Suzuki 2005 DR-Z400SMK5 Supplementary Service Manual
Suzuki 2005 DR-Z400SMK5 is a liquid-cooled, four-stroke, DOHC motorcycle with a dry mass of 134 kg (295 lbs). It has a 398 cm3 (24.3 cu. in) displacement, a 11.3:1 compression ratio, and a 5-speed constant mesh transmission. The DR-Z400SMK5 is equipped with a wet multi-plate clutch, a dry sump lubrication system, and an electric starter. It has a 2.733 (41/15) final reduction ratio and is driven by an RK520KZO, 110-link drive chain. The DR-Z400SMK5 has a 260 mm (10.2 in) ground clearance and a seat height of 890 mm (35.0 in).
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Top DR-Z400SM USE THIS MANUAL WITH: DR-Z400S SERVICE MANUAL (99500-43034-01E) 99501-43110-01E Printed in Japan K5 No. 10539 99501-43110-01E DR-Z400SM_01E Supply Cover14 for PS printing 2004.12.13 Bottom DR-Z400SMK5 (’05-MODEL) DR-Z400SMK5 (’05-MODEL) FOREWORD This manual describes service data, service specifications and servicing procedures which differ from those of the DR-Z400SK5 (’05-model). NOTE: * Any differences between the DR-Z400SK5 (’05-model) and DR-Z400SMK5 (’05-model) in specifications and service data are indicated with an asterisk mark (*). * Please refer to the Service Manual for details which are not given in this manual. CONTENTS SPECIFICATIONS ............................................................................................... 2 SERVICE DATA .................................................................................................. 3 FRONT FORK......................................................................................................11 DRIVE CHAIN ADJUSTMENT ............................................................................26 TIGHTENING TORQUE.......................................................................................27 FRONT AXLE ......................................................................................................28 REAR AXLE ........................................................................................................29 FRONT BRAKE HOSE ROUTING ......................................................................30 REAR BRAKE HOSE ROUTING ........................................................................31 WIRING DIAGRAM..............................................................................................32 E L P M A S COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE E-02 E-19 E-03 E-28 E-33 UE-19 COUNTRY or AREA U.K. E.U. U.S.A. (Except for california) Canada California (U.S.A.) E.U. © COPYRIGHT SUZUKI MOTOR CORPORATION 2004 EFFECTIVE FRAME NO. JS1B8111100100001 – JS1B8111200100001 – JS1SK44A 52100001 – JS1SK44A 52100001 – JS1SK44A 52100001 – JS1B8211100100001 – 1 2 DR-Z400SMK5 (’05-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ......................................................................................* 2 225 mm (87.6 in) Overall width .......................................................................................* 870 mm (34.3 in) Overall height ......................................................................................* 1 185 mm (46.7 in) Wheelbase ..........................................................................................* 1 460 mm (57.5 in) Ground clearance................................................................................* 260 mm (10.2 in) Seat height. .........................................................................................* 890 mm (35.0 in) Dry mass.............................................................................................* 134 kg (295 lbs) ...................................E-03, 28, 33 * 135 kg (297 lbs) ...................................Others ENGINE Type..................................................................................................... Number of cylinders ............................................................................ Bore .................................................................................................... Stroke.................................................................................................. Displacement ...................................................................................... Compression ratio ............................................................................... Carburetor. .......................................................................................... Air cleaner ........................................................................................... Starter system..................................................................................... Lubrication system .............................................................................. Idle speed ........................................................................................... Four-stroke, liquid-cooled, DOHC 1 90.0 mm (3.543 in) 62.6 mm (2.465 in) 398 cm3 (24.3 cu. in) 11.3 : 1 MIKUNI BSR36, single Polyurethane foam element Electric Dry sump 1 500 ± 100 r/min DRIVE TRAIN Clutch .................................................................................................. Transmission ....................................................................................... Gearshift pattern ................................................................................. Primary reduction ratio........................................................................ Gear ratios, Low ................................................................................. 2nd.................................................................................. 3rd .................................................................................. 4th................................................................................... Top .................................................................................. Final reduction ratio.............................................................................* Drive chain ..........................................................................................* Wet multi-plate type 5-speed constant mesh 1-down, 4-up 2.960 (74/25) 2.285 (32/14) 1.733 (26/15) 1.375 (22/16) 1.090 (24/22) 0.863 (19/22) 2.733 (41/15) RK520KZO, 110 links CHASSIS Front suspension.................................................................................* Rear suspension ................................................................................. Front suspension stroke ......................................................................* Rear wheel travel. ...............................................................................* Caster .................................................................................................* Trail......................................................................................................* Steering angle.....................................................................................* Turning radius .....................................................................................* Front brake .......................................................................................... Rear brake .......................................................................................... Front tire size ......................................................................................* Rear tire size .......................................................................................* A S P M ELECTRICAL Ignition type......................................................................................... Ignition timing. ..................................................................................... Spark plug........................................................................................... Generator ............................................................................................ Fuse .................................................................................................... Battery................................................................................................. Headlight ............................................................................................. Turn signal light ................................................................................... Brake light/Taillight .............................................................................. Speedometer light ............................................................................... Neutral indicator light .......................................................................... High beam indicator light .................................................................... Turn signal indicator light .................................................................... Water temperature warning light ......................................................... CAPACITIES Fuel tank, including reserve ............................................................... reserve .............................................................................. Engine oil, oil change......................................................................... with