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Suzuki DR-Z400S 2001 Service Manual

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DR-Z400S
9 9 5 0 0 - 4 3 0 3 2 - 0 1 E

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Summary of Contents for Suzuki DR-Z400S 2001

  • Page 1 DR-Z400S 9 9 5 0 0 - 4 3 0 3 2 - 0 1 E...
  • Page 2 GROUP INDEX FOREWORD This manual contains an introductory description on the SUZUKI DR-Z400S and procedures for its inspec- GENERAL INFORMATION tion, service, and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to famil- PERIODIC MAINTENANCE iarize yourself with the motorcycle and its maintenance.
  • Page 3 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.
  • Page 4 Apply oil. Use engine oil unless other- Measure in voltage range. wise specified. Apply molybdenum oil solution. Measure in resistance range. (mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in current range. 99000-25030 (For USA) 99000-25010 (For the other countries) Apply SUZUKI SILICONE GREASE.

  • Page 6: Table Of Contents

    GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE................1- 2 GENERAL PRECAUTIONS ................1- 2 SUZUKI DR-Z400SY (2000-MODEL) .............. 1- 4 SERIAL NUMBER LOCATION ................ 1- 4 FUEL, OIL, AND ENGINE COOLANT RECOMMENDATIONS ....... 1- 4 FUEL ......................1- 4 ENGINE OIL ....................1- 5 BRAKE FLUID .....................

  • Page 7: Warning/Caution/Note

    GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
  • Page 8 GENERAL INFORMATION If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equiva- lent. When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.

  • Page 9: Suzuki Dr-Z400Sy (2000-Model)

    ) method or 91 octane or higher rated by the Research Method. SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol.

  • Page 10: Engine Oil

    Use an antifreeze designed for aluminum radiators. SUZUKI recommends the use of SUZUKI COOLANT antifreeze. If this is not available, use an equivalent antifreeze for aluminum radiators.

  • Page 11: Break-In Procedures

    GENERAL INFORMATION BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life.

  • Page 12: Information Labels

    GENERAL INFORMATION INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME E-02 E-03 E-19 E-28 E-33 E-54 Engine starting label Noise label — — — — Information label — — — — ICES Canada label — — — — — Fuel caution label —...

  • Page 13: Specifications

    GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ........... 2 310 mm (90.9 in) Overall width ............ 875 mm (34.4 in) Overall height ........... 1 240 mm (48.8 in) Wheelbase ............1 485 mm (58.5 in) Ground clearance ..........300 mm (11.8 in) Seat height ............
  • Page 14 GENERAL INFORMATION CHASSIS Front suspension ..........Telescopic, coil spring, oil damped, spring preload fully ad- justable, compression damping force 11-way adjustable Rear suspension ..........Link type, coil spring, oil damped, spring preload fully adjust- able, compression damping force 26-way adjustable Front fork stroke ..........

  • Page 15: Country And Area Codes

    1-10 GENERAL INFORMATION COUNTRY AND AREA CODES The following are codes and their applicable country or area. CODE COUNTRY OR AREA E-02 E-03 E-19 E-28 Canada E-33 California (USA) E-54 Israel...
  • Page 16 PERIODIC MAINTENANCE 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 ................

  • Page 17: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months, and are dependent on whichever comes first. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.

  • Page 18: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the periodic maintenance chart on the previous page. AIR CLEANER Inspect every 6 000 km (4 000 miles, 6 months). Replace every 18 000 km (11 000 miles, 18 months). If the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in power output and an in- crease in fuel consumption.

  • Page 19: Exhaust Pipe Nut And Bolt And Muffler Nut And Bolts

    PERIODIC MAINTENANCE EXHAUST PIPE NUT AND BOLT AND MUFFLER NUT AND BOLTS Tighten initially at 1 000 km (600 miles, 1 month) and every 12 000 km (7 500 miles, 12 months) thereafter. Remove the right frame cover. ( 6-2) Tighten the exhaust pipe nut 1, exhaust pipe bolt 2, muffler connection bolt 3, muffler mounting bolt 4, and muffler mount- ing nut 5 to the specified torque.

  • Page 20: Tappet Clearance

    PERIODIC MAINTENANCE TAPPET CLEARANCE Inspect every 24 000 km (15 000 miles, 24 months). INSPECTION Remove the fuel tank. ( 4-2) Drain the engine oil. ( 2-11) Disconnect the spark plug cap and remove the spark plug. 2-9 and 2-10) Loosen the horn mounting bracket bolt.
  • Page 21 After ro- tating the crankshaft, check the tappet clearance again to make sure that it is within specification. When installing the cylinder head cover, apply SUZUKI BOND “1207B” to the cam end caps of the cylinder head cover gas- ket.
  • Page 22 PERIODIC MAINTENANCE INTAKE SIDE...
  • Page 23 PERIODIC MAINTENANCE EXHAUST SIDE...

  • Page 24: Spark Plug

    PERIODIC MAINTENANCE SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months). Replace every 12 000 km (7 500 miles, 12 months). Remove the fuel tank. ( 4-2) Disconnect the spark plug cap and remove the spark plug. Cold type Standard Hot type...

  • Page 25: Spark Arrester (For E-03, 28, 33)

    2-10 PERIODIC MAINTENANCE SPARK PLUG INSTALLATION To avoid damaging the cylinder head threads; first, fin- ger tighten the spark plug, and then tighten it to the specified torque using the spark plug wrench. Insert the spark plug and finger tighten it to the cylinder head, and then tighten it to the specified torque.

  • Page 26: Engine Oil And Oil Filter

    PERIODIC MAINTENANCE 2-11 ENGINE OIL AND OIL FILTER ENGINE OIL Replace initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. ENGINE OIL FILTER Replace initially at 1 000 km (600 miles, 1 month) and every 18 000 km (11 000 miles, 18 months) thereafter.

  • Page 27: Engine Oil Hoses

    2-12 PERIODIC MAINTENANCE OIL FILTER REPLACEMENT Drain the engine oil as described in the engine oil replace- ment procedure. Remove the oil filter cap 1 and oil filter 2. Replace the oil filter with a new one. NOTE: Before replacing the oil filter cap, make sure that the spring 3 and a new O-ring 4 are installed correctly.

  • Page 28: Throttle Cable Play (Carburetor)

    PERIODIC MAINTENANCE 2-13 THROTTLE CABLE PLAY (CARBURETOR) Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Remove the fuel tank. ( 4-2) A twin throttle cable system is used in this motorcycle. Cable 1 is for pulling and cable 2 is for returning.

  • Page 29: Engine Idle Speed (Carburetor)

    2-14 PERIODIC MAINTENANCE ENGINE IDLE SPEED (CARBURETOR) Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. NOTE: Make this adjustment when the engine is hot. Connect the multi circuit tester to the high-tension cord. Start the engine and set the engine idle speed between 1 400 and 1 600 r/min by turning the throttle stop screw 1.

  • Page 30: Radiator Hoses

    PERIODIC MAINTENANCE 2-15 ENGINE COOLANT REPLACEMENT Remove the right side cover. ( 6-2) Loosen the stopper screw 1. Remove the radiator cap 2 and drain plug 3, and then drain the engine coolant. Tighten the drain plug 3. Pour the specified engine coolant slowly into the radiator. Engine coolant: Use an antifreeze designed for aluminum radiators mixed with distilled water only.

  • Page 31: Clutch

    Excessive wear Missing O-ring seals If any damages are found, replace the drive chain with a new one. The standard drive chain is RK520KZO. SUZUKI rec- ommends to use this standard drive chain as a replace- ment. NOTE: When replacing the drive chain, replace the drive chain and sprockets as a set.
  • Page 32 PERIODIC MAINTENANCE 2-17 Count out 21 pins (20-pitch) on the drive chain and measure the distance between the two points. If the distance exceeds the service limit, replace the drive chain with a new one. 09900-20103: Vernier calipers Drive chain 20-pitch length Service Limit: 319.4 mm (12.57 in) Place the motorcycle on the side stand.

  • Page 33: Brakes

    2-18 PERIODIC MAINTENANCE BRAKES Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. BRAKE PADS The extent of brake pad wear can be checked by observing the limit line 1 on the brake pad. When the wear exceeds the grooved limit line, replace the pads with new ones.

  • Page 34: Brake Fluid

    PERIODIC MAINTENANCE 2-19 BRAKE FLUID Inspect every 6 000 km (4 000 miles, 6 months). Replace every two years. BRAKE FLUID LEVEL Keep the motorcycle upright and place the handlebar straight. Check the brake fluid level by observing the lower limit line on the front and rear brake fluid reservoir.
  • Page 35 2-20 PERIODIC MAINTENANCE FRONT BRAKE Bleed air from the brake system. Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will re- move the tension of the brake lever causing it to touch the handlebar grip.

  • Page 36: Brake Hoses

    PERIODIC MAINTENANCE 2-21 BRAKE HOSES Inspect every 6 000 km (4 000 miles, 6 months). Replace every four years. Check the brake hoses for leakage, cracks, wear and dam- age. If any damages are found, replace the brake hoses with new ones.

  • Page 37: Spoke Nipples

    2-22 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be ad- versely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. Cold inflation tire pressure Solo riding Front: 125 kPa (1.25 kgf/cm...

  • Page 38: Steering

    PERIODIC MAINTENANCE 2-23 STEERING Inspect initially at 1 000 km (600 miles, 1 month) and every 12 000 km (7 500 miles, 12 months) thereafter. The steering should be adjusted properly for smooth turning of the handlebar and safe operation. Overtight steering prevents smooth turning of the handlebar and too loose steering will cause poor stability.

  • Page 39: Chassis Nuts And Bolts

    2-24 PERIODIC MAINTENANCE CHASSIS NUTS AND BOLTS Tighten initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Check that all chassis nuts and bolts are tightened to their specified torque. (Refer to page 2-25 for the locations of the following nuts and bolts.) ITEM N·m...
  • Page 40 PERIODIC MAINTENANCE 2-25...

  • Page 41: General Lubrication

    2-26 PERIODIC MAINTENANCE GENERAL LUBRICATION Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. 1 Speedometer cable 5 Swingarm pivot 2 Speedometer gearbox 6 Brake pedal pivot 3 Sidestand pivot and spring hook 7 Brake lever holder 4 Drive chain...

  • Page 42: Compression Pressure Check

    PERIODIC MAINTENANCE 2-27 COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. Compression pressure Standard: 950 kPa (9.5 kgf/cm , 135 psi)

  • Page 43: Oil Pressure Check

    2-28 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Oil pressure: Above 40 kPa (0.4 kgf/cm , 5.7 psi) at 3 000 r/min Below 140 kPa (1.4 kgf/cm , 19.9 psi) Low or high oil pressure can indicate any of the following conditions: LOW OIL PRESSURE...
  • Page 44 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE ........3- 2 ENGINE REMOVAL AND REMOUNTING ................. 3- 3 ENGINE REMOVAL ....................... 3- 3 ENGINE REMOUNTING ......................3- 8 ENGINE DISASSEMBLY ......................3-11 ENGINE COMPONENTS INSPECTION AND SERVICE ............3-22 CYLINDER HEAD .........................
  • Page 45 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and installed without removing the engine from the frame. Refer to the page listed in each section for removal and installation instructions. ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION...

