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drz 400E
Suzuki drz 400E Service Manual
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ENGINE
3-39
TRANSMISSION
DISASSEMBL
Y
Disassemble the transmission gears as shown.
1
Countershaft
2
5th (top) drive gear
3
Circlip
4
3rd drive gear
5
Circlip
6
4th drive gear
7
2nd drive gear
8
Circlip
9
Bearing
0
Bearing
A
Driveshaft
B
Washer
C
2nd driven gear
D
Spacer
E
Bearing
F
Oil seal
G
4th driven gear
H
3rd driven gear
I
Washer
J
Circlip
K
5th (top) driven gear
L
Washer
M
1st (low) driven gear
N
Spacer
O
Washer
P
Bearing
80
82
Table of Contents
Group Index
2
Table of Contents
2
General Information
5
Warning/Caution/Note
6
General Precautions
6
Suzuki Dr-Z400Y/Dr-Z400Ey (2000-Model)
8
Serial Number Location
8
Fuel, Oil, and Engine Coolant Recommendations
8
Fuel
8
Engine Oil
9
Brake Fluid
9
Front Fork Oil
9
Rear Shock Absorber Oil
9
Engine Coolant
9
Break-In Procedures
10
Information Labels
11
Specifications
12
Country and Area Codes
14
Periodic Maintenance
15
Periodic Maintenance Schedule
16
Periodic Maintenance Chart
16
Engine
16
Maintenance and Tune-Up Procedures
17
Air Cleaner
17
Exhaust Pipe Nut and Bolt and Muffler Nut and Bolts
18
Tappet Clearance
19
Spark Plug
23
Spark Arrester
24
Fuel Line
24
Decompression Lever (Dr-Z400)
24
Engine Oil and Oil Filter
25
Engine Oil Hoses
26
Throttle Cable Play
27
Engine Idle Speed
28
Engine Coolant
28
Radiator Hoses
29
Clutch
30
Drive Chain
30
Brakes
32
Brake Fluid
33
Brake Hoses
35
Tires
35
Spoke Nipples
36
Steering
37
Front Fork
37
Rear Suspension
37
Chassis Nuts and Bolts
38
General Lubrication
40
Compression Pressure Check (Dr-Z400E)
41
Compression Test Procedure
41
Oil Pressure Check
42
Oil Pressure Test Procedure
42
Engine
43
Engine Removal and Remounting
45
Engine Removal
45
Engine Remounting
50
Engine Disassembly
53
Engine Components Inspection and Service
64
Cylinder Head
64
Camshaft/Automatic Decompression Assembly
73
Cylinder
75
Piston and Piston Ring
75
Conrod
77
Crankshaft
78
Starter Clutch (Dr-Z400E)
78
Starter Torque Limiter (Dr-Z400E)
79
Oil Pump
79
Clutch
79
Gearshift Fork and Gear
80
Transmission
81
Bearings
84
Oil Seals
87
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
Kick Starter (Dr-Z400)
96
Cam Chain
97
Clutch
97
Right Crankcase Cover
99
Clutch Cover
99
Generator Rotor Cover
99
Starter Drive Gear Cover (Dr-Z400E)
100
Piston Ring
100
Piston and Cylinder
101
Cylinder Head
102
Camshaft/Automatic Decompression Assembly
103
Cylinder Head Cover
105
Cam Chain Tension Adjuster
106
Fuel and Lubrication System
107
Fuel Tank
108
Removal
108
Remounting
108
Fuel Valve
109
Removal and Inspection
109
Fuel Strainer
109
Remounting
109
Carburetor
110
Construction
110
Specifications
111
I.D. No. Location
111
Slow System
112
Coasting Enrichment System
112
Main System
113
Accelerator Pump System
114
Starter System
115
Float System
115
Removal
116
Disassembly
116
Cleaning
119
Inspection
120
Reassembly
120
Remounting
121
Lubrication System
122
Engine Lubrication System Chart
122
Oil Pan
122
Cooling System
123
Cooling System
124
Description
124
Construction
125
Engine Coolant
126
Radiator
127
Inspection
127
Removal
128
Remounting
128
Water Pump
129
Chassis
132
Exterior Parts
133
Removal
133
Remounting
133
Front Wheel
134
Construction
134
Removal and Disassembly
136
Inspection
137
Reassembly and Remounting
139
Front Fork
141
Construction
141
Removal and Disassembly
142
Inspection
144
Reassembly and Remounting
145