filter change .............................................................. overhaul. .......................................................................... Coolant................................................................................................ These specifications are subject to change without notice. E L Inverted telescopic, coil spring, oil damped Link type, coil spring, oil damped 260 mm (10.2 in) 276 mm (10.9 in) 26° 15’ 94 mm (3.70 in) 38° (right & left) 2.6 m (8.5 ft) Disc brake Disc brake 120/70R17M/C 58H, tube type 140/70R17M/C 66H, tube type Electronic ignition (CDI) 7° B.T.D.C. at 1 500 r/min NGK CR8E or DENSO U24ESR-N Three-phase A.C. generator 20 A 12 V 21.6 kC (6 Ah) /10 HR 12 V 60/55 W 12 V 21 W × 4 12 V 21/5 W LED LED LED LED LED 9.5 L (2.5/2.1 US/Imp gal)...................E-33 10.0 L (2.6/2.2 US/Imp gal)...................Others 2.3 L (0.6/0.5 US/Imp gal) 1 700 ml (1.8/1.5 US/Imp qt) 1 800 ml (1.9/1.6 US/Imp qt) 1 900 ml (2.0/1.7 US/Imp qt) 1.3 L (1.4/1.1 US/Imp qt) DR-Z400SMK5 (’05-MODEL) 3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM Valve diam. IN. EX. Tappet clearance (when cold) IN. EX. Valve guide to valve stem clearance IN. EX. 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) LIMIT — — — — — — Valve stem deflection IN. & EX. — 0.35 (0.014) Valve guide I.D. IN. & EX. — Valve stem O.D. IN. EX. 5.000 – 5.012 (0.1969 – 0.1973) 4.975 – 4.990 (0.1959 – 0.1965) 4.955 – 4.970 (0.1951 – 0.1957) Valve stem runout IN. & EX. — Valve head thickness IN. & EX. Valve seat width Valve head radial runout Valve spring free length (IN. & EX.) Valve spring tension (IN. & EX.) E L P M — — — 0.05 (0.002) 0.5 (0.02) IN. & EX. 0.9 – 1.1 (0.035 – 0.043) — IN. & EX. — INNER — OUTER — 0.03 (0.001) 32.6 (1.28) 36.3 (1.43) A S INNER OUTER 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) — — 4 DR-Z400SMK5 (’05-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM Cam height STANDARD 36.490 – 36.540 (1.4366 – 1.4386) 35.790 – 35.840 (1.4091 – 1.4110) 0.019 – 0.053 (0.0007 – 0.0021) 22.012 – 22.025 (0.8666 – 0.8671) 21.972 – 21.993 (0.8653 – 0.8659) IN. EX. Camshaft journal oil clearance IN. & EX. Camshaft journal holder I.D. IN. & EX. Camshaft journal O.D. IN. & EX. Camshaft runout 15th pin — Cylinder head cover distortion — E L CYLINDER + PISTON + PISTON RING ITEM Compression pressure (Automatic de-comp. actuated) Piston to cylinder clearance Cylinder bore Piston diam. Cylinder distortion Piston ring free end gap Piston ring end gap Piston ring to groove clearance STANDARD 950 kPa (9.5 kgf/cm2, 135 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. P M A S — 1st R Approx. 6.9 (0.27) 2nd R Approx. 11.5 (0.45) 2nd 0.08 – 0.20 (0.003 – 0.008) 0.08 – 0.20 (0.003 – 0.008) 1st — 2nd — 1st Piston ring groove width 1st 2nd Oil — — 0.10 (0.004) — 0.05 (0.002) 0.05 (0.002) — Cam chain pin (at arrow “3”) Cylinder head distortion LIMIT 36.190 (1.4248) 35.490 (1.3972) 0.150 (0.0059) 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) 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) — — — — DR-Z400SMK5 (’05-MODEL) ITEM Piston ring thickness 1st 2nd Piston pin bore Piston pin O.D. STANDARD 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) CONROD + CRANKSHAFT STANDARD 20.010 – 20.018 (0.7878 – 0.7881) Conrod deflection — Conrod big end side clearance 0.30 – 0.65 (0.012 – 0.026) 21.95 – 22.00 (0.864 – 0.866) 62.0 ± 0.1 (2.441 ± 0.004) Conrod big end width P M Crank web to web width Crankshaft runout E L Drive plate thickness (No. 1 & No. 2) Drive plate claw width (No. 1 & No. 2) Driven plate distortion Clutch spring free length — — 20.030 (0.7886) 19.980 (0.7866) LIMIT 20.040 (0.7890) 3.0 (0.12) 1.0 (0.04) — — 0.08 (0.003) STANDARD 2.220 (74/25 × 20/16 × 12/20) Above 40 kPa (0.4 kgf/cm2, 5.7 psi) Below 140 kPa (1.4 kgf/cm2, 19.9 psi) at 3 000 r/min LIMIT — CLUTCH ITEM Clutch cable play — — A S ITEM Oil pump reduction ratio Oil pressure (at 60 °C, 140 °F) LIMIT Unit: mm (in) ITEM Conrod small end I.D. OIL PUMP 5 — Unit: mm (in) STANDARD 10 – 15 (0.4 – 0.6) 2.92 – 3.08 (0.115 – 0.121) 13.7 – 13.8 (0.539 – 0.543) — — LIMIT — 2.62 (0.103) 13.2 (0.520) 0.10 (0.004) 49.9 (1.96) 6 DR-Z400SMK5 (’05-MODEL) TRANSMISSTION + DRIVE CHAIN ITEM Primary reduction ratio Final reduction ratio Gear ratios Low 2nd 3rd 4th Top Shift fork to groove clearance Shift fork groove width No. 1, No. 2 & No. 3 No. 1, No. 2 & No. 3 Type Links 20-pitch length Shift fork thickness Drive chain Unit: mm (in) Except ratio STANDARD 2.960 (74/25) * 2.733 (41/15) 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 * 110 Drive chain