  • Page 46: Engine Removal And Remounting

    ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame, wash the engine us- ing a steam cleaner. Engine removal is sequentially explained in the following steps. Remove the seat, side covers, and frame covers. ( 6-2) Drain the engine oil.
  • Page 47 ENGINE Remove the regulator/rectifier. Remove the engine coolant overflow tank mounting bolt. Disconnect the spark plug cap 1 , engine oil breather hose 2, engine oil hose 3, and remove the engine oil tank 4. Remove the clutch release arm 5 and remove the starter motor 6.
  • Page 48 ENGINE Remove the exhaust pipe 1 and muffler 2. Disconnect the engine oil pipe 3 and engine oil hose union bolt 4.
  • Page 49 ENGINE Remove the gearshift lever. Remove the engine sprocket cover. Flatten the washer 1 and remove the engine sprocket nut 2 while pressing down on the rear brake pedal. Remove the engine sprocket. Remove the cotter pins and brake pedal. Replace the removed cotter pins with new ones.
  • Page 50 ENGINE Disconnect the horn coupler 1 and remove the horn 2. Remove the PAIR (air supply) valve assembly. (For E-02, 19, Remove the engine from the frame.

  • Page 51: Engine Remounting

    ENGINE ENGINE REMOUNTING Remount the engine in the reverse order of engine removal. Install the engine mounting nuts and bolts. NOTE: Temporally tighten the nuts at this stage. The engine mounting nuts are self-locking. Once the nut has been removed, it is no longer of any use. Replace the engine mounting nuts with new ones.
  • Page 52 ENGINE Tighten the brake pedal bolt to the specified torque. Brake pedal bolt: 29 N·m (2.9 kgf-m, 21.0 lb-ft) NOTE: After installing the brake pedal, install the new cotter pins into the brake pedal bolt and pin. Install the engine sprocket, with side A of the sprocket facing toward the engine.
  • Page 53 3-10 ENGINE Tighten the exhaust pipe nut 1, exhaust pipe bolt 2, muffler connection bolt 3, muffler mounting bolt 4, and muffler mount- ing nut 5 to the specified torque. Be sure to tighten the nuts and bolts in the following order. Exhaust pipe nut and exhaust pipe bolt (1, 2) Muffler mounting nut 5 Muffler mounting bolt 4...

  • Page 54: Engine Disassembly

    ENGINE 3-11 ENGINE DISASSEMBLY Remove the cap bolt 1 and cam chain tension adjuster 2. Remove the top-dead-center (TDC) plug 3 and generator cover cap 4. Turn the generator rotor until the “T” line on the generator ro- tor is aligned with the center of the hole in the generator cover. NOTE: When removing the cylinder head cover, the piston must be at TDC of the compression stroke.
  • Page 55 3-12 ENGINE Remove the cam chain guide 1 and camshaft journal hold- ers 2. Remove the dowel pins 3, intake camshaft 4 and exhaust camshaft 5. NOTE: Do not drop the dowel pins into the crankcase. Remove the cylinder head side bolt. NOTE: Do not drop the cam chain into the crankcase.
  • Page 56 ENGINE 3-13 Remove the cylinder head bolts, and then remove the cylinder head. NOTE: If the cylinder head does not come off easily, lightly tap it using a plastic mallet. Remove the cylinder head gasket 1 and dowel pins 2. Remove the cam chain guide 3.
  • Page 57 3-14 ENGINE Remove the starter drive gear cover 1 and starter drive gear 2. Remove the generator rotor cover. Remove the starter driven gear 3 , dowel pins 4 , and gasket 5. Remove the neutral switch 6 , switch contacts 7 , and springs.
  • Page 58 ENGINE 3-15 Remove the water pump cover. Remove the clutch cover. Remove the right crankcase cover. Remove the dowel pins 1 and gasket 2. Loosen the clutch spring set bolts working in diagonal stages, and then remove them when they are fully loosened.
  • Page 59 3-16 ENGINE Remove the clutch pressure plate, clutch drive plates, and clutch driven plates. Remove the push rod, spring washer, and spring washer seat. Flatten the clutch sleeve hub washer. Hold the clutch sleeve hub using the special tool, and then remove the clutch sleeve hub nut.
  • Page 60 ENGINE 3-17 Remove the primary driven gear assembly and collar. Remove the cam chain tensioner 1 and cam chain 2. Remove the retainer 3 and spacer 4. Remove the oil pump idle gear 5 and oil pump driven gear 6. Remove the pin 7 and oil pump assembly.
  • Page 61 3-18 ENGINE Remove the gearshift shaft 1 by removing the circlip 2. Remove the gearshift arm stopper 3. Remove the gearshift pawl lifter 4 and gearshift cam driven gear 5. Remove the gearshift cam stopper arm. Remove the gearshift cam driven gear bolt.
  • Page 62 ENGINE 3-19 Hold the generator rotor using a 26 mm offset wrench, and then remove the balancer driven gear nut. Remove the plate, balancer driven gear, and key. Hold the generator rotor using a 26 mm offset wrench, and then remove the primary drive gear nut. Remove the washer, primary drive gear, pin, key, and bal- ancer drive gear.
  • Page 63 3-20 ENGINE Remove the left crankcase securing bolts. Remove the right crankcase securing bolts. Separate the crankcase using the special tool. 09920-13120: Crankcase separating tool NOTE: Fit the crankcase separating tool to the right side, so that the tool plate is paralleled with the end face of the crankcase. Remove the dowel pins.
  • Page 64 ENGINE 3-21 Remove the countershaft assembly 1 and driveshaft assem- bly 2. Remove the balancer shaft. Remove the crankshaft from the crankcase using the special tool. 09920-13120: Crankcase separating tool Remove the oil sump filter.

  • Page 65: Engine Components Inspection And Service

    3-22 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD DISASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups (i.e., exhaust or in- take) so that they can be installed in their original posi- tions. Remove the intake pipe.
  • Page 66 ENGINE 3-23 Remove the oil seal with long-nose pliers. Remove the valve spring seat. NOTE: Removal of valves completes ordinary disassembling work. If valve guides have to be removed for replacement after inspect- ing the related parts, carry out the steps shown in the valve guide servicing.
  • Page 67 3-24 ENGINE VALVE HEAD RADIAL RUNOUT Support the valve using a V-block and measure the valve head radial runout using the dial gauge, as shown. If the runout ex- ceeds the service limit, replace the valve with a new one. 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm)
  • Page 68 ENGINE 3-25 VALVE GUIDE SERVICING Drive the valve guide out toward the camshaft side using the valve guide remover. 09916-44310: Valve guide remover/installer NOTE: Discard the removed valve guide. Only oversized valve guides are available as replacement parts. Refinish the valve guide holes in the cylinder head using the valve guide reamer and handle.
  • Page 69 3-26 ENGINE VALVE SEAT WIDTH Coat the valve seat uniformly with prussian blue. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.
  • Page 70 ENGINE 3-27 When installing the solid pilot 1, rotate it slightly. Seat the pilot snugly. Install the 45° cutter 2, attachment 3, and T-handle 4. INITIAL SEAT CUT Descale and clean up the seat using the 45° cutter. Rotate the cutter one or two turns. Measure the valve seat width W after every cut.
  • Page 71 3-28 ENGINE TOP NARROWING CUT Contact area too high and If the contact area is too high on the valve, or if it is too wide, too wide on face of valve use the 30° cutter (for the intake side) and the 15° cutter (for the exhaust side) to lower and narrow the contact area.
  • Page 72 ENGINE 3-29 VALVE SEAT SEALING CONDITION INSPECTION With the valve and valve spring assembled, pour a small quan- tity of gasoline into the intake or exhaust port. Check that no gasoline leaks through the valve seat. If leakage is found, correct the sealing surface. Gasoline is highly flammable and explosive.
  • Page 73 3-30 ENGINE REASSEMBLY Install each valve spring seat. Apply molybdenum oil solution to each oil seal and press-fit them into position. Do not reuse the oil seals. Apply molybdenum oil solution to the valve as shown, and then insert them into the valve guides. When inserting each valve into the valve guides, make sure not to damage the lip of the oil seal.

  • Page 74: Camshaft/Automatic Decompression Assembly

    ENGINE 3-31 CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBLY Do not attempt to disassemble the camshaft/automatic decompression assembly. It is not serviceable. AUTOMATIC DECOMPRESSION Move the automatic decompression weight by hand to inspect if it is operating smoothly. If the automatic decompression weight does not operate smoothly, replace it with a new one. CAM WEAR Worn-down cams are often the cause of mistimed valve opera- tion resulting in reduced power output.
  • Page 75 3-32 ENGINE CAMSHAFT JOURNAL WEAR Measure the oil clearance, with the camshaft installed, using the plastigauge. 09900-22301: Plastigauge 09900-22302: Plastigauge Camshaft journal oil clearance (IN & EX) Service Limit: 0.150 mm (0.0059 in) Tighten the camshaft journal holder bolts evenly and in diagonal stages to the specified torque.

  • Page 76: Cylinder

    ENGINE 3-33 CYLINDER CYLINDER DISTORTION Check the gasket surface of the cylinder block for distortion us- ing a straightedge and thickness gauge. Take clearance read- ings at several places. If any clearance reading exceeds the ser- vice limit, replace the cylinder block with a new one. 09900-20803: Thickness gauge Cylinder distortion Service Limit: 0.05 mm (0.002 in)
  • Page 77 3-34 ENGINE PISTON-RING-TO-GROOVE CLEARANCE Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. If any clearance reading exceeds the service limit, replace both the piston and piston rings. 09900-20803: Thickness gauge 09900-20205: Micrometer (0 – 25 mm) Piston-ring-to-groove clearance Service Limit: 1st: 0.18 mm (0.0071 in)

  • Page 78: Conrod

    ENGINE 3-35 PISTON PIN AND PIN BORE Measure the piston pin bore diameter using the small bore gauge. If the diameter exceeds the service limit, replace the piston with a new one. 09900-20602: Dial gauge (1/1000 mm) 09900-22403: Small bore gauge (18 – 35 mm) Piston pin bore Service Limit: 20.030 mm (0.7886 in) Measure the piston pin outside diameter at three positions us-...

  • Page 79: Crankshaft

    3-36 ENGINE CRANKSHAFT CRANKSHAFT RUNOUT Support the crankshaft using V-blocks and measure the crank- shaft runout using the dial gauge, as shown. If the runout ex- ceeds the service limit, replace the crankshaft with a new one. 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09910-21304: V-block set (100 mm) Crankshaft runout...

  • Page 80: Starter Torque Limiter

    OIL PUMP The oil pump case securing screw is applied with SUZUKI THREAD LOCK SUPER “1303”. If an attempt is made to overhaul the oil pump assembly, the screw may be damaged. Only the oil pump unit is available as a replacement.

  • Page 81: Clutch

    3-38 ENGINE CLUTCH CLUTCH DRIVE PLATES Measure the thickness of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the service limit, re- place the clutch plates as a set. 09900-20101: Vernier calipers Drive plate thickness (No.1 & No.2) Service Limit: 2.62 mm (0.103 in) Drive plate claw width (No.1 &...

  • Page 82: Gearshift Fork And Gear

    ENGINE 3-39 GEARSHIFT FORK AND GEAR GEARSHIFT-FORK-TO-GEARSHIFT-FORK GROOVE CLEARANCE Clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting process. Measure the gearshift fork clearance in the groove of its respec- tive gear using the thickness gauge. If the clearance exceeds specification, replace the fork, its re- spective gear, or both.