Suspension Setting
148
Steering
149
Construction
149
Removal and Disassembly
150
Inspection
152
Reassembly and Remounting
153
Rear Wheel
156
Construction
156
Removal and Disassembly
158
Inspection
159
Reassembly and Remounting
159
Rear Suspension
162
Construction
162
Rear Shock Absorber Removal
164
Rear Shock Absorber Inspection and Disassembly
166
Rear Shock Absorber Disposal
166
Oil Replacement Procedure
167
Rear Shock Absorber Reassembly and Remounting
169
Rear Shock Absorber Damping Force Adjustment
170
Rear Swingarm and Cushion Lever Removal
171
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
183
Master Cylinder Reassembly and Remounting
183
Rear Brake
185
Construction
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
191
Master Cylinder Inspection
192
Master Cylinder Reassembly and Remounting
192
Electrical System
194
Cautions in Servicing
195
Connectors
195
Couplers
195
Clamps
195
Fuse (Dr-Z400E)
195
Semiconductor Equipped Parts
195
Battery (Dr-Z400E)
196
Connecting the Battery (Dr-Z400E)
196
Wiring Procedure
196
Using the Multi Circuit Tester
197
Location of Electrical Components
198
Charging System (Dr-Z400E)
200
Description
200
Troubleshooting
201
Inspection
202
Starter System (Dr-Z400E)
205
Description
205
Troubleshooting
205
Starter Motor Removal and Disassembly
206
Starter Motor Inspection
207
Starter Motor Reassembly and Remounting
208
Starter Relay Inspection
209
Ignition System (Dr-Z400)
210
Description
210
Troubleshooting
210
Inspection
212
Ignition System (Dr-Z400E)
215
Description
215
Troubleshooting
215
Inspection
217
Odometer
219
Removal
219
Lamps
220
Headlight
220
Taillight
221
Switches
222
Battery (Dr-Z400E)
223
Removal
223
Specifications
223
Servicing
223
Recharging Operation
224
Servicing Information
225
Troubleshooting
226
Engine
226
Carburetor
229
Chassis
230
Brakes
231
Electrical
232
Battery (Dr-Z400E)
233
Wiring Diagram
234
Dr-Z400
234
Dr-Z400E
235
Wire Harness, Cable, and Hose Routing
236
Wire Routing
236
Cable Routing
238
Fuel Hose and Fuel Tank Mounting
239
Oil Return Tank Hose Routing
240
Cooling System Hose Routing
241
Front Brake Hose Routing
242
Rear Brake Hose Routing
242
Special Tools
243
Tightening Torque
246
Engine
246
Chassis
247
Tightening Torque Chart
248
Service Data
249
Dr-Z400Ey (E-24 Model)
258
Specifications
259
Service Data
261
Battery
267
Brake Light/Taillight
267
Fuse
267
Headlight
267
High Beam Indicator Light
267
Neutral Indicator Light
267
Speedometer Light
267
Turn Signal Indicator Light
267
Turn Signal Light
267
Side-Stand/Ignition Interlock System
269
Switches
270
Speedometer
271
Wiring Diagram
274
Wire, Cable and Hose Routing
275
Dr-Z400/Ek1 ('01-Model)
280
Specifications
281
DR-Z400/E (for E-01, 03 and 28)
281
DR-Z400E (for E-24)
283
Service Data
285
DR-Z400/E (for E-01, 03 and 28)
285
DR-Z400E (for E-24)
293
Battery (Dr-Z400E)
301
Initial Charging
301
Dr-Z400/Ek2 ('02-Model)
304
Specifications
305
DR-Z400/E (E-01, 03 and 28)
305
Dr-Z400E (E-24)
306
Brake Disc
306
PERIODIC MAINTENANCE SCHEDULE (for E-24)
309
Service Data
310
DR-Z400/E (E-01, 03 and 28)
310
Dr-Z400E (E-24)
313
Rear Shock Absorber
326
Oil Replacement Procedure
326
Reassembly and Remounting
328
Damping Force Adjustment
329
Wiring Diagram
330
Cooling System Hose Routing
332
4
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Suzuki drz 400E Specifications
General
Brand
Suzuki
Model
drz 400E
Category
Motorcycle
Language
English
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