Suzuki drz 400 2002 Service Manual

CHASSIS 6-1
CHASSIS
,---- - - - --- ---- - CONTENTS ----------- -,
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 ......................................................................................................................... 6-16
STEERING .................................... .. ...................................................................................... .. ....... ... ............. 6- 17
CON!':TRIlCTION .. 6-17
REMOVAL AND DISASSEMBLY ............................................................................................................ 6-18
INSPECTION ........................................................................................................................................... 6-21
REASSEMBLY AND REMOUNTING ............................... ... ........... ... ...................................................... 6-21
REAR WHEEL .... . ..... . . ......... . . ... . ...................... . ...................... 6_24
CONSTRUCTION .................................................................................................................................... 6-24
REMOVAL AND DISASSEMBLY ............................................................................................................ 6-26
INSPECTION ........................................................................................................................................... 6-27
REASSEMBLY AND REMOUNTING ................................................ .. .................................. ... ....... .. ...... 6-27
REAR SUSPENSION ................................................................ ... .......... ... ....... .. . .. ............ ... . ... ........ ...... .. ... .. 6-30
CONSTRUCTION
.................................................................................................................................... 6-30
REAR SHOCK ABSORBER REMOVAL .................................................... ... ........... .. ....... .. ................... 6-32
REAR SHOCK ABSORBER INSPECTION ............................................................................................ 6- 33
REAR SHOCK ABSORBER DISPOSAL ............................................................................................... 6-33
REAR SHOCK ABSORBER REMOUNTING ......................................................................................... 6-34
REAR SHOCK ABSORBER DAMPING FORCE ADJUSTMENT ......................................................... 6-35
nEAn SWINCAnM AND CUSHION LEVEn nEMOVAL ....................................................................... 6-36
INSPECTION AND DISASSEMBLY ............................. .. ... ..... ... . .. ........... .. .......... ... ................................ 6-37
REASSEMBLY AND REMOUNTING .............. ... ...... ... ......... ... ............. ... ........... .... . .. .............................. 6-39
FINAL INSPECTION AND ADJUSTMENT ....... .. ................ .. ............................................................... .. 6-40
FRONT BRAKE ............................................................................................................................................. 6~41
CONSTRUCTION .................................................................................................................................. .. 6-41
BRAKE PAD REPLACEMENT ................................................................................................................ 6-42
BRAKE FLUID REPLACEMENT .................... .. .................................................................... .. ................ 6-43
BRAKE CALIPER REMOVAL AND DISASSEMBLY ............................................................................. 6-43
BRAKE CALIPER INSPECTION ............................... .. ..... .. ................ ... ................... .. ......... ... ...... ... ....... 6-44
BRAKE CALIPER REASSEMBLY AND REMOUNTING .... .. ................................................................. 6-45
BRAKE DISC INSPECTION ..................................... ... .................. ... ........ .. ............................................. 6-46
MASTER CYLINDER REMOVAL AND DISASSEMBLY ............... ... ....... .. ............................................. 6-47
MASTER CYLINDER INSPECTION ............................................. .... ................. ... .................. .. ......... .. ... 6- 48
MASTER CYLINDER REASSEMBLY AND REMOUNTING .................................................................. 6-48
REAR BRAKE ..................... .. ..................................................................................... .. ................................. 6-50
eONS I Hue liON .................................................................................................................................... 6-50
BRAKE PAD REPLACEMENT .............................................................. .. ...................... ... ....................... 6-51
BRAKE FLUID REPLACEMENT ........................................ ... ........... .. .................................................... 6-52
BRAKE CALIPER REMOVAL AND DISASSEMBLY ............. ... ...... ...... . .. ... ...... .. ................................... 6-53
BRAKE CALIPER INSPECTION ............................................................................................................ 6-54
BRAKE CALIPER REASSEMBLY AND REMOUNTING ....................................................................... 6-54
BRAKE DISC INSPECTION .................................................................................................................... 6-55
MASTER CYLINDER REMOVAL AND DISASSEMBLY ........................................................................ 6-55
MASTER CYLINDER INSPECTION ....................................................................................................... 6-56
MASTER CYLINDER REASSEMBLY AND REMOUNTING .................................................................. 6-57
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Suzuki drz 400 2002 Specifications

General

Displacement	398 cc
Bore x Stroke	90.0 mm x 62.6 mm
Compression Ratio	11.3:1
Cooling System	Liquid-cooled
Fuel System	Mikuni BSR36 carburetor
Starter	Electric
Transmission	5-speed constant mesh
Final Drive	Chain
Front Suspension	Telescopic, coil spring, oil damped
Rear Suspension	Link type, coil spring, oil damped
Front Tire	80/100-21
Seat Height	935 mm (36.8 in)
Ground Clearance	300 mm (11.8 in)
Wheelbase	1, 485 mm (58.5 in)
Dry Weight	119 kg (262 lbs)
Engine Type	4-stroke, single cylinder, DOHC
Ignition	CDI
Front Brakes	Disc
Rear Brakes	Disc
Rear Tire	120/90-18
Fuel Capacity	10.0 L (2.6 US gal)