  • Page 83: Transmission

    3-40 ENGINE TRANSMISSION DISASSEMBLY Disassemble the transmission gears as shown. 1 Countershaft E Bearing 2 5th (top) drive gear F Oil seal 3 Circlip G 4th driven gear 4 3rd drive gear H 3rd driven gear 5 Circlip I Washer 6 4th drive gear J Circlip 7 2nd drive gear...
  • Page 84 ENGINE 3-41 REASSEMBLY Reassemble the transmission in the reverse order of disassem- bly. Pay special attention to the following points: NOTE: Before installing the gears, apply engine oil to the inner surface of each gear and bushing. Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed.
  • Page 85 3-42 ENGINE 1 Driveshaft 2 Countershaft...

  • Page 86: Bearings

    ENGINE 3-43 BEARINGS Play Wash the bearing with a cleaning solvent and lubricate it with Play motor oil before inspection. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defec- tive and must be replaced with a new one as follows.
  • Page 87 3-44 ENGINE DRIVESHAFT BEARINGS Remove the right and left driveshaft bearings using the spe- cial tool. 09921-20220: Bearing remover set Replace the removed bearings with new ones. Install the right and left driveshaft bearings using the special tool. 09913-70210: Bearing installer set CRANKSHAFT BEARINGS Remove the right and left crankshaft bearings using the spe- cial tool.
  • Page 88 ENGINE 3-45 LEFT GEARSHIFT CAM BEARING Remove the left gear shift cam bearing. Replace the removed bearing with a new one. Install the left gearshift cam bearing. RIGHT BALANCER SHAFT BEARING Remove the right balancer shaft bearing using the special tool.

  • Page 89: Oil Seals

    Install the oil seals into the crankcase, clutch housing case, and generator rotor cover. Pay attention to the following points: Replace the removed oil seals with new ones. Apply SUZUKI SUPER GREASE “A” to the lip of the oil seals. For USA 99000-25030: SUZUKI SUPER GREASE “A”...

  • Page 90: Oil Check Valve

    ENGINE 3-47 Install the driveshaft oil seal into the left crankcase slowly, using the special tool. 09913-70210: Bearing installer set GEARSHIFT SHAFT OIL SEAL Remove the gearshift shaft oil seal from the left crankcase, slowly using the special tool. 09913-50121: Oil seal remover Replace the removed oil seal with a new one.

  • Page 91: Engine Reassembly

    3-48 ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. Pay special attention to the following points: NOTE: Apply engine oil to each running and sliding part before reas- sembling the engine. CRANKSHAFT 1 Bearing 2 Crankshaft (R) 3 Conrod 4 Bearing 5 Crank pin...

  • Page 92: Gearshift Cam And Fork

    ENGINE 3-49 GEARSHIFT CAM AND FORK 1 Gearshift fork No.1 2 Gearshift fork No.2 3 Gearshift fork shaft 4 Bearing 5 Pin 6 Gearshift cam 7 Bearing 8 Gearshift fork No.3 9 Gearshift fork shaft Install the gearshift forks into the gearshifting grooves in the correct position and direction.

  • Page 93: Crankcase

    Install the dowel pins to the left crankcase. Apply engine oil to the conrod big end and to the transmis- sion gears. Apply SUZUKI BOND “1207B” or “1215” to the mating sur- face of the right crankcase and section A of both crankcases as shown.

  • Page 94: Starter Clutch And Generator Rotor

    ENGINE 3-51 Tighten the crankcase bolts to the specified torque. Crankcase bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) After the crankcase bolts have been tightened, check if the crankshaft, countershaft, and driveshaft rotate smoothly. If a large resistance is felt to rotation, try to free the shafts by tapping them with a plastic mallet.

  • Page 95: Balancer Shaft

    3-52 ENGINE BALANCER SHAFT 1 Plate 2 Balancer driven gear 3 Inner race 4 Bearing 5 Pin 6 Balancer shaft 7 Bearing A Balancer shaft nut ITEM N·m kgf-m lb-ft 36.0 When installing the balancer drive gear, align the pin 1 with the groove 2.

  • Page 96: Primary Drive Gear

    ENGINE 3-53 PRIMARY DRIVE GEAR Install the key 1 and primary drive gear 2. Hold the generator rotor using the 26 mm offset wrench, and then tighten the primary drive gear nut to the specified torque. Primary drive gear nut: 110 N·m (11.0 kgf-m, 79.5 lb-ft) GEARSHIFT CAM DRIVEN GEAR Tighten the gearshift cam driven gear bolt to the specified torque.

  • Page 97: Gearshift Shaft

    3-54 ENGINE GEARSHIFT SHAFT Tighten the gearshift arm stopper to the specified torque. Gearshift arm stopper: 19 N·m (1.9 kgf-m, 13.5 lb-ft) OIL PUMP Before mounting the oil pump, apply engine oil to the sliding surfaces of the oil pump case, outer rotor, inner rotor, and shaft.

  • Page 98: Cam Chain

    ENGINE 3-55 CAM CHAIN Install the cam chain 1 on to the sprocket. Tighten the cam chain tensioner mounting bolt 2 to the speci- fied torque. Cam chain tensioner mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) CLUTCH 1 Clutch release camshaft 2 Bolt 3 Spring retainer 4 Spring...
  • Page 99 3-56 ENGINE Hold the clutch sleeve hub using the special tool, and then tighten the clutch sleeve hub nut to the specified torque. 09920-53740: Clutch sleeve hub holder Clutch sleeve hub nut: 70 N·m (7.0 kgf-m, 50.5 lb-ft) Bend the tongue of the washer securely. Install the spring washer seat 1 and spring washer 2 onto the clutch sleeve hub correctly.

  • Page 100: Right Crankcase Cover

    ENGINE 3-57 RIGHT CRANKCASE COVER Install the dowel pins 1 and new gasket 2. Use a new gasket to prevent oil leakage. Tighten the right crankcase cover bolts securely. NOTE: Install the new gasket onto the right crankcase cover bolt A as shown.

  • Page 101: Starter Drive Gear Cover

    3-58 ENGINE Tighten the generator rotor cover bolts securely. STARTER DRIVE GEAR COVER Tighten the starter drive gear cover screws securely. PISTON RING Install the oil ring first, the 2nd ring second, and the 1st ring last. NOTE: The 1st 1 and 2nd 2 piston rings differ in shape. The 1st piston ring should be installed with the grooved por- tion of the ring facing up.

  • Page 102: Piston And Cylinder

    ENGINE 3-59 First, install a spacer 1 into the oil ring groove, and then in- stall the two side rails 2. The spacer and side rails do not have a designated top and bottom. They can be installed in any position. When installing the spacer, be careful not to allow its two ends to overlap in the groove.

  • Page 103: Cylinder Head

    3-60 ENGINE Install the dowel pins 1 and new gasket 2 onto the crank- case. Use a new gasket to prevent oil leakage. Hold each piston ring with the piston ring sections positioned correctly and put it into the cylinder. Make sure that the piston rings are caught by the cylinder skirt.

  • Page 104: Camshaft/Automatic Decompression Assembly

    ENGINE 3-61 With the head snugly seated on the cylinder, secure it by tight- ening the bolts in diagonal stages. Tighten the cylinder head bolts to the specified torque. Cylinder head bolt Initial: 25 N·m (2.5 kgf-m, 18.0 lb-ft) Final: 46 N·m (4.6 kgf-m, 33.5 lb-ft) NOTE: Apply engine oil to the threaded parts of the cylinder head bolts and its washers.
  • Page 105 3-62 ENGINE NOTE: Just before installing the camshaft into the cylinder head, apply molybdenum oil solution to the camshaft journals and cam faces. Also, apply engine oil to the camshaft journal holders. Place each camshaft into the correct position. NOTE: Camshafts which are marked “EX”...

  • Page 106: Cylinder Head Cover

    TDC on the compression stroke. CYLINDER HEAD COVER Thoroughly wipe off oil from the fitting surfaces of the cylinder head and cover. Apply SUZUKI BOND “1207B” to the end caps of the cylinder head cover gasket as shown. For USA 99104-31140: SUZUKI BOND “1207B”...

  • Page 107: Cam Chain Tension Adjuster

    3-64 ENGINE CAM CHAIN TENSION ADJUSTER Install the cam chain tension adjuster. Pay special attention to the following points: Apply engine oil to the push rod. Turn the adjusting screw clockwise with a flat-bladed screw- driver until the push rod is locked. Fit a new gasket to the chain tension adjuster body.

  • Page 108: Removal

    ENGINE 3-65 PAIR (AIR SUPPLY) SYSTEM (FOR E-02, 19, 54) REMOVAL Remove the left radiator. ( 5-6 and 5-7) Disconnect the clamp 1 and vacuum hose 2. Remove the PAIR (air supply) pipe from the cylinder head. Remove the PAIR (air supply) valve assembly. Remove the PAIR (air supply) pipe 3 and air cleaner hose 4.

  • Page 109: Remounting

    3-66 ENGINE REED VALVE Inspect the reed valve for carbon deposits. If carbon deposits are found in the reed valve, replace the reed valve with a new one. PAIR VALVE Inspect that air flows through the PAIR (air supply) valve air inlet port A to the air outlet parts B.
  • Page 110 FUEL AND LUBRICATION SYSTEM FUEL AND LUBRICATION SYSTEM CONTENTS FUEL TANK ....................... 4- 2 REMOVAL ....................4- 2 REMOUNTING ..................... 4- 2 FUEL VALVE ..................... 4- 3 REMOVAL AND INSPECTION ..............4- 3 FUEL STRAINER ..................4- 3 REMOUNTING ..................... 4- 3 CARBURETOR ....................

  • Page 111: Fuel Tank

    FUEL AND LUBRICATION SYSTEM FUEL TANK REMOVAL Remove the seat and side covers. ( 6-2) Turn the fuel valve to the “OFF” position. Disconnect the fuel hose. Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. Remove the fuel tank.

  • Page 112: Fuel Valve

    FUEL AND LUBRICATION SYSTEM FUEL VALVE REMOVAL AND INSPECTION Remove the fuel tank. ( 4-2) Drain the fuel completely. Remove the fuel valve. Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. Replace the removed O-ring with a new one to pre- vent fuel leakage.

  • Page 113: Carburetor

    FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION 1 Top cap 2 Spring 3 Jet needle stopper 4 O-ring 5 Spring 6 Washer 7 E-ring 8 Washer 9 Spacer 0 Jet needle A Diaphragm B Piston valve C O-ring D Pilot air jet E Carburetor body F Coasting richer pump assembly G Starter plunger assembly...

  • Page 114: Specifications

    FUEL AND LUBRICATION SYSTEM SPECIFICATIONS SPECIFICATION ITEM E-02, 19, 54 E-03, 28 E-33 ← ← Carburetor type MIKUNI BSR36 ← ← Bore size 36 mm (1.4 in) I.D. No. 29FA 29FB 29FC ← ← Idle r/min 1500 ± 100 r/min ←...

