (0.4 kgf/cm 2 , 5.7 psi)
Below 140 kPa (1.4 kgf/cm 2 , 19.9 psi) at 3 000 r/min.
STANDARD
0.78 – 0.80
(0.0307 – 0.0315)
1.30 – 1.32
(0.0512 – 0.0520)
0.81 – 0.83
(0.0319 – 0.0327)
2.01 – 2.03
(0.0791 – 0.0799)
0.71 – 0.76
(0.0280 – 0.0299)
1.08 – 1.10
(0.0425 – 0.0433)
0.77 – 0.79
(0.0303 – 0.0311)
20.002 – 20.008
(0.7875 – 0.7877)
19.995 – 20.000
(0.7872 – 0.7874)
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
———
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
———
DR-Z400/EK2 (’02-MODEL) 11-17
LIMIT
———
———
———
———
———
———
———
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
LIMIT
20.040
(0.7890)
3.0
(0.12)
1.0
(0.04)
———
———
0.08
(0.003)
LIMIT
———
———
11-18 DR-Z400/EK2 (’02-MODEL)
ITEM
Clutch cable play
Drive plate thickness
(No. 1 & No. 2)
Drive plate claw width
(No. 1 & No. 2)
Driven plate distortion
Clutch spring free length
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
———
———
Unit: mm (in)
LIMIT
———
2.62
(0.103)
13.2
(0.520)
0.10
(0.004)
49.9
(1.96)
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
No.1, No.2
& No.3
No.1, No.2
& No.3
Type
Links
20-pitch length
STANDARD
2.960 (74/25)
3.357 (47/14)
2.285 (32/14)
1.733 (26/15)
1.375 (22/16)
1.090 (24/22)
0.863 (19/22)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
4.6 – 4.7
(0.181 – 0.185)
RK520KZO
112
———
Drive chain slack 40 – 50
(1.6 – 2.0)
ITEM
Carburetor type
Bore size
I.D. No
Idle r/min.
Float height
Main jet
Jet needle
Needle jet
(M.J.)
(J.N.)
(N.J.)
SPECIFICATION
KEIHIN FCR39H
39 mm
(1.5 in)
29F6
1 800 ± 100 r/min
9.0 ± 1.0 mm
(0.35 ± 0.04 in)
#165
OBDXP-4th
2.9 mm
(0.11 in)
Unit: mm (in) Except ratio
LIMIT
———
———
———
———
———
———
———
0.5
(0.020)
———
———
———
———
319.4
(12.57)
———
DR-Z400/EK2 (’02-MODEL) 11-19
ITEM
Slow jet
Slow air jet
Air jet
Pilot screw
Throttle cable play
(pulling cable)
(S.J.)
(S.A.J.)
(A.J.)
(P.S.)
SPECIFICATION
#45
#60
#90
2¾ turns back
2 – 4 mm
(0.08 – 0.16 in)
ITEM
Radiator cap valve opening pressure
Engine coolant type
Engine coolant capacity
STANDARD/SPECIFICATION
95 – 125 kPa
(0.95 – 1.25 kgf/cm 2 , 13.5 – 17.8 psi)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50 : 50.