slack CARBURETOR ITEM Carburetor type Bore size I.D. No. Idle r/min Float height Main jet Jet needle Needle jet Pilot jet Pilot air jet Pilot screw Throttle cable play (pulling cable) E L — 40 – 50 (1.6 – 2.0) P M A S (M.J.) (J.N.) (N.J.) (P.J.) (P.A.J.) (P.S.) E-02, 19 MIKUNI BSR36 36 mm (1.4 in) 29FA 1 500 ± 100 r/min 130 ± 1.0 mm (0.51 ± 0.04 in) #142.5 5DH36-2nd P-0M #22.5 #165 3 turns back 2 – 4 mm (0.08 – 0.16 in) LIMIT — — — — — — — 0.5 (0.020) — — — — 319.4 (12.57) — SPECIFICATION E-03, 28 ← ← 29FB ← E-33 ← ← 29FC ← ← ← # 5DH37 # #135 PRE-SET ← ← ← ← ← ← ← ← DR-Z400SMK5 (’05-MODEL) 7 THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT ITEM Thermostat valve opening temperature Thermostat valve lift Engine coolant temp. switch operating temperature Radiator cap valve opening pressure Cooling fan thermo-switch operating temperature Engine coolant type Engine coolant capacity STANDARD/SPECIFICATION LIMIT Approx. 75 °C (167 °F) — Over 6 mm (0.24 in) at 90 °C (194 °F) OFF→ON Approx. 117 °C (243 °F) ON→OFF Approx. 100 °C (212 °F) 95 – 125 kPa (0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi) OFF→ON Approx. 96 °C (205 °F) ON→OFF Approx. 91 °C (196 °F) 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/lmp qt) — — — BRAKE + WHEEL Rear brake pedal height Brake disc thickness A S Front Rear Master cylinder piston diam. Front Rear Brake caliper cylinder bore Front Rear Brake caliper piston diam. Front Rear Brake fluid type Wheel rim runout STANDARD/SPECIFICATION 0.1 – 0.3 (0.004 – 0.010) 5 (0.2) * 4.0 ± 0.2 (0.16 ± 0.008) 4.5 ± 0.2 (0.177 ± 0.008) P M Front Rear Master cylinder bore — — — — Unit: mm (in) ITEM Brake lever play Brake disc runout — E L — 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) 26.918 – 26.968 (1.0598 – 1.0617) 26.900 – 26.950 (1.0591 – 1.0610) DOT 4 Axial — Radial — LIMIT — — 3.5 (0.138) 4.0 (0.16) 0.30 (0.012) — — — — — — — — — 2.0 (0.08) 2.0 (0.08) 8 DR-Z400SMK5 (’05-MODEL) ITEM Wheel axle runout STANDARD/SPECIFICATION Wheel rim size Front — Rear — * Front * Rear 17M/C × MT 3.50 17M/C × MT 4.50 LIMIT 0.25 (0.010) 0.25 (0.010) — — TIRE ITEM Cold inflation tire pressure (Solo riding) * Front * Rear * Front * Rear * Front * Rear * Front * Rear Cold inflation tire pressure (Dual riding) Tire size Tire type Tire tread depth STANDARD/SPECIFICATION 175 kPa (1.75 kgf/cm2, 25 psi) 200 kPa (2.00 kgf/cm2, 29 psi) 175 kPa (1.75 kgf/cm2, 25 psi) 225 kPa (2.25 kgf/cm2, 33 psi) 120/70R17M/C 58H 140/70R17M/C 66H DUNLOP D208F SM DUNLOP D208 SM * Front P M * Rear SUSPENSION ITEM Front fork stroke Front fork inner tube O.D. Front fork spring free length — A S STANDARD/SPECIFICATION * 260 (10.2) Front fork oil type Front fork oil capacity (each leg) Front fork damping force adjuster * OUTER * INNER * Rebound Compression Rear shock absorber gas pressure Rear shock absorber spring pre-set length Rear shock absorber damping force adjuster * Rebound * Compression Rear wheel travel Swingarm pivot shaft runout E L — * 450 (17.7) SUZUKI FORK OIL SS-05 or an equivalent fork oli 350 ml (11.830/12.324 US/Imp oz) 182 ml (6.152/6.408 US/Imp oz) 17th clicks turn back 13th clicks turn back * 981 kPa (9.81 kgf/cm2, 139 psi) * 254 (10) 14th clicks turn back High speed 1 and 1/8 turns out Low speed 10th clicks turn back * 276 (10.9) — LIMIT — — — — — — — — 1.6 (0.06) 2.0 (0.08) Unit: mm (in) LIMIT — 441 (17.3) — — — — — — — — — — — 0.3 (0.01) DR-Z400SMK5 (’05-MODEL) ELECTRICAL ITEM Spark plug Type Gap Spark performance Ignition coil resistance Ignition coil primary peak voltage 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 WATTAGE ITEM Headlight 0.1 – 1.0 Ω Secondary 12 – 20 kΩ Charging Signal coil Pick-up coil LO Position light Brake light/Taillight Turn signal light Speedometer light Neutral indicator light Turn signal indicator light High beam indicator light Water temp. indicator light More than 150 V 0.50 – 1.25 Ω 0.05 – 0.20 Ω 390 – 600 Ω More than 5.0 V More than 1.4 V Terminal – Ground Plug cap – Terminal +: B/W, -: B/Y Y–Y B–W G – Bl +: Bl, -: G +: B, -: W More than 75 V (AC) at 5 000 r/min Y–Y E L 13.5 – 15.0 V at 5 000 r/min 200 W at 5 000 r/min 3–5Ω YT7B-BS 12 V 21.6 kC (6 Ah)/10 HR 20 A P M A S HI Unit: mm (in) NOTE SPECIFICATION DENSO: U24ESR-N NGK: CR8E 0.7 – 0.8 (0.028 – 0.031) Over 8 mm (0.3 in) at 1 atm. Primary 9 Unit: W SPECIFICATION E-02, 19 60 55 4 21/5 21 LED LED LED LED LED E-03, 28, 33 ← ← ← ← ← ← ← ← ← 10 DR-Z400SMK5 (’05-MODEL) FUEL + OIL ITEM Fuel type Fuel tank capacity including reserve reserve Engine oil type Engine oil capacity SPECIFICATION Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. 