  • Page 115: Removal

    FUEL AND LUBRICATION SYSTEM REMOVAL Remove the fuel tank. ( 4-2) Remove the left frame cover. ( 6-2) Disconnect the throttle position sensor coupler 1 and piston valve control solenoid coupler 2 (Except for E-03, 28, 33). Disconnect the throttle cables. Disconnect the air vent hose 3 and vacuum hose 4.
  • Page 116 FUEL AND LUBRICATION SYSTEM Remove the piston valve control solenoid 1 and joint pipe 2 (Except for E-03, 28, 33). Remove the throttle position sensor. Remove the coasting richer pump assembly. Remove the starter plunger assembly. Remove the top cap.
  • Page 117 FUEL AND LUBRICATION SYSTEM Remove the spring 1 and piston valve along with its diaphragm 2. Remove the jet needle stopper 3, O-ring 4, spring 5, wash- ers 6, and jet needle assembly 7. Remove the float chamber 8 and throttle stop screw 9. Replace the removed O-ring with a new one to prevent fuel leakage.
  • Page 118 FUEL AND LUBRICATION SYSTEM Remove the following parts. 1 Valve seat 5 Needle jet 2 Main jet 6 Starter jet 3 Pilot jet 7 Pilot air jet 4 Pilot screw NOTE: Before removing the pilot screw 4 , its setting must be deter- mined.

  • Page 119: Cleaning

    4-10 FUEL AND LUBRICATION SYSTEM CLEANING Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions for proper use, handling and storage. Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.
  • Page 120 FUEL AND LUBRICATION SYSTEM 4-11 NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the needle valve, the gasoline will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur.

  • Page 121: Reassembly

    4-12 FUEL AND LUBRICATION SYSTEM REASSEMBLY Reassemble the carburetor in the reverse order of disassembly. Pay special attention to the following points: PILOT SCREW After cleaning, install the pilot screw 1 to the original setting by turning the screw in until it lightly seats, and then backing it out the same number of turns counted during disassembly.

  • Page 122: Lubrication System

    FUEL AND LUBRICATION SYSTEM 4-13 LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART CYLINDER WALL FRAME (OIL TANK) PISTON CONROD SMALL END IN & EX CAM FACE OIL SUMP FILTER CAM CHAIN CONROD BIG END BEARING CAMSHAFT JOURNAL CRANK PIN CYLINDER HEAD RIGHT CRANKSHAFT PISTON PIN CYLINDER...
  • Page 124 COOLING SYSTEM COOLING SYSTEM CONTENTS COOLING SYSTEM ..................5- 2 DESCRIPTION .................... 5- 2 CONSTRUCTION ..................5- 3 ENGINE COOLANT ..................5- 4 RADIATOR AND COOLING FAN ..............5- 5 INSPECTION ....................5- 5 REMOVAL ....................5- 6 REMOUNTING .................... 5- 7 COOLING FAN THERMOSWITCH ..............

  • Page 125: Cooling System

    COOLING SYSTEM COOLING SYSTEM DESCRIPTION The engine is cooled by the forced circulation of engine coolant, using a high-capacity, centrifugal water pump, through water jackets formed in the cylinder and cylinder head, and through the radiator. The tube- and-fin type radiator is made of aluminum, which is characterized by lightness in weight and good heat dissipation.

  • Page 126: Construction

    COOLING SYSTEM CONSTRUCTION 1 Radiator cap 2 Radiator (R) 3 Radiator (L) 4 Radiator inlet hose 5 Radiator outlet hose 6 Overflow hose 7 Overflow tank A Air bleeder bolt B Cooling fan thermoswitch C Engine coolant temperature thermoswitch ITEM N·m kgf-m lb-ft...

  • Page 127: Engine Coolant

    COOLING SYSTEM ENGINE COOLANT (kgf/cm , lb-ft) At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol antifreeze. This mixture will provide optimum corrosion and heat protec- tion, and will protect the cooling system from freezing at above –31°C (–24°F).

  • Page 128: Radiator And Cooling Fan

    COOLING SYSTEM RADIATOR AND COOLING FAN INSPECTION RADIATOR Before removing the radiator and draining the engine coolant, check the following. Check the cooling system for leaks with a radiator tester 1. Remove the radiator cap and connect the radiator tester to the filler.

  • Page 129: Removal

    COOLING SYSTEM COOLING FAN Remove the fuel tank. ( 4-2) Disconnect the cooling fan motor coupler. Test the cooling fan motor for load current using an ammeter connected as shown. The voltmeter is for making sure that the battery applies 12 volts to the motor.

  • Page 130: Remounting

    COOLING SYSTEM Disconnect the radiator hoses and radiator covers. Remove the radiators. Remove the cooling fan. REMOUNTING Remount the radiator in the reverse order of removal. After remount- ing the radiator, be sure to add engine coolant. ( 2-15)

  • Page 131: Cooling Fan Thermoswitch

    COOLING SYSTEM COOLING FAN THERMOSWITCH The cooling fan is secured behind the radiator by three bolts and is automatically controlled by the thermoswitch. The thermoswitch remains open when the temperature of the engine coolant is low, but closes when the temperature reaches approximately 96°C (205°F) setting the cooling fan in motion. Fuse Ignition switch Cooling fan...

  • Page 132: Inspection

    ON → → → → → OFF: Approximately 91°C (196°F) INSTALLATION Install the cooling fan thermoswitch in the reverse order of re- moval. Pay attention to the following points: Apply SUZUKI SUPER GREASE “A” to the O-ring. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 133: Engine Coolant Temperature Thermoswitch

    ON → → → → → OFF: Approximately 100°C (212°F) INSTALLATION Install the engine coolant temperature thermoswitch in the re- verse order of removal. Pay attention to the following points: Apply SUZUKI SUPER GREASE “A” to the O-ring. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 134: Thermostat

    COOLING SYSTEM 5-11 THERMOSTAT REMOVAL Drain the engine coolant. ( 2-15) Remove the right radiator. ( 5-6 and 5-7) Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or va- por.

  • Page 135: Installation

    INSTALLATION Install the thermostat in the reverse order of removal. Pay at- tention to the following points. Apply SUZUKI SUPER GREASE “A” to the rubber seal on the thermostat. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 136: Water Pump

    COOLING SYSTEM 5-13 WATER PUMP REMOVAL AND DISASSEMBLY Drain the engine coolant. ( 2-15) Drain the engine oil. ( 2-11) Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or va- por.

  • Page 137: Inspection

    5-14 COOLING SYSTEM INSPECTION Play WATER PUMP BEARING Play Inspect the inner race play of the water pump bearing by hand while it is in the water pump housing. Rotate the inner race by hand to inspect it for abnormal noise and smooth rotation. If ab- normal noise occurs or if rough movement is noted, replace the water pump bearing with a new one.
  • Page 138 COOLING SYSTEM 5-15 Apply SUZUKI SUPER GREASE “A” to the new O-ring. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A” When installing the water pump driven gear align the pin 1 with the groove 2.
  • Page 140 CHASSIS 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 ..............................

  • Page 141: Exterior Parts

    CHASSIS EXTERIOR PARTS REMOVAL SEAT Remove the right frame cover. ( 6-2) Remove the seat 1. SIDE COVERS Remove the left and right side covers 1. FRAME COVERS Remove the left frame cover 1 and right frame cover 2. BATTERY COVER Remove the battery cover 1.

  • Page 142: Front Wheel

    CHASSIS FRONT WHEEL CONSTRUCTION 1 Front axle 2 Speedometer 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...
  • Page 143 CHASSIS Left Right Left Right Left Right Spacer Clearance...

  • Page 144: Removal And Disassembly

    CHASSIS REMOVAL AND DISASSEMBLY Disconnect the speedometer cable 1 and remove the axle nut cap 2. (Except for E-03, 28, 33) Remove the front axle nut 3 and loosen the front axle pinch bolts 4. Support the motorcycle with a jack or wooden block and re- move the front axle 5 and front wheel 6.

  • Page 145: Inspection

    CHASSIS INSPECTION SPEEDOMETER GEARBOX DUST SEAL Inspect the speedometer gearbox dust seal for damage. If any damage is found, replace the speedometer gearbox with a new one. WHEEL HUB DUST SEAL Inspect the wheel hub dust seal for damage. If any damage is found, replace the wheel hub dust seal with a new one.
  • Page 146 CHASSIS Remove the wheel bearings as follows: Remove the wheel hub dust seal. ( 6-6) Insert the bearing remover attachment 1 into the wheel bear- ing. Insert the wedge bar 2 from the opposite side and lock it into the slit of the bearing remover attachment. Drive out the wheel bearing by striking the wedge bar.

  • Page 147: Reassembly And Remounting

    First, install the left wheel bearing, and then install the right wheel bearing. ( 6-4) WHEEL HUB DUST SEAL Apply SUZUKI SUPER GREASE “A” to the lip of dust seal. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 148 CHASSIS SPEEDOMETER GEARBOX Apply SUZUKI SUPER GREASE “A” to the speedometer gear- box dust seal. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A” Align the grooves 1 on the speedometer gearbox with the lugs 2 on the wheel hub.

  • Page 149: Front Fork

    6-10 CHASSIS FRONT FORK CONSTRUCTION 1 O-ring 2 Fork spring 3 Damper rod ring 4 Damper rod 5 Rebound spring 6 Dust seal 7 Stopper ring 8 Oil seal 9 Oil seal retainer 0 Inner tube antifriction metal A Inner tube B Outer tube antifriction metal C Clamp D Boot...

  • Page 150: Removal And Disassembly

    CHASSIS 6-11 REMOVAL AND DISASSEMBLY Remove the front wheel. ( 6-5) Remove the front brake caliper. ( 6-43) Remove the brake hose clamp 1 and speedometer cable guide 2. Remove the front fork after loosening the front fork upper clamp bolts 3 and lower clamp bolts 4.
  • Page 151 6-12 CHASSIS Remove the dust seal 1 and stopper ring 2. Place the front fork in a vise with soft jaws. NOTE: Clamp the right front fork axle holder and the left front fork brake caliper bracket using the vise. Do not over tighten the vise or the outer tube will be damaged.

  • Page 152: Inspection

    CHASSIS 6-13 Remove the oil seal 1 , oil seal retainer 2 , outer tube antifriction metal 3 inner tube antifriction metal 4, and oil lock piece 5. The outer and inner tube’s antifriction metals must be replaced along with the oil seal and dust seal when assembling the front fork.

  • Page 153: Reassembly And Remounting

    Apply front fork oil to the lip of oil seal lightly before installing 99000-99001-SS5: SUZUKI FORK OIL SS-05 Install the oil lock piece 1, outer tube antifriction metal 2, oil seal retainer 3, and oil seal 4 onto the inner tube.
  • Page 154 FORK OIL Place the front fork vertically without the spring. Pour the specified fork oil into the inner tube. 99000-99001-SS5: SUZUKI FORK OIL SS-05 Standard fork oil capacity (each leg): 709 ml (24.0 US oz, 25.0 Imp oz) Move the inner tube slowly several times.

  • Page 155: Suspension Setting

    6-16 CHASSIS FRONT FORK When remounting the front fork, align the inner tube 1 so that it protrudes 5 mm (0.2 in) from the upper surface 2 of the steering stem upper bracket. Tighten the front fork lower clamp bolts 1, front fork cap bolt 2, and front fork upper clamp bolts 3 to the specified torque.

  • Page 156: Steering

    CHASSIS 6-17 STEERING CONSTRUCTION 1 Rear view mirror 2 Handlebar 3 Washer 4 Handlebar clamp 5 Steering stem upper bracket 6 Steering stem nut 7 Bearing 8 Steering stem 9 Bearing 0 Headlight cover bracket A Handlebar clamp bolt B Steering stem head nut C Front fork upper clamp bolt D Front fork lower clamp bolt ITEM...