1 250 ml
(1.3/1.1 US/Imp qt)
ITEM
Brake lever play
Rear brake pedal height
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Front
Rear
STANDARD/SPECIFICATION
0.1 – 0.3
(0.004 – 0.010)
5
(0.2)
3.0 ± 0.2
(0.118 ± 0.008)
4.5 ± 0.2
(0.177 ± 0.008)
———
Front
Rear
Front
Rear
Front
Rear
Front
Rear
12.700 – 12.743
(0.5000 – 0.5017)
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
12.657 – 12.684
(0.4983 – 0.4994)
27.000 – 27.050
(1.0630 – 1.0650)
27.000 – 27.050
(1.0630 – 1.0650)
26.900 – 26.950
(1.0591 – 1.0610)
26.900 – 26.950
(1.0591 – 1.0610)
DOT 4
NOTE
———
———
———
———
———
———
Unit: mm (in)
LIMIT
———
———
2.5
(0.098)
4.0
(0.16)
0.30
(0.012)
———
———
———
11-20 DR-Z400/EK2 (’02-MODEL)
ITEM
Wheel rim runout
Wheel axle runout
Wheel rim size
Axial
Radial
Front
Rear
Front
Rear
STANDARD
———
———
———
———
1.60 × 21
2.15 × 18
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
———
———
ITEM
Cold inflation tire pressure
(Solo riding)
Tire size
Tire tread depth
Front
Rear
Front
Rear
STANDARD/SPECIFICATION
125 kPa (1.25 kgf/cm 2 , 18 psi)
125 kPa (1.25 kgf/cm
2
, 18 psi)
80/100-21 51P or 80/100-21 M/C 51P
120/90-18 65P or 120/90-18 M/C 65P
Front ———
Rear
———
ITEM
Front fork stroke
Front fork spring free length
STANDARD/SPECIFICATION
288
(11.3)
510.6
(20.1)
122
(4.8)
Front fork oil level
(without spring)
Front fork oil type
Front fork oil capacity
(each leg)
Front fork damping force adjuster Rebound
SUZUKI FORK OIL SS-05 or an equivalent fork oil
720 ml
(24.3/25.4 US/Imp oz)
15th clicks turn back
Rear shock absorber gas pressure
Rear shock absorber oil type
Rear shock absorber oil capacity
Rear shock absorber spring pre-set length
Rear shock absorber damping force adjuster
Compression 12th clicks turn back
900 kPa
(9.0 kgf/cm
2
, 128 psi)
SUZUKI REAR SUSPENSION OIL SS-25 or an equivalent suspension oil
380 ml
(12.8/13.4 US/Imp oz)
258.0
(10.2)
13th clicks turn back Rebound
Compression
*High speed 1¼ turns out
*Low speed 10th clicks turn back
LIMIT
———
———
———
———
4.0 mm
(0.16 in)
4.0 mm
(0.16 in)
———
———
———
———
———
———
Unit: mm (in)
LIMIT
———
500
(19.7)
———
———
———
———
———
———
ITEM
Rear wheel travel
Swingarm pivot shaft runout
STANDARD/SPECIFICATION
295
(11.6)
———
Spark plug
ITEM
Spark performance
Ignition coil resistance
Type
Gap
Primary
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8 mm
(0.028 – 0.031 mm)
Over 8 mm (0.3 in) at 1 atm.
0.1 – 1.0
Ω
Secondary 12 – 20 k
Ω
Ignition coil primary peak voltage
More than 150 V
Generator coil resistance
Pick-up coil peak voltage
Signal coil peak voltage
Generator no-load voltage
(when engine is cold)
Regulated voltage
Generator Max. output
Starter relay resistance
Battery Type designation
Capacity
Charging
Signal coil
Pick-up coil
0.50 – 1.25
Ω
0.05 – 0.20
Ω
390 – 600
Ω
More than 5.0 V
More than 1.4 V
More than 75 V (AC) at 5 000 r/min.
13.5 – 15.0 V at 5 000 r/min.
200 W at 5 000 r/min.
3 – 5
Ω
YT7B-BS
12 V 21.6 kC (6 Ah)/10 HR
Headlight
ITEM
Brake light/Taillight
Turn signal light
Speedometer light
Neutral indicator light
High beam indicator light
Turn signal indicator light
HI
LO
SPECIFICATION
60
55
21/5
21
LED
2
2
2
DR-Z400/EK2 (’02-MODEL) 11-21
LIMIT
———
0.3
(0.01)
NOTE
Terminal –
Ground
Plug cap –
Terminal
: B/W,
: B/Y
Y – Y
B – W
G – Bl
: Bl, : G
: B, : W
Y – Y
Unit: W
11-22 DR-Z400/EK2 (’02-MODEL)
ITEM
Fuel type
Fuel tank including reserve reserve
Engine oil type
Engine oil capacity
SPECIFICATION
Gasoline used should be graded 95 octane or higher. An unleaded gasoline is recommended.