9.5 L (2.5/2.1 US/lmp qt) 10.0 L (2.6/2.2 US/lmp qt) 2.3 L (0.6/0.5 US/lmp qt) * SAE 10W-40, API SF/SG or SH/SJ with JASO MA 1 700 ml Change (1.8/1.5 US/lmp qt) 1 800 ml Filter change (1.9/1.6 US/lmp qt) 1 900 ml Overhaul (2.0/1.7 US/lmp qt) E L A S P M NOTE E-03, 28, 33 E-33 The others DR-Z400SMK5 (’05-MODEL) FRONT FORK CONSTRUCTION E L P M A S ITEM ) * + , N·m kgf-m lb-ft 90 9.0 65.0 23 2.3 16.5 45 4.5 32.5 18 1.8 13.0 ITEM . / 0 N·m kgf-m lb-ft 30 3.0 21.5 35 3.5 25.5 23 2.3 16.5 70 7.0 50.5 11 12 DR-Z400SMK5 (’05-MODEL) REMOVAL • Place a block under the chassis tubes. • Remove the fork protectors, brake hose guide and brake hose clamp. • Remove the front brake caliper. • Remove the front wheel. • Remove the handlebars. • Loosen the front fork cap bolt 1 – 2 turns to facilitate later disassembly. 09941-53630: Front fork top cap wrench P M E L A S • Loosen the front fork upper clamp bolts 1. • Hold the fork body and loosen the fork lower clamp bolts 2. • Remove the front fork. DR-Z400SMK5 (’05-MODEL) DISASSEMBLY • Set rebound and compression damper settings to the minimum settings (softest) before disassembling. Record the setting before turning the adjuster. • Thoroughly clean the fork before disassembly. Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak. Avoid scratching or damaging the inner tube or the oil seal. Use a mild detergent or car wash soap and sponge out dirt with plenty of water. • Clamp the outer tube with a vise. Protect the outer tube surface using a rag. • Loosen and remove the fork cap bolt (sub-tank) from the outer tube and slowly slide down the outer tube. E L 09941-53630: Front fork top cap wrench Clamping the outer tube too tight can damage it which will affect riding stability. P M Do not clamp the outer tube too tight. A S • Place a drain pan under the front fork and drain fork oil. NOTE: Face the oil hole A on the sub-tank downward. • Raise the outer tube and temporarily tighten the fork cap bolt 1 (sub-tank) to the outer tube. 13 14 DR-Z400SMK5 (’05-MODEL) • Clamp the axle holder 2 with a vise. Protect the axle holder surface using a rag. • Loosen the center bolt 3 completely with a 21 mm socket wrench. Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight. • Compress the outer tube by hands and install the conrod holder (special tool) between the axle holder bottom 2 and locknut 4. 09910-20115: Conrod holder • Hold the locknut with a wrench and remove the center bolt. P M E L • Remove the push rod. A S DR-Z400SMK5 (’05-MODEL) • With the outer tube compressed by hands, remove the special tool. Removing the locknut 4 and pushing the inner rod thread into the damper rod will damage the inner rod oil seal. Do not remove the locknut 4 from the inner rod. • Loosen the fork cap bolt 1 (sub-tank) and remove the sub-tank 5 along with the damper rod assembly 6. • Remove the fork spring 7. Disassembling the damper rod assembly can lead to trouble. Do not disassemble the damper rod assembly. Do not separate the sub-tank and damper rod assembly. P M E L A S • Remove the dust seal 8 and the stopper ring 9. Scratches on the inner tube could cause oil leaks. Avoid scratching when removing. 15 16 DR-Z400SMK5 (’05-MODEL) INNER TUBE • Separate the inner tube out of the outer tube. • Remove the slide bushing from the inner tube. • Remove the following parts from the inner tube. Guide bushing 1 Seal retainer 2 Oil seal 3 Stopper ring 4 Dust seal 5 A S P M • Clamp the bottom (flat part) of the sub-tank with a vise. Do not clamp the sub-tank too tight. • Loosen the compression damper unit. E L DR-Z400SMK5 (’05-MODEL) • Remove the compression damper unit from the sub-tank. NOTE: Slowly compress the inner rod until it stops so that the compression damper unit can be removed easily. • Drain the fork oil from the damper rod assembly by moving the inner rod several strokes. E L P M INSPECTION CENTER BOLT • Inspect the adjuster rod of the center bolt for damage. If it is damaged, replace it with a new one. • Replace the O-ring with a new one. A S COMPRESSION DAMPER UNIT • Inspect the compression damper unit for damage. If it is damaged, replace it with a new one. • Replace the O-ring with a new one. Disassembling the compression damper unit can lead to trouble. Do not disassemble the compression damper unit. 17 18 DR-Z400SMK5 (’05-MODEL) INNER TUBE AND OUTER TUBE • Inspect the inner tube for scratches. If it has scratches, replace it with a new one. • Inspect the outer tube for dent. If it is dented all the way to the inner side, replace it with a new one. • Measure the inner tube runout using the V-blocks and dial gauge. Inner tube