  • Page 157: Removal And Disassembly

    6-18 CHASSIS REMOVAL AND DISASSEMBLY Remove the front fork. ( 6-11) Remove the master cylinder assembly. ( 6-47) Remove the headlight assembly. ( 7-29) Remove the front brake hose guide bolt. Disconnect the speedometer cable 1, indicator lights cou- pler 2, and speedometer coupler 3. Remove the speedometer assembly.
  • Page 158 CHASSIS 6-19 Remove the clamp 1, right handlebar switch 2, and throttle cables 3. Remove the throttle grip. Remove the clamp 4, left handlebar switch 5 and left rear view mirror 6. Disconnect the clutch cable. Remove the front fender.
  • Page 159 6-20 CHASSIS Remove the handlebar 1 and ignition switch 2. Remove the steering stem head nut. Remove the washer 3 and steering stem upper bracket 4. Remove the steering stem nut using the special tools. 09940-14911: Steering nut socket wrench 09940-14960: Steering nut wrench socket Remove the steering stem lower bracket.

  • Page 160: Inspection

    CHASSIS 6-21 INSPECTION Inspect the removed parts for the following abnormalities. If any damages are found, replace the respective part with a new one. Steering race wear and brinelling. Bearing wear or damage. Abnormal bearing noise. Distortion of steering stem or handlebar. Remove the steering stem lower bearing using a chisel.
  • Page 161 6-22 CHASSIS Apply SUZUKI SUPER GREASE “A” to the steering stem upper and lower bearings. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A” STEERING STEM Tighten the steering stem nut to the specified torque using the special tools.
  • Page 162 CHASSIS 6-23 CLUTCH CABLE AND THROTTLE CABLES Apply SUZUKI SUPER GREASE “A” to the end of clutch cable and throttle cables. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A” HANDLEBAR SWITCHES Align the grooves 1 on the handlebar with the lugs 2 on the handlebar switches.

  • Page 163: Rear Wheel

    6-24 CHASSIS REAR WHEEL CONSTRUCTION 1 Cotter pin (For E-03, 28, 33) 2 Washer 3 Chain adjuster 4 Brake disc 5 Spacer 6 Dust seal 7 Bearing 8 Rear wheel 9 Rear sprocket 0 Spacer A Bearing B Bearing C Dust seal D Spacer E Rear axle A Rear axle nut...
  • Page 164 CHASSIS 6-25 Left Right (Except E-03, 28, 33) Left Right Left Right Spacer Clearance...

  • Page 165: Removal And Disassembly

    6-26 CHASSIS REMOVAL AND DISASSEMBLY Remove the cotter pin. (For E-03, 28, 33) Remove the rear axle nut. Replace the removed cotter pin with a new one. Support the motorcycle with a jack or wooden block and re- move the rear axle 1 and rear wheel. Do not operate the brake pedal during or after rear wheel removal.

  • Page 166: Inspection

    Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay special attention to the following points: WHEEL BEARINGS Apply SUZUKI SUPER GREASE “A” to the left wheel bear- ing. For USA 99000-25030: SUZUKI SUPER GREASE “A”...
  • Page 167 6-28 CHASSIS WHEEL HUB DUST SEALS Apply SUZUKI SUPER GREASE “A” to the wheel hub dust seals. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A” Install the wheel hub dust seals using the special tool.
  • Page 168 CHASSIS 6-29 REAR WHEEL Adjust the drive chain slack after installing the rear wheel axle. ( 2-16 and 2-17) Tighten the rear axle nut to the specified torque. Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft).. For E-03, 28, 33 110 N·m (11.0 kgf-m, 79.5 lb-ft)..

  • Page 169: Rear Suspension

    6-30 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 2 Cushion lever rod 3 Cushion lever 4 Swingarm pivot shaft 5 Swingarm 6 Chain guide 7 Chain buffer 8 Chain case A Rear shock absorber nut B Cushion rod mounting nut C Cushion lever mounting nut D Cushion lever mounting nut E Swingarm pivot nut...
  • Page 170 CHASSIS 6-31 ITEM N·m kgf-m lb-ft 40.0 40.0 10.0 72.5 10.0 72.5 10.0 72.5 55.5...

  • Page 171: Rear Shock Absorber Removal

    6-32 CHASSIS REAR SHOCK ABSORBER REMOVAL Remove the muffler. ( 3-5) Remove the battery. ( 7-34) Remove the clamps and CDI unit cover 1. Disconnect the brake light/taillight coupler 2, left and right turn signal light couplers 3, starter relay coupler 4, and starter relay lead wires 5.

  • Page 172: Rear Shock Absorber Inspection

    CHASSIS 6-33 Support the motorcycle with a jack or wooden block and re- move the rear shock absorber. REAR SHOCK ABSORBER INSPECTION Inspect the rear shock absorber for damage and oil leakage. If any damages are found, replace the rear shock absorber with a new one.

  • Page 173: Rear Shock Absorber Remounting

    6-34 CHASSIS REAR SHOCK ABSORBER REMOUNTING Remount the rear shock absorber in the reverse order of re- moval. Pay special attention to the following points: Turn the adjuster 1 to obtain the spring length A of 258.0 mm (10.16 in). Tighten the lock ring 2 to the specified torque.

  • Page 174: Rear Shock Absorber Damping Force Adjustment

    CHASSIS 6-35 REAR SHOCK ABSORBER DAMPING FORCE ADJUSTMENT After installing the rear suspension, adjust the compression damping force as follows. Fully turn the damping adjuster clockwise to the hard setting position, and then turn it out to the standard setting position. Standard setting position: Compression damping force adjuster A: 11 clicks out...

  • Page 175: Rear Swingarm And Cushion Lever Removal

    6-36 CHASSIS REAR SWINGARM AND CUSHION LEVER REMOVAL Remove the rear wheel. ( 6-26) Remove the rear shock absorber. ( 6-32 and 6-33) Remove the rear brake caliper. ( 6-53) Remove the drive chain guide 1 and chain case 2. Disconnect the brake hose from the brake hose guide.

  • Page 176: Inspection And Disassembly

    CHASSIS 6-37 Remove the cushion lever 1 and cushion lever rods 2. INSPECTION AND DISASSEMBLY SPACERS Remove the dust seals, washers and spacers from the swingarm and cushion lever. Inspect the spacers for any flaws or other damage. If any dam- ages are found, replace the spacers with new ones.
  • Page 177 6-38 CHASSIS SWINGARM Inspect the swingarm for damage. If any damages are found, replace the swingarm with a new one. CUSHION LEVER NEEDLE BEARINGS Insert the spacers into the needle bearings, move the spacer up and down and check for any play. If there is excessive play, re- place the bearings with new ones.

  • Page 178: Reassembly And Remounting

    Reassemble and remount the rear suspension in the reverse order of removal and disassembly. Pay special attention to the following points: SWINGARM NEEDLE BEARINGS Apply SUZUKI SUPER GREASE “A” to the spacers, dust seals and needle bearings. For USA 99000-25030: SUZUKI SUPER GREASE “A”...

  • Page 179: Final Inspection And Adjustment

    6-40 CHASSIS Tighten the swingarm pivot shaft nut to the specified torque. Pivot shaft nut: 77 N·m (7.7 kgf-m, 55.5 lb-ft) Tighten the cushion lever mounting nut to the specified torque. Cushion lever mounting nut: 100 N·m (10.0 kgf·m, 72.5 lb-ft) FINAL INSPECTION AND ADJUSTMENT After installing the rear wheel, adjust the following before riding.

  • Page 180: Front Brake

    CHASSIS 6-41 FRONT BRAKE CONSTRUCTION 1 Cap 2 Diaphragm 3 Master cylinder 4 Piston set 5 Brake hose 6 Caliper holder 7 Caliper 8 Pad set 9 Piston 0 Piston and dust seal A Master cylinder mounting bolt B Brake hose union bolt C Air bleeder valve D Brake caliper mounting bolt E Brake pad mounting pin...

  • Page 181: Brake Pad Replacement

    6-42 CHASSIS BRAKE PAD REPLACEMENT Remove the brake pad mounting pin. Remove the brake pads. Do not operate the brake lever during or after brake pad removal. Replace the brake pads as a set, otherwise braking performance will be adversely affected. Install the new brake pads.

  • Page 182: Brake Fluid Replacement

    CHASSIS 6-43 BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handle- bar straight. Remove the master cylinder reservoir cap and diaphragm. Remove as much old brake fluid as possible. Fill the reservoir with new brake fluid. Specification and classification: DOT 4 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle.

  • Page 183: Brake Caliper Inspection

    6-44 CHASSIS Remove the brake pads. ( 6-42) Remove the brake caliper holder. Remove the spring. Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using com- pressed air. Do not use extremely high pressure to remove the brake caliper pistons, otherwise damage to the pistons will result.

  • Page 184: Brake Caliper Reassembly And Remounting

    Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly. PISTON SEALS Install the piston seals 1 and dust seals 2 as shown. BRAKE CALIPER HOLDER Apply SUZUKI SILICON GREASE to the brake caliper holder. 99000-25100: SUZUKI SILICONE GREASE...

  • Page 185: Brake Disc Inspection

    6-46 CHASSIS Tighten the brake pad mounting pin 1, brake caliper mount- ing bolts 2, and brake hose union bolt 3 to the specified torque. Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) Brake caliper mounting bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft) Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) NOTE:...

  • Page 186: Master Cylinder Removal And Disassembly

    CHASSIS 6-47 MASTER CYLINDER REMOVAL AND DISASSEMBLY Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid. Remove the brake hose union bolt and disconnect the brake hose. Immediately wipe off any brake fluid contacting any part of the motorcycle.

  • Page 187: Master Cylinder Inspection

    6-48 CHASSIS Remove the piston assembly. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one. PISTON AND RUBBER PARTS Inspect the piston surface, primary/secondary cup, and dust boot for any scratches, wear or damage.
  • Page 188 CHASSIS 6-49 When remounting the master cylinder on the handlebar, align the master cylinder holder’s mating surface 1 with the punch mark 2 on the handlebar, and then tighten the upper clamp bolt first. Master cylinder clamp bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) A Master cylinder B Master cylinder upper clamp bolt C Handlebar...

  • Page 189: Rear Brake

    6-50 CHASSIS REAR BRAKE CONSTRUCTION 1 Cap 2 Diaphragm 3 Master cylinder 4 Piston set 5 Brake hose 6 Reservoir cover 7 Caliper 8 Caliper holder 9 Piston and dust seal 0 Piston A Pad set A Master cylinder mounting bolt B Brake hose union bolt C Rear brake rod locknut D Plug...

  • Page 190: Brake Pad Replacement

    CHASSIS 6-51 BRAKE PAD REPLACEMENT Remove the brake pad mounting pin. Remove the brake pads. Do not operate the brake pedal during or after brake pad removal. Replace the brake pads as a set, otherwise braking performance will be adversely affected. Install the new brake pads.

  • Page 191: Brake Fluid Replacement

    6-52 CHASSIS BRAKE FLUID REPLACEMENT Remove the reservoir cover 1 and reservoir tank mounting bolt 2. Remove the reservoir cap and diaphragm. Replace the brake fluid. ( 6-43) Specification and classification: DOT 4 Bleed air from the brake system. 2-19 and 2-20)

  • Page 192: Brake Caliper Removal And Disassembly

    CHASSIS 6-53 BRAKE CALIPER REMOVAL AND DISASSEMBLY Remove the rear wheel. ( 6-26) Disconnect the brake hose from the brake caliper by remov- ing the brake hose union bolt and allow the brake fluid to drain into a suitable receptacle. Remove the brake caliper.