10.0 L
(2.6/2.2 US/lmp gal)
2.3 L
(0.6/0.5 US/lmp gal)
Change
SAE 10W/40, API SF or SG
1 700 ml
(1.8/1.5 US/lmp qt)
Filter change
Overhaul
1 800 ml
(1.9/1.6 US/lmp qt)
1 900 ml
(2.0/1.7 US/lmp qt)
NOTE
TOOLS AND EQUIPMENT
• The following tools and equipment are required to perform oil replacement.
DR-Z400/EK2 (’02-MODEL) 11-23
1
Screwdriver or small punch
2
Vise*
3
Drain pan
4
Specified shock oil (SS-25)
5
Rags
6
Nitrogen tank
7
Filler hose and nozzle
8
Regulator assembly
9
Service manual
* Not shown in the illustration
OIL REPLACEMENT
• Remove the rear shock absorber unit from the frame (
33), and then clean and dry it.
• Remove the spring from the rear shock absorber unit. (
34)
6-
6-
• Remove the valve cap, and then press the valve with a screwdriver to bleed out nitrogen gas.
* Releasing high pressure gas from the rear shock absorber unit can be hazardous. Never perform any servicing until the nitrogen gas pressure has been released from the rear shock absorber unit.
* When releasing the gas pressure, place a rag over the gas valve and use the tip of a screwdriver to press the valve. Do not use your finger to depress the gas valve, and be sure to direct the valve away from your face and body.
* Be sure to always wear eye protection when performing this procedure.
• Remove the compression adjuster assembly from the rear shock absorber using special tool.
09941-53640: R.C.U. compression adjuster wrench
11-24 DR-Z400/EK2 (’02-MODEL)
• Move the rod and drain the oil completely into a drain pan.
• Push the valve core again to equalize atmospheric pressure.
• Fill a drain pan with the specified rear suspension oil.
• Place the rear shock absorber into the drain pan so that the drain hole is submerged in the oil, and then fill the rear shock absorber with the oil by stroking the rod.
99000-99001-S25:
SUZUKI REAR SUSPENSION OIL SS-25
Oil capacity:
Approximately 380 ml (12.8 US oz, 13.4 lmp oz)
• When fitting the orifice in the compression adjuster hole, face the conical side to the valve side.
• Tighten the compression adjuster assembly to the specified torque using the special tool.
Replace the remove O-rings with new ones.
Compression adjuster assembly:
30 N·m (3.0 kgf.m, 21.5 lb-ft)
09941-53640: R.C.U. compression adjuster wrench
• Fill the rear shock absorber unit with nitrogen gas.
Rear shock absorber gas pressure:
900 kPa (9.0 kgf/cm 2 , 128 psi)
• Tighten the gas valve cap.
* Use of flammable gas for pressuring the rear shock absorber unit can be hazardous. Flammable gas such as gas welding oxygen can create a fire hazard.
* Use nitrogen gas. If nitrogen gas is not available, compressed air free from water can be substituted.
* Applying too much pressure to the rear shock absorber unit may rupture the rear shock absorber unit.
* Be sure to fill the rear shock absorber unit to the specified pressured.
Riding the motorcycle with abnormal gas pressure can damage the rear shock absorber unit. Low gas pressure can result in oil leakage. Abnormal gas pressure cannot provide normal performance of the rear shock absorber.
Be sure to fill the rear shock absorber unit to the specified pressure.
Reassemble and remount the rear shock absorber in the reverse order of removal and disassembly. Pay special attention to the following points:
• Install the spring, spring seat, and circlip.
• Turn the adjuster
1
to obtain the spring length
A
of
258.0 mm (10.16 in).
• Tighten the lock ring
2
to the specified torque.
Rear shock absorber lock ring:
90 N·m (9.0 kgf.m, 65.0 lb-ft)
SPRING SETTING TABLE
Standard
258.0 mm
(10.16 in)
Spring preset length
Softest
259.5 mm
(10.22 in)
Stiffest
247.5 mm
(9.74 in)
Do not set the spring less than 247.5 mm (9.74 in).
DR-Z400/EK2 (’02-MODEL) 11-25
• Tighten the rear shock absorber upper and lower mounting nut to the specified torque.
