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drz 400 2003
Suzuki drz 400 2003 Service Manual
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6-56
CHASSIS
•
Loosen
Ihe
locknul
CD
and
remove
the
master
cylinder
as-
sembly
.
•
Remove
Ihe
circlip
@
and
reservoir
assembly
Q).
•
Pull
Ihe
dust
boot
@
out
and
remove
the
circlip
@.
•
Remove
the
push
rod
®
and
piston
assembly
!D.
MASTER
CYLINDER
INSPECTION
MASTER
CYLINDER
..
.....
......................
.
...................
c:::r
6·48
PISTON
AND
RUBBER
PARTS
.............................
.
..
c:::r
6·48
http://www.motorcycle.in.th
190
192
Table of Contents
Table of Contents
4
Warning/Caution/Note
5
General Precautions
5
Serial Number Location
7
Fuel
7
Engine Oil
8
Brake Fluid
8
Front Fork Oil
8
Engine Coolant
8
Break-In Procedures
9
Information Labels
10
Specifications
11
Country and Area Codes
13
Table of Contents
14
Periodic Maintenance Schedule
15
Periodic Maintenance Chart
15
Maintenance and Tune-Up Procedures
16
Air Cleaner
16
Exhaust Pipe Nut and Bolt and Muffler Nut and Bolts
17
Tappet Clearance
18
Spark Plug
22
Spark Arrester
23
Engine Oil and Oil Filter
24
Engine Oil Hoses
25
Throttle Cable Play (Carburetor)
26
Engine Idle Speed (Carburetor)
27
Engine Coolant
27
Radiator Hoses
28
Clutch
29
Drive Chain
29
Brakes
31
Brake Fluid
32
Brake Hoses
34
Tires
34
Spoke Nipples
35
Steering
36
Front Fork
36
Rear Suspension
36
Evaporative Emission Control System (for E-33)
36
Pair (Air Supply) System (for
36
Chassis Nuts and Bolts
37
General Lubrication
39
Compression Pressure Check
40
Compression Test Procedure
40
Oil Pressure Check
41
Oil Pressure Test Procedure
41
Table of Contents
42
Engine Components Removable with the Engine in Place
43
Engine Removal and Remounting
44
Engine Remounting
49
Engine Disassembly
52
Engine Components Inspection and Service
63
Cylinder Head
71
Camshaft/Automatic Decompression Assembly
72
Cylinder
74
Piston and Piston Ring
74
Conrod
76
Crankshaft
77
Starter Clutch
77
Oil Pump
78
Clutch
79
Transmission
81
Bearings
84
Oil Seals
87
Oil Check Valve
88
Engine Reassembly
89
Crankshaft
89
Gearshift Cam and Fork
90
Crankcase
91
Starter Clutch and Generator Rotor
92
Balancer Shaft
93
Primary Drive Gear
94
Gearshift Cam Driven Gear
94
Gearshift Shaft
95
Oil Pump
95
Cam Chain
96
Clutch
96
Right Crankcase Cover
98
Clutch Cover
98
Generator Rotor Cover
98
Neutral Switch
98
Starter Drive Gear Cover
99
Piston Ring
99
Piston and Cylinder
100
Cylinder Head
101
Camshaft/Automatic Decompression Assembly
102
Cylinder Head Cover
104
Cam Chain Tension Adjuster
105
Removal
106
Inspection
106
Remounting
107
Table of Contents
108
Fuel Tank
109
Removal
109
Remounting
109
Fuel Valve Removal and Inspection
110
Fuel Strainer
110
Remounting
110
Carburetor
111
Construction
111
Specifications
112
1.0. No. Location
112
Removal
113
Disassembly
113
Cleaning
117
Inspection
117
Reassembly
119
Remounting
119
LUBRICATION System
120
Engine Lubrication System Chart
120
Table of Contents
121
Cooling System
122
Description
122
Construction
123
Engine Coolant
124
Radiator and Cooling Fan
125
Inspection
125
Removal
126
Remounting
127
Cooling Fan Thermoswitch
128
Removal
128
Inspection
129
INSTALLA Tlon
129
Engine Coolant Temperature Thermoswitch Removal
130
Inspection
130
Installation
130
Thermostat
131
Removal
131
Inspection
131
Installation
132
Water Pump
133
Removal and Disassembly
133
Inspection
134
Reassembly
134
Table of Contents
136
Exterior Parts
137
Removal
137
Remounting
137
Front Wheel
138
Construction
138
Removal and Disassembly
140
Inspection
141
Reassembly and Remounting
143
Front Fork
145
Construction
145
Removal and Disassembly
146
Inspection
148
Reassembly and Remounting
149
Suspension Setting
151
Steering
152
Removal and Disassembly
153
Inspection
156
Reassembly and Remounting
156
Rear Wheel
159
Construction
159
Removal and Disassembly
161
Inspection
162
Reassembly and Remounting
162
Rear Suspension
165
Construction
165
Rear Shock Absorber Removal
167
Rear Shock Absorber Inspection
168
Rear Shock Absorber Disposal
168
Rear Shock Absorber Remounting
169
Rear Shock Absorber Damping Force Adjustment
170
Inspection and Disassembly
172
Reassembly and Remounting
174
Final Inspection and Adjustment
175
Front Brake
176
Construction
176
Brake Pad Replacement
177
Brake Fluid Replacement
178
Brake Caliper Removal and Disassembly
178
Brake Caliper Inspection
179
Brake Caliper Reassembly and Remounting
180
Brake Disc Inspection
181
Master Cylinder Removal and Disassembly
182
Master Cylinder Inspection
182
Master Cylinder Reassembly and Remounting
183
Rear Brake
185
Brake Pad Replacement
186
Brake Fluid Replacement
187
Brake Caliper Removal and Disassembly
188
Brake Caliper Inspection
189
Brake Caliper Reassembly and Remounting
189
Brake Disc Inspection
190
Master Cylinder Removal and Disassembly
190
Master Cylinder Inspection
191
Master Cylinder Reassembly and Remounting
192
Table of Contents
193
CAUTIONS in Servicing
194
Connectors
194
Couplers
194
Clamps
194
Fuse
194
Semiconductor Equipped Parts
194
Battery
195
CONNECTING the Battery
195
Wiring Procedure
195
Using the Multi Circuit Tester
196
Location of Electrical Components
197
Charging System
199
Description
199
Troubleshooting
200
Inspection
201
Starter System
204
Description
204
Troubleshooting
204
STARTER MOTOR REMOVAL and Disassembly
205
Starter Motor Inspection
206
Starter Motor Reassembly and Remounting
207
Starter Relay Inspection
208
Side Standiignition Interlock System Parts Inspection
209
IGNITION System
211
Description
211
Troubleshooting
211
Inspection
213
Speedometer
216
Removal
216
Parts Names
217
Operating Procedure
217
Lamps
221
Headlight
221
Front and Rear Turn Signal Light
222
BRAKE Llghtitailllght
223
Relays
224
Starter Relay
224
TURN SIGNAUSIDE STAND Relay
224
Switches
225
Battery
226
Removal
226
Specifications
226
Servicing
226
Recharging Operation
227
4
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Suzuki drz 400 2003 Specifications
General
Brand
Suzuki
Model
drz 400 2003
Category
Motorcycle
Language
English
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