  • Page 193: Brake Caliper Inspection

    Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly. PISTON SEAL Install the piston seal 1 and dust seal 2 as shown. BRAKE CALIPER HOLDER Apply SUZUKI SILICON GREASE to the brake caliper holder. 99000-25100: SUZUKI SILICONE GREASE...

  • Page 194: Brake Disc Inspection

    CHASSIS 6-55 Tighten the brake hose union bolt to the specified torque. Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) NOTE: Before remounting the rear wheel, push the brake caliper pis- tons all the way into the caliper. Bleed air from the system after remounting the rear wheel.

  • Page 195: Master Cylinder Inspection

    6-56 CHASSIS Loosen the locknut 1 and remove the master cylinder as- sembly. Remove the circlip 2 and reservoir assembly 3. Pull the dust boot 4 out and remove the circlip 5. Remove the push rod 6 and piston assembly 7. MASTER CYLINDER INSPECTION MASTER CYLINDER ..........

  • Page 196: Master Cylinder Reassembly And Remounting

    CHASSIS 6-57 MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse or- der of removal and disassembly. Pay special attention to the fol- lowing points: Wash the master cylinder components with new brake fluid before reassembly. Do not wipe the brake fluid off after washing the com- ponents.
  • Page 198 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING..................7- 2 CONNECTORS ....................7- 2 COUPLERS ....................... 7- 2 CLAMPS ......................7- 2 FUSE ........................7- 2 SEMICONDUCTOR EQUIPPED PARTS ............7- 2 BATTERY ......................7- 3 CONNECTING THE BATTERY................7- 3 WIRING PROCEDURE ..................

  • Page 199: Cautions In Servicing

    ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS When disconnecting a connector, be sure to hold the termi- nals; do not pull the lead wires. When connecting a connector, push it in so it is firmly attached. Inspect the connector for corrosion, contamination and any breakage in the cover.

  • Page 200: Battery

    ELECTRICAL SYSTEM BATTERY The battery has been pre-filled with electrolyte so there is no need to add fluid at any time. The MF battery used in this motorcycle does not require main- tenance (e.g., electrolyte level inspection, distilled water re- plenishment).

  • Page 201: Using The Multi Circuit Tester

    ELECTRICAL SYSTEM USING THE MULTI CIRCUIT TESTER Properly use the multi circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. If the voltage and current values are not known, begin mea- suring in the highest range. When measuring the resistance, make sure that no voltage is applied.

  • Page 202: Location Of Electrical Components

    ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 CDI unit 2 Starter relay 3 Engine coolant temperature thermoswitch 4 Horn 5 Ignition switch 6 Speedometer 7 Front brake light switch 8 Right handlebar switch 9 Rear brake light switch...
  • Page 203 ELECTRICAL SYSTEM 0 Left handlebar switch A Clutch lever position switch B Cooling fan thermoswitch C Cooling fan motor D Ignition coil E Battery F Fuse box G Side stand switch H Regulator/rectifier I Generator J Starter motor K Neutral switch L Throttle position sensor M Turn signal/side stand relay N Piston valve control solenoid...

  • Page 204: Charging System

    ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION The charging system consists of a generator, regulator/rectifier, and battery. The AC current, which is gener- ated by the generator, is converted by the regulator/rectifier into DC current. The regulator/rectifier is one unit with two functions. The regulator prevents overcharging of the battery by grounding the excessive AC current.

  • Page 205: Troubleshooting

    ELECTRICAL SYSTEM TROUBLESHOOTING Battery runs down quickly. Check accessories which use excessive Accessories • Remove accessories amounts of electricity. are installed No accessories Check the battery for current leak- Current leaks • Short circuit of the wire age. 7-9) harness •...

  • Page 206: Inspection

    ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAKAGE Turn the ignition switch to the “OFF” position. Remove the battery cover. ( 6-2) Disconnect the - battery lead wire. Measure the current between the - battery terminal and the - battery lead wire using the multi circuit tester. If the reading ex- ceeds the specified value, leakage is evident.
  • Page 207 7-10 ELECTRICAL SYSTEM STATOR COIL RESISTANCE Remove the left frame cover. ( 6-2) Disconnect the stator coil lead wire coupler. Measure the resistance between the three lead wires using the multi circuit tester. If the resistance is not within the specified value, replace the stator coil with a new one.
  • Page 208 ELECTRICAL SYSTEM 7-11 REGULATOR/RECTIFIER Remove the left frame cover. ( 6-2) Disconnect the regulator/rectifier couplers. Measure the voltage between the terminals using the multi cir- cuit tester, as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.

  • Page 209: Starter System

    7-12 ELECTRICAL SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components: the starter motor, starter relay, side stand switch, neutral switch, turn signal/side stand relay, clutch lever position switch, starter button, engine stop switch, ignition switch, and battery. Pressing the starter button energizes the starter relay, causing the contact points to close, thus, completing the circuit from the starter motor to the battery.

  • Page 210: Starter Motor Removal And Disassembly

    ELECTRICAL SYSTEM 7-13 Measure the starter relay voltage at the starter relay connectors (between Y/B No voltage • Faulty ignition switch and B/W ) when the starter button is • Faulty engine stop switch pushed. • Faulty starter button • Faulty clutch lever position switch •...

  • Page 211: Starter Motor Inspection

    7-14 ELECTRICAL SYSTEM Disassemble the starter motor, as shown. ITEM N·m kgf-m lb-ft STARTER MOTOR INSPECTION CARBON BRUSHES Inspect the carbon brushes for abnormal wear, cracks, or smooth- ness in the brush holder. If any damages are found, replace the brush assembly with a new one.

  • Page 212: Starter Motor Reassembly And Remounting

    Pay special attention to the follow- ing points: Replace the removed O-rings with new ones to pre- vent oil leakage and moisture. Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. For USA 99000-25030: SUZUKI SUPER GREASE “A” For the other countries 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 213: Starter Relay Inspection

    7-16 ELECTRICAL SYSTEM STARTER RELAY INSPECTION Remove the right frame cover. ( 6-2) Disconnect the starter motor lead wire, battery lead wire, and starter relay coupler at the starter relay. Remove the starter relay. Apply 12 V to the terminals and check for continuity between the positive and negative terminals using the multi circuit tester.

  • Page 214: Side Stand/Ignition Interlock System Parts Inspection

    ELECTRICAL SYSTEM 7-17 SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. NEUTRAL INDICATOR LIGHT SWITCH The neutral indicator light switch coupler is located under the seat.
  • Page 215 7-18 ELECTRICAL SYSTEM TURN SIGNAL/SIDE STAND RELAY AND DIODE The turn signal/side stand relay, which is located behind the headlight bracket, is composed of the turn signal relay/side stand relay and diode. Remove the headlight assembly. ( 7-29) Remove the turn signal/side stand relay. Side stand relay First, check the insulation between the D and E terminals us- ing the multi circuit tester.

  • Page 216: Ignition System

    ELECTRICAL SYSTEM 7-19 IGNITION SYSTEM DESCRIPTION In the capacitor discharged ignition system, the electrical energy generated by the generator charges the capacitor. This energy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil.
  • Page 217 7-20 ELECTRICAL SYSTEM Measure the ignition coil primary peak voltage. 7-21) Inspect the spark plug. NOTE: The ignition coil peak voltage Correct 2-9 and 2-10) inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Correct Incorrect Correct...

  • Page 218: Inspection

    ELECTRICAL SYSTEM 7-21 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Remove the fuel tank. ( 4-2) Remove the spark plug cap and spark plug. Connect a new spark plug to the spark plug cap and ground it to the cylinder head. NOTE: Make sure that the spark plug cap and spark plug are connected properly.
  • Page 219 7-22 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE Remove the fuel tank. ( 4-2) Disconnect the ignition coil lead wire, and then remove the ignition coil. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi circuit tester. If the resistance in both the primary and secondary windings is close to the speci- fied values, the windings are in sound condition.
  • Page 220 ELECTRICAL SYSTEM 7-23 PICKUP COIL AND SIGNAL COIL RESISTANCE Remove the seat. ( 6-2) Remove the CDI unit cover 1 and disconnect the generator coupler 2. Measure the resistance between the lead wires using the multi circuit tester. If the resistance is not within the specified value, the pickup coil and signal coil must be replaced.

  • Page 221: Speedometer

    7-24 ELECTRICAL SYSTEM SPEEDOMETER 1 Indicator light assembly 2 Speedometer assembly 3 Speedometer cable REMOVAL Remove the headlight assembly. ( 7-29) Disconnect the speedometer cable 1, speedometer coupler 2, and indicator lights coupler 3. Remove the speedometer assembly.

  • Page 222: Parts Names

    ELECTRICAL SYSTEM 7-25 PARTS NAMES 1 Turn signal indicator light 2 Neutral indicator light TIME CLOCK 3 High beam indicator light km/h 4 Engine coolant temperature TRIP TRIP indicator light TOTAL 5 Tripmeter A 6 Speedometer TIME/ – TRIP TIME TRIP TRIP 7 Clock/stopwatch/timer...
  • Page 223 7-26 ELECTRICAL SYSTEM With each press of the MODE TIME button, the display changes between the clock, the stopwatch and the timer as shown below. Clock Stopwatch Timer TRIP TIME TIME TIME TIME CLOCK CLOCK CLOCK MODE Hold down the SELECT button for three seconds to change the display as shown below.
  • Page 224 ELECTRICAL SYSTEM 7-27 ODOMETER Displays the total distance travelled TRIP TIME TOTAL MODE TRIPMETER Displays the distance travelled since the tripmeter was last reset. NOTE: The tripmeters A and B can be used independently. TRIP TIME TRIP TRIP MODE Switching between addition and subtraction modes S u b t r a c t i o n No sign indicates mode...
  • Page 225 7-28 ELECTRICAL SYSTEM STOPWATCH This 24-hour stopwatch displays the minutes, seconds and 1/100 seconds up to one hour. After one hour, the hours, min- utes and seconds are displayed. TRIP TIME TIME MODE TIME/ TIME/ TRIP TRIP TRIP TRIP Hold down the button for three TIME TIME Start...

  • Page 226: Lamps

    ELECTRICAL SYSTEM 7-29 LAMPS HEADLIGHT Headlight bulb : 12 V 60/55 W Position light : 12 V 4 W (Except for E-03, 28, 33) BULB REPLACEMENT Remove the headlight cover 1 and headlight bracket mount- ing bolt 2. Remove the position light coupler 3. (For E-02, 19, 54) Remove the turn signal/side stand relay 4.

  • Page 227: Front And Rear Turn Signal Light

    7-30 ELECTRICAL SYSTEM Remove the rubber cap. Remove the bulb. Install the new bulb in the reverse order of removal. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy wa- ter to prevent premature bulb failure.

  • Page 228: Brake Light/Taillight

    ELECTRICAL SYSTEM 7-31 BRAKE LIGHT/TAILLIGHT Brake light/taillight: 12 V 21/5 W BRAKE LIGHT/TAILLIGHT BULB REPLACEMENT Remove the brake light/taillight lens. Remove the brake light/taillight bulb. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy wa- ter to prevent premature bulb failure.

  • Page 229: Relays

    7-32 ELECTRICAL SYSTEM RELAYS STARTER RELAY The starter relay is located behind the right frame cover. 7-16) TURN SIGNAL/SIDE STAND RELAY The turn signal/side stand relay, which is located behind the headlight bracket, is composed of the turn signal relay, and the side stand relay and diode.