runout Service Limit: 0.4 mm (0.02 in) 09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block DAMPER ROD • Inspect the damper rod assembly for scratches or bending. If it has scratches or is bent, replace it with a new one. P M E L A S FORK SPRING • Measure the free length of front fork spring. Service Limit: 441 mm (17.36 in) DR-Z400SMK5 (’05-MODEL) SLIDE BUSHING AND GUIDE BUSHING Inspect the “teflon coating metals” (slide bushing and guide bushing) for wear or damage. If they are worn or damaged, replace them with new ones. Inspect the metal particles on the “teflon coating metals”. If they are not clean, clean them with a nylon brush and fork oil. REASSEMBLY NOTE: * Clean all fork parts before reassembling. * Replace the O-rings, oil seal and dust seal with the new ones. * Apply specified front fork oil when installing the O-rings, slide bushing, guide bushing, damper unit and other sliding parts. INNER TUBE • Apply front fork oil to the oil seal lip and the dust seal. • Cover the inner tube with a plastic film. • Install the following parts to the inner tube: New dust seal 1 Stopper ring 2 New oil seal 3 E L P M A S Scratches on the oil seal lip can cause oil leaks. When installing the seals, place a plastic film over the bushing attachment groove and edges of the inner tube to avoid damaging the seals’ lip. NOTE: The side of the oil seal that has a mark should face the dust seal. • Remove the plastic film and install the seal retainer 4, guide bushing 5 and slide bushing 6. • Clean the parts and keep them free from dust. NOTE: Inspect the bushings for burrs. If there is a burr, remove it with a knife, taking care not to peel off the teflon coating. If the bushings have a large crack or excessive play after installing them, replace them with new ones. • Insert the inner tube into the outer tube. 19 20 DR-Z400SMK5 (’05-MODEL) • Install the new oil seal 3 with the special tool until the stopper ring groove of the outer tube can be seen. 09940-52861: Front fork oil seal installer set • Attach the stopper ring securely to the stopper ring groove of the outer tube. • Attach the dust seal 1. NOTE: After attaching the dust seal, make sure that there are no cracks around the circumference of the seal. Cracks could allow water, mud and the like to enter and cause an oil leak. Use of grease as a substitute fork oil when installing the oil seal can result in an oil leak. Applying grease to the dust seal and oil seal can cause dirt to accumulate and damage the dust seal lip and oil seal lip. Use only a thin coat of fork oil on the oil seal. COMPRESSION DAMPER UNIT • Clean each threaded part before installing. P M E L A S • With the damper rod in fully extended position, pour the specified amount of fork oil. Fork oil quantity (Inside the damper rod): 182 ml (6.152/6.408 US/lmp oz) 99000-99001-SS5: SUZUKI FORK OIL SS-05 DR-Z400SMK5 (’05-MODEL) • Apply fork oil to the O-rings and bushing on the compression damper unit. • With the damper rod held immovable in fully extended position, gently install the compression damper unit to the sub-tank. • Clamp the bottom (flat part) of the sub-tank with a vise. Do not clamp the sub-tank too tight. • Tighten the compression damper unit to the specified torque. Compression damper unit: 30 N·m (3.0 kgf-m, 21.5 lb-ft) E L • With the damper rod held in vertical position, slowly move the inner rod several strokes. P M A S • Tighten the locknut by hand completely. • With the damper rod held in vertical position, compress the damper rod fully to discharge an excess of oil. Protect the inner rod end with a rag when compressing the damper rod. NOTE: Set the compression damper setting to the softest. 100 mm (3.9 in) 21 22 DR-Z400SMK5 (’05-MODEL) • Force out the remaining oil (discharged oil) using compressed air completely. • With the damper rod in horizontal position, move the inner rod by hand to inspect it if operating smoothly. If the inner rod is not extend, repeat the “COMPRESSION DAMPER UNIT” procedures (Pour the specified amount fork oil and discharge an excess of oil). (21) • Make sure approx. 10 mm (0.39 in) of inner rod thread is exposed on the end. P M A S • Completely wipe off the fork oil from the spring and damper rod assembly. • Insert the spring and damper rod assembly into the fork. • Temporarily tighten the fork cap bolt (sub-tank). 09941-53630: Front fork top cap wrench 100 mm (3.9 in) E L Approx.10 mm (0.39 in) Locknut DR-Z400SMK5 (’05-MODEL) • Clamp the axle holder with a vise. Protect the axle holder with a rag when using a vise. Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight. • Compress the outer tube by hands and install the conrod holder (special tool) between the axle holder bottom and locknut. 09910-20116: Conrod holder • Insert the push rod into the inner rod. • Insert the rod. shaped projection of center bolt into the push E L P M • Slowly turn the center bolt clockwise until resistance is felt and check the clearance between the locknut and center bolt to provide more than 1 mm (0.04 in). A S 1 mm • Turn the locknut counterclockwise until it contacts with the center bolt. • With the locknut held immovable using a wrench, tighten the locknut/center bolt to the specified torque. Locknut/center bolt: 23 N·m (2.3 kgf-m, 16.0 lb-ft) • With the outer tube compressed by hands, remove the special tool. 23 24 DR-Z400SMK5 (’05-MODEL) • Apply THREAD LOCK “1342” to the center bolt. • Tighten the center bolt to the specified torque. Center bolt: 70 N·m (7.0 kgf-m, 51.0 lb-ft) 99000-32050: THREAD LOCK “1342” • Loosen and remove the fork cap bolt (sub-tank) from the outer tube and slowly slide down the outer tube. 09941-53630: Front fork top cap wrench • Pour the specified amount of fork oil into the outer tube. Oil quantity: 350 ml (11.83/12.32 US/lmp oz) 99000-99001-SS5: SUZUKI FORK OIL SS-05 • Raise the outer tube and temporarily tighten the fork cap bolt (sub-tank). 09941-53630: Front fork top cap wrench P M E L A S DR-Z400SMK5 (’05-MODEL) INSTALLATION • Install the front fork with the line T aligned with the upper surface of the upper bracket. • Check that the air valve A is positioned at the front. • Tighten the fork lower clamp bolts to the specified torque. Fork lower clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) E L • Tighten the fork upper clamp bolts to the specified torque. P M Fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Tighten the fork cap bolt (sub-tank) to the specified torque. 09941-53630 : Front fork top cap wrench A S Fork cap bolt: 35 N·m (3.5 kgf-m, 25.5 lb-ft) • Install the handlebars. (DR-Z400SY 6-22) • Install the front wheel. (28) • Install the brake caliper. (DR-Z400SY 6-45) • Check that the front fork protectors move smoothly. If not, loosen and adjust the protector guide. INSPECTION AFTER INSTALLATION • Front fork (DR-Z400SY 2-23) • Steering (DR-Z400SY 2-23) • Front brake hose routing (30) 25 26 DR-Z400SMK5 (’05-MODEL) COMPRESSION DAMPING FORCE ADJUSTMENT Soft Hard Soft Hard • Turn the adjuster screw clockwise until it stops (full hard position). • Turn the adjuster screw counterclockwise. 13th position is the standard position. Compression damping force adjuster Standard setting: 13 clicks turn back REBOUND DAMPING FORCE ADJUSTMENT • Turn the adjuster screw clockwise until it stops (full hard position). • Turn the adjuster screw counterclockwise. 17th position is the standard position. Rebound damping force adjuster Standard setting: 17 clicks turn back DRIVE CHAIN ADJUSTMENT P M E L • Remove the cotter pin. (For E-03, 28, 33) • Loosen the axel nut 1. • Loosen the locknuts 2 and adjust the drive chain slack to the specification by turning the adjusters 3. Make sure that the right and left adjuster plates 4 are at the same position on scales 5. • With the adjusters 3 held in position, tighten the locknuts 2. • Push the adjuster plates 4 to the adjusters 3 and tighten the axel nut 1. A S Axel nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft) For E-03, 28, 33 110 N·m (11.0 kgf-m, 79.5 lb-ft) For the other countries • Tighten the locknut 2. NOTE: After installing the rear axel nut, insert a new cotter pin into the rear axel. (For E-03, 28, 33) DR-Z400SMK5 (’05-MODEL) TIGHTENING TORQUE CHASSIS ITEM Handlebar clamp bolt Front fork upper clamp bolt Front fork lower clamp bolt Steering stem head nut Front fork cap bolt Front fork center bolt Compression damper unit 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, 33 The other countries Rear sprocket nut Drive chain roller mounting bolt (upper & lower) Spoke nipple (front & rear) Swingarm pivot nut 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 N·m 23 * 23 * 23 90 * 35 * 70 * 30 10 10 23 26 18 2.5 *6 18 29 10 * 39 18 35 35 100 110 30 40 3 77 * 44 E L P M A S kgf-m 2.3 * 2.3 * 2.3 9.0 * 3.5 * 7.0 * 3.0 1.0 1.0 2.3 2.6 1.8 0.25 * 0.6 1.8 2.9 1.0 * 3.9 1.8 3.5 3.5 10.0 11.0 3.0 4.0 0.3 7.7 * 4.4 lb-ft 16.5 * 16.5 * 16.5 65.0 * 25.5 * 50.5 * 21.5 7.0 7.0 16.5 19.0 13.0 1.8 * 4.3 13.0 21.0 7.0 * 28.0 13.0 25.5 25.5 72.5 79.5 21.5 29.0 2.0 55.5 * 32.0 60 6.0 43.5 100 100 100 50 55 10.0 10.0 10.0 5.0 5.5 72.5 72.5 72.5 36.0 40.0 27 28 DR-Z400SMK5 (’05-MODEL) FRONT AXLE 10 N·m (1.0 kgf-m, 7.0 lb-ft) E L P M ( ( 18 N·m 1.8 kgf-m 13.0 lb-ft 39 N·m 3.9 kgf-m 28 lb-ft ) A S ) ) 09941-34513: Bearing installer * 09913-70210: Bearing installer set Clearance DR-Z400SMK5 (’05-MODEL) REAR AXLE 30 N·m (3.0 kgf-m, 21.