Rear shock absorber upper and lower mounting nut:
55 N·m (5.5 kgf.m, 40.0 lb-ft)
11-26 DR-Z400/EK2 (’02-MODEL)
• Apply THREAD LOCK SUPER “1303” to the seat rail lower mounting bolt
4
.
99000-32030: THREAD LOCK SUPER “1303”
• Tighten the seat rail upper mounting nut
3
and lower mounting bolts
4
to the specified torque.
Seat rail upper mounting nut:
35 N·m (3.5 kgf-m, 25.5 lb-ft)
Seat rail lower mounting bolt:
35 N·m (3.5 kgf-m, 25.5 lb-ft)
After installing the rear suspension, adjust the rebound and compression damping force as follows.
Fully turn the damping force adjuster
1
clockwise. It is at stiffest position and turn it out to standard position.
Standard setting position: 13 clicks out
COMPRESSION DAMPING FORCE ADJUSTMENT
Compression damping force could be adjusted in two stage by turning the two adjusters.
High speed damping force
Fully turn the high speed damping force adjuster
2
clockwise. It is at stiffest position and turn it out to standard position.
Low speed damping force
Fully turn the low speed damping force adjuster
3
clockwise. It is at stiffest position and turn it out to standard position.
Standard setting position
High speed damping: 1 turn out
Low speed damping: 10 clicks out
DR-Z400/EK2 (’02-MODEL) 11-27
B
Y
Bl
B/Y
B/W
B/W
O
W
B/Y
Bl
B
Y
G
W
Bl
W
B/W
B/Y
B/W
Bl
Y
B/W
B/W
B/W
O
Y
Y
Y
O
B/W
B/W
O
R
Y
Y
Y
B/W
Y
Y
Y
Bl
W
B
G
B
11-28 DR-Z400/EK2 (’02-MODEL)
Y
B
Bl
Y/G
Y/G Y/G
Y/G
W
B/W
Bl
Y
B
G
W
Bl
B/W
W
O
B/Y
Bl
Y
B/W
B/Y
O
Y/G
O
B/Y
B/W
B/Y
B/W
B/W
Y/G R/W
B/W
O
R
R
B/W
R
Y
Y
R
Y
B/W
R
R
B/W
O
R
Gr
Y
Y
Y
Bl
G
B
W
R
Y
Y
Y
B/W
DR-Z400/EK2 (’02-MODEL) 11-29
Prepared by
3rd Ed. February, 2002
1st Ed. December, 1999
Part No. 99500-43022-01E
Printed in Japan
336
Printed in Japan
Y K1 K2
TK
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Liquid-cooled 4-stroke engine
DOHC design
12.2:1 compression ratio
KEIHIN FCR39 carburetor
Electric start
Dry sump lubrication
5-speed transmission
Telescopic front fork
Link-type rear suspension
Disc brakes front and rear
For the USA, SUZUKI recommends using SUZUKI PERFORMANCE 4 MOTOR OIL or an oil rated SF or SG under the API service classification. The recommended viscosity is SAE 10W/40. For other countries, use a premium 4-stroke motor oil rated SF or SG with viscosity SAE 10W-40.
For USA and Canada, use unleaded gasoline with a pump octane of at least 90 (R + M). For other countries, use gasoline graded 95 octane (research method) or higher. Unleaded gasoline is recommended.
The tappet clearance must be checked and adjusted periodically. The clearance is adjusted by replacing the existing tappet shim with a thicker or thinner shim. Ensure the piston is at TDC on the compression stroke.
How to install the kick starter on a DR-Z400 model?
To install the kick starter on a DR-Z400 model, align the punch mark on the kick starter with the line on the kick starter shaft. Then, install the kick starter shaft assembly, ensuring the end of the spring is hooked onto the crankcase boss. When installing the kick lever bolt, apply SUZUKI THREAD LOCK SUPER “1303” and tighten it to the specified torque. This process is specific to the DR-Z400 model.
What is the recommended service schedule for a Suzuki DR-Z400?
Inspections, replacements, and tightening are recommended at 5, 30, and 60 hours of operation. More frequent service is needed under severe conditions. Engine coolant and brake fluid should be replaced every two years, and brake hoses and the decompression lever every four years.
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