  • Page 230: Switches

    ELECTRICAL SYSTEM 7-33 SWITCHES Measure each switch for continuity using a multi circuit tester. If any abnormality is found, replace the re- spective switch assemblies with a new one. 09900-25008: Multi circuit tester set IGNITION SWITCH STARTER BUTTON Color Color Position Position •...

  • Page 231: Battery

    7-34 ELECTRICAL SYSTEM BATTERY REMOVAL Remove the battery cover. ( 6-2) Remove the battery holder. Remove the battery. NOTE: Disconnect the - battery lead wire, first. SPECIFICATIONS Type designation GT7B-4 Capacity 12 V, 23.4 kC (6.5 Ah)/10 HR SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one.

  • Page 232: Recharging Operation

    ELECTRICAL SYSTEM 7-35 RECHARGING OPERATION Charging period Stop charging Measure the battery voltage using the multi circuit tester or digital volt meter. If the voltage reading is less than the 12.6 V (DC), recharge the battery with a MF battery charger. When recharging the battery, remove the battery from the motorcycle.
  • Page 234 SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING ..................8- 2 ENGINE ......................8- 2 CARBURETOR .................... 8- 5 CHASSIS ...................... 8- 6 BRAKES ....................... 8- 7 ELECTRICAL ....................8- 8 BATTERY ...................... 8- 9 WIRING DIAGRAM ................... 8-10 FOR E-02, 19, 54 ..................8-10 FOR E-03, 28, 33 ..................

  • Page 235: Troubleshooting

    SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Worn cylinder. Replace. 2. Worn piston ring. Replace. 3. Worn valve guide or improper valve seating. Repair or replace. 4.
  • Page 236 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine is noisy. Excessive valve chatter 1. Excessive tappet clearance. Adjust. 2. Weak or broken valve spring. Replace. 3. Worn camshaft. Replace. 4. Worn or burnt camshaft journal. Replace. Noise seems to come from the piston 1.
  • Page 237 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Transmission jumps 1. Worn gear. Replace. out of gear. 2. Worn or distorted gearshift fork. Replace. 3. Weakened gearshift stopper spring. Replace. 4. Worn gearshift pawl. Replace. Engine idles poorly. 1. Tappet clearance out of adjustment. Adjust.

  • Page 238: Carburetor

    SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats. 1. Carbon buildup on piston crown. Clean. 2. Insufficient amount of engine oil. Check level and add. 3. Defective oil pump. Replace. 4. Clogged oil circuit. Clean. 5. Float chamber fuel level too low. Adjust float height.

  • Page 239: Chassis

    SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Steering is heavy. 1. Overtightened steering stem nut. Adjust. 2. Broken bearing in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Low tire pressure. Regulate. Handlebar wobbles. 1. Loss of balance between right and left front forks. Adjust or replace.

  • Page 240: Brakes

    SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Brake power insuffi- 1. Leakage of brake fluid. Repair or replace. cient. 2. Worn brake pad. Replace. 3. Oil on brake pad surface. Clean brake disc and brake pads. 4. Worn brake disc. Replace.

  • Page 241: Electrical

    SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil. Replace. sparking. 2. Defective spark plug. Replace. 3. Defective generator. Replace. 4. Defective CDI unit. Replace. Spark plug is wet or 1. Excessively rich air/fuel mixture. Adjust carburetor.

  • Page 242: Battery

    SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy Sulfation or spots on 1. Cracked battery case. Replace. surfaces cell 2. Battery has been left in a run-down condition for a long Replace. plates. time. Battery runs down 1. Incorrect charging method. Check generator, regulator/ quickly.

  • Page 243: Wiring Diagram

    8-10 SERVICING INFORMATION WIRING DIAGRAM FOR E-02, 19, 54...
  • Page 244 SERVICING INFORMATION 8-11 FOR E-03, 28, 33...

  • Page 245: Wire Routing

    8-12 SERVICING INFORMATION WIRE HARNESS, CABLE, AND HOSE ROUTING WIRE ROUTING Clamp Wire harness Engine coolant temperature - battery lead wire thermoswitch Clamp + battery terminal - battery terminal Wire harness Fuse - battery lead wire Side stand switch Neutral switch VIEW B + battery lead wire Clamp...
  • Page 246 SERVICING INFORMATION 8-13 Clamp Clamp Handlebar switch (L) Clamp Handlebar switch (R) Cooling fan Clutch switch Wire harness thermoswitch Clutch cable VIEW A Clamp Wire harness Engine stop switch Clamp Throttle cable Generator Regulator/rectifier Side stand switch Neutral switch - battery lead wire Throttle position sensor Piston valve control solenoid (For E-02, 19, 54) Generator...
  • Page 247 8-14 SERVICING INFORMATION Starter motor lead wire VIEW E VIEW A Generator lead wire - battery lead wire Neutral switch lead wire Neutral switch lead wire VIEW C VIEW D VIEW B...
  • Page 248 Front brake hose Cable guide Clutch cable Throttle cable Overflow hose Clutch cable VIEW A Clutch cable VIEW C VIEW B Inlet hose Clamp Front brake hose Throttle cable Cable guide Clutch cable Radiator hose Throttle cable Breather hose Overflow hose Clutch cable 1 Clutch cable must be passed outside overflow hose and inlet hose.
  • Page 249 8-16 SERVICING INFORMATION Speedometer assembly Headlight bracket Clamp Speedometer cable Speedometer gearbox stopper VIEW A Speedometer cable Front fork stopper...

  • Page 250: Oil Return Tank Hose Routing

    SERVICING INFORMATION 8-17 OIL RETURN TANK HOSE ROUTING 1 Face the tip of clip to the front 2 Face the tip of clip to the bottom...
  • Page 251 1 Face the tip of clip to the top 2 Face the tip of clip to the bottom 3 Face the tip of clip to the right 4 Face the head of screw to the front 5 Face the head of screw to the back 6 Face the head of screw to the right 7 Do not touch the pipe to the frame...

  • Page 252: Front Brake Hose Routing

    SERVICING INFORMATION 8-19 FRONT BRAKE HOSE ROUTING 1 After touching the brake hose union to the stopper, tighten the union bolt to the specified torque. 2 Set brake hose in front of throttle cables. 3 Set brake hose in front of clutch cable. REAR BRAKE HOSE ROUTING 1 After touching the brake hose union to the stopper, tighten the union bolt to the specified torque.

  • Page 253: Pair (Air Supply) System Hose Routing

    8-20 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING PAIR (air supply) vacuum hose PAIR (air supply) pipe Clamp Clamp Clamp PAIR (air supply) cleaner PAIR (air supply) valve assembly Upper side Lower side VIEW A...

  • Page 254: Special Tools

    SERVICING INFORMATION 8-21 SPECIAL TOOLS 09900-00401 09900-00410 Hexagon wrench Hexagon wrench 09900-06104 09900-06105 09900-06108 Snap ring pliers Snap ring pliers Snap ring pliers 09900-20202 09900-20204 09900-09004 09900-20101 09900-20103 Micrometer Micrometer Impact driver set Vernier calipers Vernier calipers (25 – 50 mm) (75 –...
  • Page 255 8-22 SERVICING INFORMATION 09917-47010 09913-70210 09915-64510 Vacuum pump 09913-50121 Bearing installer 09915-63310 Compression gauge Oil seal remover Adapter gauge set 09915-74510 09915-70610 Oil pressure gauge 09916-10911 09916-14510 09916-14910 Adapter Valve lapper set Valve lifter Attachment 09916-20610 09916-21110 09916-22420 09916-22430 09916-24311 Seat cutter Valve seat Valve seat cutter...
  • Page 256 SERVICING INFORMATION 8-23 09924-84510 09924-84521 09921-74510 09923-73210 09923-74510 Bearing installer Bearing installer Bearing remover Bearing remover Bearing remover 09925-18010 09930-73170 09930-73180 Steering bearing 09930-30102 09930-31921 Starter torque Starter torque installer Sliding hammer Rotor remover set limiter holder limiter socket 09940-14911 09940-14960 09940-52841 Steering stem nut...

  • Page 257: Tightening Torque

    8-24 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt 10.0 Spark plug Cylinder head bolt 33.5 Cylinder head side bolt 10.0 Cylinder nut Camshaft journal holder bolt Balancer shaft nut 36.0 Primary drive gear nut 11.0 79.5 Generator rotor nut...

  • Page 258: Chassis

    SERVICING INFORMATION 8-25 CHASSIS ITEM N·m kgf-m lb-ft Handlebar clamp bolt 16.5 Front fork upper clamp bolt 21.5 Front fork lower clamp bolt 23.0 Steering stem head nut 65.0 Front fork cap bolt 16.5 Front fork damper rod bolt 58.0 Front brake master cylinder mounting bolt Rear brake master cylinder mounting bolt Brake hose union bolt (front &...

  • Page 259: Tightening Torque Chart

    8-26 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A A A A A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft...

