Suzuki drz 400 2002 Service Manual

PERIODIC MAINTENANCE 2-1
PERIODIC MAINTENANCE
,-------------- 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 PL UG .. ____ . __ . ________ . __________ . __ .. __ ... __ ... ______ ..... ______ ... __ ......... ________ . __ . __ . ____ 2- 9
SPARK ARRESTER (FOR E-03, 28, 33) .. ______ .... __ .. __ .. __ .... __ .... __ .. __ .. __ .... __ . __ . 2-10
FUEL LINE ................................................. .. ........... .. .................................. 2-10
ENGINE OIL AND OIL FILTER ______________ . __ . ____ . ____________ __ __ . __ . __ .. ____ .. ______ . __ . __ .. 2-11
ENGINE OIL HOSES _________________ . _________________ . ____________ . _____________ . __ .. __ . __ . _____ .___ 2-12
THROTTLE CABLE PLAY (CARBURETOR) ____ .... ____ .. __ .. ______ .. __ __ .... __ ... __ .. __ 2-13
ENGINE IDLE SPEED (CARBURETOR) ____ . __ . ____ . ________ .. ____ .. . ________ . __ . __ . __ . __ . 2-14
ENGINE COOLANT __ ____ .. __ .......... ____ .... __ ...... __ ....... __ ____ .. __ .. __ __ __ .. __ __ .. ...... __ .. ___ 2-14
RADIATOR HOSES ._. __ . __ . _________ .. __________ . __ . ____________________ .. __ . __ . __ . _______ . __ . __ .______ 2-15
CL UTC H ___________ . ______ .. __ . __ . _ .. _______ . _____________ . _ .. __ . ____ . __ . __________ . __ . __ . _______ . __ . _ __ _ __ _ __ 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
EVAPORATIVE EMISSION CONTROL SYSTEM (FOR E-33) ...... ____________ 2-23
PAIR (AIR SUPPLY) SYSTEM (FOR E-02, 19,54) .................................... 2-23
CHASSIS NUTS AND BOLTS ________________________________________________ __ __________________ 2-24
GENERAL LUBRICATION ............ __ . __ ................ .. .................... .. ...... .. ......... 2-26
COMPRESSION PRESSURE CHECK . ________ . ________________________ . ____ . ____ .. __ . __ . ____ . __ 2-27
COMPRESSION TEST PROCEDURE ________________________________ ______________ __ ________ 2-27
OIL PRESSURE CHECK ____ .. __ .. ____________ . __ . __________ . ______ .. ____ . ____ .. __ . __ .. __ ____ . __ . __ . __ .. 2-28
OIL PRESSURE TEST PROCEDURE __ .. __ .. __ ...... __ .. .. __ .... .. __ .. .. ____ __ __ . .. __ __ ... __ 2-28
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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)