DR-Z400S (ID=1940).pdf

DR-Z400S

99500-43032-01E

FOREWORD

GROUP INDEX

This manual contains an introductory description on

the SUZUKI DR-Z400S and procedures for its inspec-

tion, service, and overhaul of its main components.

Other information considered as generally known is not

included.

Read the GENERAL INFORMATION section to famil-

iarize yourself with the motorcycle and its maintenance.

Use this section as well as other sections as a guide

for proper inspection and service.

This manual will help you know the motorcycle better

so that you can assure your customers of fast and reli-

able service.

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent of this manual and the actual motorcycle.

Illustrations in this manual are used to show

the basic principles of operation and work pro-

cedures. They may not represent the actual mo-

torcycle exactly in detail.

This manual is written for persons who have

enough knowledge, skills and tools, including

special tools, for servicing SUZUKI motorcycles.

If you do not have the proper knowledge and

tools, ask your authorized SUZUKI motorcycle

dealer to help you.

FUEL AND LUBRICATION

SYSTEM

COOLING SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

Inexperienced mechanics or mechanics with-

out the proper tools and equipment may not

be able to properly perform the services de-

scribed in this manual. Improper repair may

result in injury to the mechanic and may ren-

der the motorcycle unsafe for the rider and

passenger.

DR-Z400SK1 (’01-MODEL)

DR-Z400SK2 (’02-MODEL)

Overseas Service Department

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING

FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right will allow

you to find the first page of the section easily.

4. The contents are listed on the first page of each sec-

tion to help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit there is an exploded view which provides work instructions and other

service information (e.g., tightening torque, lubricating points, and locking agent points).

Example: Front wheel

1 Front axle

2 Odometer gearbox

3 Bearing (R)

4 Front wheel

5 Spacer

6 Bearing (L)

7 Dust seal

8 Brake disc

9 Spacer

0 Washer

A Front axle nut

B Brake disc mounting bolt

ITEM

N·m

kgf-m

lb-ft

A 42

4.2

30.5

B 10

1.0

7.0

SYMBOLS

Listed in the table below are the symbols indicating instructions and other information necessary for servic-

ing. The meaning of each symbol is also included in the table.

SYMBOL

DEFINITION

SYMBOL

DEFINITION

Torque control required.

Data beside it indicates specified torque.

Apply THREAD LOCK “1342”.

99000-32050

Indicates service data.

Apply or use brake fluid.

Apply oil. Use engine oil unless other-

wise specified.

Measure in voltage range.

Apply molybdenum oil solution.

(mixture of engine oil and SUZUKI

MOLY PASTE in a ratio of 1:1)

Measure in resistance range.

Apply SUZUKI SUPER GREASE “A”.

99000-25030 (For USA)

99000-25010 (For the other countries)

Measure in current range.

Apply SUZUKI SILICONE GREASE.

99000-25100

Measure in diode test range.

Apply SUZUKI MOLY PASTE.

99000-25140

Measure in continuity test range.

Apply SUZUKI BOND “1207B”.

99104-31140 (For USA)

99000-31140 (For the other countries)

Use special tool.

Apply SUZUKI BOND “1215”.

99000-31110 (Except USA)

Use engine coolant.

99000-99032-11X (Except USA)

Apply THREAD LOCK SUPER “1303”.

99000-32030

Use fork oil.

99000-99001-SS5

Apply THREAD LOCK SUPER “1322”.

99000-32110 (Except USA)

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