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) E L P M A S Left Right For E-03, 28, 33 100 N·m (10.0 kgf-m, 72.5 lb-ft) The others 110 N·m (11.0 kgf-m, 79.5 lb-ft) Left Right Spacer ) 09941-34513: Bearing installer set Clearance 29 A S P M Front fork protector Front brake hose Clutch cable Front brake hose ! " # $ the brake hose union bolt to the specified torque. Set the brake hose in front of the throttle cables. Set the brake hose outside of the front fork. Set the brake hose in front of the clutch cable. Clump the upper difference portion in brake hose diameter. Set the brake hose guide outside of the turn signal bracket. Set the brake hose end between the hose stopper then tighen E L Turn signal (L) Master cylinder Brake hose Clutch cable Front brake hose 30 DR-Z400SMK5 (’05-MODEL) FRONT BRAKE HOSE ROUTING 21˚ Rear brake hose Hose guide E L A S tighten the union bolt to the specified torque. Insert the reservior hose until dead end. After touching the brake hose union to the stopper, P M Brake hose 30˚ DR-Z400SMK5 (’05-MODEL) REAR BRAKE HOSE ROUTING 31 B/W Br B/W B B/W Br Lg Lg Y/W Bl/B Bl/B O PUSH Y/G O ON OFF CLUTCH SWITCH HORN B/Bl PASSING LIGHT L SWITCH PUSH R TURN SIGNAL LIGHT SWITCH PUSH HORN BUTTON B B Y Y Y/W B/G HANDLEBAR SWITCH (L) B/Y Y B/G DIMMER SWITCH HI LO FAN MOTOR B/R FAN MOTOR SWITCH ON OFF B/W B/R B/W B/W O/G O B/R B B/W O Bl FRONT TURN SIGNAL LIGHT (L) B/W B POSITION LIGHT HEADLIGHT B/W B/Bl B/W Lg Lg B/Y B/W B/W B/Bl R Lbl O R Lbl B/W O B B B/W O O/R B Y/W Y/W O Gr NEUTRAL SWITCH P Lg B/W Bl B Bl/B O/W Bl B/W FUSE BOX G FRONT TURN SIGNAL LIGHT (R) Y/B O/Y O Bl O Y/G Y/G ON OFF B/G B/G R R Y/G ON OFF REAR BRAKE LIGHT SWITCH G G REGULATOR/ RECTIFIER GENERATOR STARTER MOTOR STARTER RELAY CDI UNIT R FUSE BOX 20 A Y WATER TEMP. SWITCH PUSH FREE Bl SIDE-STAND SWITCH G W H N T O B/W P BATTERY THROTTLE POSITION SENSOR Bl PILOT LIGHT Lbl O/W P O O Y Y Y Bl SPEEDOMETER R R SOLENOID REAR TURN SIGNAL LIGHT (L) B B/W W/B B W/B B/W B/W Gr B/W Br BRAKE LIGHT/TAILLIGHT B B/W Lg B/W REAR TURN SIGNAL LIGHT (R) B B/W HANDLEBAR SWITCH (R) B/W B/W W Y/G B/W B/W B W/B B/W B/W Gr Y B/W B/W Y Br Br Y O ENGINE STOP STARTER FRONT BRAKE BUTTON LIGHT SWITCH SWITCH OFF OFF RUN PUSH ON IGNITION SWITCH B/R OFF ON IGNITION P COIL G B B/G W: WATER TEMP. WARNING LIGHT H : HIGH BEAM INDICATOR LIGHT N : NEUTRAL INDICATOR LIGHT T : TURN SIGNAL INDICATOR LIGHT Y W/B O Y Gr A S P M W B/W R/W B/G R W/B E L Bl Y/B Bl/W O/W B/W B/W W R R B O/W 32 DR-Z400SMK5 (’05-MODEL) WIRING DIAGRAM E-02, 19 B B/W B B/W B/Y Y B/Y B/Bl B B Y Y Lg Lg Y/W Y/W Bl/B Bl/B B/Bl O Y/G Y/W O Gr O/Y O NEUTRAL SWITCH W Y/G B/W G FUSE BOX PUSH FREE G G Y R R O ON OFF CLUTCH SWITCH HORN R L PUSH R TURN SIGNAL LIGHT SWITCH PUSH HORN BUTTON B/W B/W B/Bl HANDLEBAR SWITCH (L) DIMMER SWITCH HI LO FAN MOTOR B/R B/R FAN MOTOR SWITCH ON OFF B/W B/W B/W B/W O B/R O/G O B B/G B/G Bl FRONT TURN SIGNAL LIGHT (L) HEADLIGHT B/W Lg Lg O R B Lbl B/W O B B/W O Lg B/W Y/B B Lbl B/W Lbl O REGULATOR/ RECTIFIER Y Y/W P Bl O/W P B W/B Bl Gr Y FRONT TURN SIGNAL LIGHT (R) Bl ON OFF R R ON OFF Bl GENERATOR O O STARTER MOTOR STARTER RELAY W/B W/B G B/W B/W B/G B/G Y/G REAR BRAKE LIGHT SWITCH CDI UNIT R FUSE BOX 20 A Y WATER TEMP. SWITCH B/W B/W O Y/G Y/G Bl W H N T Bl/B Br Br Gr Y B/W B/W Y O/W B/W B/W R SIDE-STAND SWITCH G SPEEDOMETER B/W R/W P BATTERY THROTTLE POSITION SENSOR REAR TURN SIGNAL LIGHT (L) B B/W W/B B W/B B/W B/W Gr B/W Br BRAKE LIGHT/TAILLIGHT B B/W Lg B/W REAR TURN SIGNAL LIGHT (R) Bl Bl PILOT LIGHT Y/B Bl/W O A S P M B O/W B/W Y Y HANDLEBAR SWITCH (R) Y E L W W B/W ENGINE STOP STARTER FRONT BRAKE BUTTON LIGHT SWITCH SWITCH OFF OFF RUN PUSH ON IGNITION SWITCH B/R OFF ON IGNITION P COIL B/W R R B B/W W : WATER TEMP. WARNING LIGHT H : HIGH BEAM INDICATOR LIGHT N : NEUTRAL INDICATOR LIGHT T : TURN SIGNAL INDICATOR LIGHT DR-Z400SMK5 (’05-MODEL) E-03, 28, 33 33 E L Prepared by P M December, 2004 Part No. 99501-43110-01E Printed in Japan A S 36 Top USE THIS MANUAL WITH: DR-Z400S SERVICE MANUAL (99500-43034-01E) Printed in Japan K5 Bottom
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Key Features
- Liquid-cooled, four-stroke, DOHC engine
- 398 cm3 (24.3 cu. in) displacement
- 11.3:1 compression ratio
- 5-speed constant mesh transmission
- Wet multi-plate clutch
- Dry sump lubrication system
- Electric starter
- 2.733 (41/15) final reduction ratio
- RK520KZO, 110-link drive chain
- 260 mm (10.2 in) ground clearance