Suzuki drz 400 2000 User Manual

ENGINE 3-1
ENGINE
r--------- -- ------------- CONTENTS ------ -----------------.
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 ....... .. .................................. .. ..... .... ..... .. . ... .... .............................. .. .......... 3-36
S/AH/~H IUHUUE LIMITER ............................................................................................... 3-37
OIL PUMP ................................. .. .................................................................. .. ....................... 3- 37
CLUTCH ................... .. .. .. ............................. ... .......................... .. ......................................... .. 3-38
CEAnSHIrT ronK AND GeAR ........................................................................................... 3-39
TRANSMISSION ....... .. ................................................... .. ................... .. ...................... .. ...... .. 3- 40
BEARINGS .... .. ...... .. ........ .. ............ ... . .. ........ .. ..... .. ...... .. ............. .. .................. .. ........ .. ............ 3-43
OIL SEALS .. .. .. ................................. .. ... .. .. .. ..... .. ............... .. .......... .. . .... ... .. .. . .. ....................... 3-46
OIL CHECK VALVE .......... .. ..................................................... ... ... .. ................................ .. .... 3-47
ENGINE REASSEMBLY ........... .... ......................... .. ............. .. .................................................... 3-48
CRANKSHAFT ......................................................... .. ........... .. .... .. ........................... .. ........... 3-48
GEARSHIFT CAM AND FORK ... ......... .. ..... .. .. ... .. .... .. .. ........... .. ... ................................... .... .. 3-49
CRANKCASE ....................................... .. ...... .. .......................... .. ............................... ... ......... 3- 50
STARTER CLUTCH AND GENERATOR ROTOR .............. .. .................................. .. ............. 3- 51
BALANCER SHAFT ....... .. .............................................. .. ........ .. ........................................... J - !J:.!
PRIMARY DRIVE GEAR ............................. .. ........................................................................ 3-53
GEARSHIFT CAM DRIVEN GEAR ..... .. .. ...................................................................... ... ..... 3-53
GEARSHIFT SHAFT ............................................................................................................. 3- 54
OIL PUMP ..... .. .... .... .... . .. ........................ ... .................. .. .... .. ........... ... .... .. ....... .. ...... .. ....... .. ..... 3-54
CAM CHAIN ................................................. .. .... ........................... ... .................. .. ................. 3-55
CLUTCH ...................... .. .. ... ....... ... ........................... ... .. ..... .. ............................... .. .... .. ....... .. .. 3-55
RIGHT CRANKCASE COVER ............ .. .. .. . .. . .. .......... .. ........ ... ..... .. .... .. ....... .. ......................... 3-57
CLUTCH COVER ...... .. ................................ .. ......................................................................... 3-57
GENERATOR ROTOR COVER ..... .. ........ .. . .. ......................................................................... 3-57
NEUTRAL SWITCH ............................................................................................................... 3-57
STARTER DRIVE GEAR COVER ......... ... .. .... ... .. . .. ... . .. ... .. .. ... ..... .... ...................................... 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
PAIR (AIR SUPLY) SYSTEM (FOR E-02, 19, 54} ....................................................................... 3-65
REMOVAL ................... .. ......................................................................................................... 3- 65
INSPECTION ........................................................................ .. ... .. ................... .. .. .. .. .. .... .. ..... .. 3-65
REMOUNTING . .. ...... .. . .. ......................... .. .. .. ......................................................................... 3-66
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Suzuki drz 400 2000 Specifications

General

Brand	Suzuki
Model	drz 400 2000
Category	Motorcycle
Language	English