  • Page 260: Service Data

    SERVICING INFORMATION 8-27 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diameter — (1.42) — (1.14) Tappet clearance (when cold) 0.10 – 0.20 — (0.0039 – 0.0079) 0.20 – 0.30 — (0.0079 – 0.0118) Valve-guide-to-valve-stem clearance 0.010 –...
  • Page 261 8-28 SERVICING INFORMATION CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.490 – 36.540 36.190 (1.4366 – 1.4386) (1.4248) 35.790 – 35.840 35.490 (1.4091 – 1.4110) (1.3972) Camshaft journal oil clearance 0.019 – 0.053 0.150 IN. & EX. (0.0007 –...
  • Page 262 SERVICING INFORMATION 8-29 ITEM STANDARD LIMIT Piston ring groove width 0.78 – 0.80 (0.0307 – 0.0315) — 1.30 – 1.32 (0.0512 – 0.0520) 0.81 – 0.83 — (0.0319 – 0.0327) 2.01 – 2.03 — (0.0791 – 0.0799) Piston ring thickness 0.71 –...
  • Page 263 8-30 SERVICING INFORMATION CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch drive plate thickness 2.92 – 3.08 2.62 (No. 1 & No. 2) (0.115 – 0.121) (0.103) Clutch drive plate claw width 13.7 –...
  • Page 264 SERVICING INFORMATION 8-31 CARBURETOR SPECIFICATION ITEM E-02, 19, 54 E-03, 28 E-33 ← ← Carburetor type MIKUNI BSR36 ← ← Bore size 36 mm (1.4 in) I.D. No. 29FA 29FB 29FC ← ← Idle r/min 1500 ± 100 r/min ← ←...
  • Page 265 8-32 SERVICING INFORMATION BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Brake lever play 0.1 – 0.3 — (0.004 – 0.012) Rear brake pedal height — (0.2) Brake disc thickness 3.5 ± 0.2 Front (0.138 ± 0.008) (0.118) 4.5 ± 0.2 Rear (0.177 ±...
  • Page 266 (22.57) (22.1) Front fork oil level (without spring) — (6.5) Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil — Front fork oil capacity (each leg) 709 ml — (24.0 US oz, 25.0 lmp oz) Front fork spring adjuster 3rd groove from top —...
  • Page 267 8-34 SERVICING INFORMATION ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: CR8E Type DENSO: U24 ESR-N 0.7 – 0.8 (0.028 – 0.031) Over 8 (0.3) at 1 atm. Spark performance 0.1 – 1.0 Ω Ignition coil resistance Primary Terminal –...
  • Page 268 SERVICING INFORMATION 8-35 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump R + M octane ( ) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corro-...
  • Page 269 8-36 SERVICING INFORMATION...
  • Page 270 DR-Z400SK1 (’01-MODEL) DR-Z400SK1 (’01-MODEL) This chapter describes specifications, service data and servicing procedures which differ from those of the DR-Z400SY (’00-MODEL). NOTE: * Any differences between DR-Z400SY (’00-MODEL) and DR-Z400SK1 (’01-MODEL) in specifica- tions and service data are cleary indicated with the asterisk mark (*). * Please refer to the chapter 1 throngh 8 for details which are not given in this chapter.
  • Page 271 DR-Z400SK1 (’01-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 310 mm (90.9 in) Overall width ............875 mm (34.4 in) Overall height ............1 240 mm (48.8 in) Wheelbase ............. 1 485 mm (58.5 in) Ground clearance ..........300 mm (11.8 in) Seat height .............
  • Page 272 DR-Z400SK1 (’01-MODEL) CHASSIS Front suspension ........... Telescopic, coil spring, oil damped, spring preload fully adjustable, compression damping force 11-way adjust- able Rear suspension ............ Link type, coil spring, oil damped, spring preload fully adjustable, compression damping force 26-way adjust- able Front fork stroke .............
  • Page 273 DR-Z400SK1 (’01-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.42) ——— (1.14) Tappet clearance (when cold) 0.10 – 0.20 ——— (0.0039 – 0.0079) 0.20 – 0.30 ——— (0.0079 – 0.0118) Valve guide to valve stem 0.010 –...
  • Page 274 DR-Z400SK1 (’01-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.490 – 36.540 36.190 (1.4366 – 1.4386) (1.4248) 35.790 – 35.840 35.490 (1.4091 – 1.4110) (1.3972) Camshaft journal oil clearance 0.019 – 0.053 0.150 IN. & EX. (0.0007 –...
  • Page 275 DR-Z400SK1 (’01-MODEL) ITEM STANDARD LIMIT Piston ring groove width 0.78 – 0.80 ——— (0.0307 – 0.0315) 1.30 – 1.32 ——— (0.0512 – 0.0520) 0.81 – 0.83 ——— (0.0319 – 0.0327) 2.01 – 2.03 ——— (0.0791 – 0.0799) Piston ring thickness 0.71 –...
  • Page 276 DR-Z400SK1 (’01-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 – 15 ——— (0.4 – 0.6) Drive plate thickness 2.92 – 3.08 2.62 (No. 1 & No. 2) (0.115 – 0.121) (0.103) Drive plate claw width 13.7 – 13.8 13.2 (No.
  • Page 277 DR-Z400SK1 (’01-MODEL) SPECIFICATION ITEM E-02, 19, 54 E-03, 28 E-33 ← Main jet (M.J.) #142.5 ← Jet needle (J.N.) 5DH36-2nd 5DH37 ← Needle jet (N.J.) P-0M ← Pilot jet (P.J.) #22.5 ← Pilot air jet (P.A.J.) #165 #135 ← Pilot screw (P.S.) 3 turns back PRE-SET...
  • Page 278 573.2 (22.57) (22.1) Front fork oil level ——— (without spring) (6.5) Front fork oil type SUZUKI FORK OIL SS-05 ——— or an equivalent fork oil Front fork oil capacity 709 ml ——— (each leg) (24.0/25.0 US/Imp oz) Front fork spring adjuster 3rd groove from top ———...
  • Page 279 9-10 DR-Z400SK1 (’01-MODEL) ITEM STANDARD/SPECIFICATION LIMIT Rear shock absorber gas 900 kPa ——— pressure (9.0 kgf/cm , 128 psi) Rear shock absorber spring 258.0 ——— pre-set length (10.2) Rear shock absorber damping Compression 11th clicks turn back ——— force adjuster Rear wheel travel ———...
  • Page 280 DR-Z400SK1 (’01-MODEL) 9-11 WATTAGE Unit: W SPECIFICATION ITEM E-02, 19, 54 E-03, 28, 33 ← Headlight ← Position light ← Brake light/Taillight 21/5 ← Turn signal light ← Speedometer light ← Neutral indicator light ← Turn signal indicator light ← High beam indicator light ←...
  • Page 281 9-12 DR-Z400SK1 (’01-MODEL) BATTERY SPECIFICATIONS Type designation YT7B-BS Capacity 12V, 21.6 kC (6 Ah)/10HR INITIAL CHARGING Filling electrolyte • Remove the aluminum tape 1 sealing the battery electrolyte filler holes. • Remove the caps 2. NOTE: * After filling the electrolyte completely, use the removed cap 2 as the sealed caps of battery-filler holes.
  • Page 282 DR-Z400SK1 (’01-MODEL) 9-13 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery.
  • Page 283 9-14 DR-Z400SK1 (’01-MODEL) RECHARGING OPERATION • Using the multi circuit tester, check the battery voltage. If the voltage reading is less than the 12.0 V (DC), recharge the battery with a battery charger. * When recharging the battery, remove the battery from the motorcycle.
  • Page 284 DR-Z400SK2 (’02-MODEL) 10-1 DR-Z400SK2 (’02-MODEL) This chapter describes service data, service specifications and servicing procedures which differ from those of the DR-Z400SK1 (’01-model). NOTE: * Any differences between DR-Z400SK1 (’01-model) and DR-Z400SK2 (’02-model) in specifications and service data are indicated with an asterisk mark (*). * Please refer to the chapter 1 through 9 for details which are not given in this chapter.

  • Page 285: Specifications

    10-2 DR-Z400SK2 (’02-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 310 mm (90.9 in) Overall width ............875 mm (34.4 in) Overall height ............1 240 mm (48.8 in) Wheelbase ............. 1 485 mm (58.5 in) Ground clearance ..........300 mm (11.8 in) Seat height .............
  • Page 286 DR-Z400SK2 (’02-MODEL) 10-3 CHASSIS Front suspension ........... Telescopic, coil spring, oil damped Rear suspension ............ Link type, coil spring, oil damped Front fork stroke ............. 288 mm (11.3 in) Rear wheel travel ........... 295 mm (11.6 in) Caster ..............27° 10’ Trail .................

  • Page 287: Service Data

    10-4 DR-Z400SK2 (’02-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.42) ——— (1.14) Tappet clearance (when cold) 0.10 – 0.20 ——— (0.0039 – 0.0079) 0.20 – 0.30 ——— (0.0079 – 0.0118) Valve guide to valve stem 0.010 –...
  • Page 288 DR-Z400SK2 (’02-MODEL) 10-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.490 – 36.540 36.190 (1.4366 – 1.4386) (1.4248) 35.790 – 35.840 35.490 (1.4091 – 1.4110) (1.3972) Camshaft journal oil clearance 0.019 – 0.053 0.150 IN. & EX. (0.0007 –...
  • Page 289 10-6 DR-Z400SK2 (’02-MODEL) ITEM STANDARD LIMIT Piston ring groove width 0.78 – 0.80 ——— (0.0307 – 0.0315) 1.30 – 1.32 ——— (0.0512 – 0.0520) 0.81 – 0.83 ——— (0.0319 – 0.0327) 2.01 – 2.03 ——— (0.0791 – 0.0799) Piston ring thickness 0.71 –...
  • Page 290 DR-Z400SK2 (’02-MODEL) 10-7 CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 – 15 ——— (0.4 – 0.6) Drive plate thickness 2.92 – 3.08 2.62 (No. 1 & No. 2) (0.115 – 0.121) (0.103) Drive plate claw width 13.7 –...
  • Page 291 10-8 DR-Z400SK2 (’02-MODEL) SPECIFICATION ITEM E-02, 19, 54 E-03, 28 E-33 ← Main jet (M.J.) #142.5 ← Jet needle (J.N.) 5DH36-2nd 5DH37 ← Needle jet (N.J.) P-0M ← Pilot jet (P.J.) #22.5 ← Pilot air jet (P.A.J.) #165 #135 ← Pilot screw (P.S.) 3 turns back...
  • Page 292 (22.57) (22.1) Front fork oil level *129 ——— (without spring) (5.07) Front fork oil type SUZUKI FORK OIL SS-05 ——— or an equivalent fork oil Front fork oil capacity *710 ml ——— (each leg) (24.0/25.0 US/Imp oz) Front fork damping force adjuster...
  • Page 293 10-10 DR-Z400SK2 (’02-MODEL) ITEM STANDARD/SPECIFICATION LIMIT Rear shock absorber gas 900 kPa ——— pressure (9.0 kgf/cm , 128 psi) Rear shock absorber spring 258.0 ——— pre-set length (10.2) Rear shock absorber damping *Rebound 13th clicks turn back ——— force adjuster *High speed 1¼...
  • Page 294 DR-Z400SK2 (’02-MODEL) 10-11 WATTAGE Unit: W SPECIFICATION ITEM E-02, 19, 54 E-03, 28, 33 ← Headlight ← Position light ← Brake light/Taillight 21/5 ← Turn signal light ← Speedometer light ← Neutral indicator light ← Turn signal indicator light ← High beam indicator light ←...

  • Page 295: Front Fork

    10-12 DR-Z400SK2 (’02-MODEL) FRONT FORK CONSTRUCTION 1 Air valve 2 O-ring 3 Push rod 4 Needle 5 Spring 6 Washer 7 Spring 8 Damper rod ring 9 Damper rod 0 Dust seal A Stopper ring B Oil seal C Oil seal retainer D Inner tube antifriction metal E Inner tube F Outer tube antifriction metal...

  • Page 296: Removal And Disassembly

    DR-Z400SK2 (’02-MODEL) 10-13 REMOVAL AND DISASSEMBLY • Remove the front wheel. ("6-5) • Remove the front brake caliper. ("6-47) • Remove the headlight assembly. ("7-23) • Remove the brake hose clamp 1 and odometer cable guide 2. • Remove the front fork after loosening the front fork upper clamp bolts 3 and lower clamp bolts 4.
  • Page 297 10-14 DR-Z400SK2 (’02-MODEL) • Invert the fork and stroke it several times to drain out the fork oil. NOTE: Hold the fork inverted for a few minutes to drain the oil. • Remove the push rod 1, needle 2, and return spring 3. •...

  • Page 298: Inspection

    DR-Z400SK2 (’02-MODEL) 10-15 • Remove the damper 1. • Slowly pull out the inner tube. NOTE: Be careful not to damage the inner tube. • Remove the oil seal 2, oil seal retainer 3, outer tube antifriction metal 4 inner tube antifriction metal 5, and oil lock piece 6.

  • Page 299: Reassembly And Remounting

    • Apply front fork oil to the lip of oil seal lightly before installing & 99000-99001-SS5: SUZUKI FORK OIL SS-05 • Install the outer tube antifriction metal 1, oil seal retainer 2, and oil seal 3 onto the inner tube.
  • Page 300 DR-Z400SK2 (’02-MODEL) 10-17 • Install the oil lock piece 1 into the inne tube. • Insert the inner tube into the outer tube and install the oil seal using the special tool. $ 09940-52861: Front fork oil seal installer set •...
  • Page 301 • Place the front fork vertically without the spring. • Pour the specified fork oil into the inner tube up to the top of the damper rod. & 99000-99001-SS5: SUZUKI FORK OIL SS-05 % Standard fork oil capacity (each leg): 710 ml (24.0 US oz, 25.0 Imp oz) •...
  • Page 302 DR-Z400SK2 (’02-MODEL) 10-19 PISTON ROD LOCKNUT AND FORK SPRING • Install the piston rod locknut to the lowest position. • Install the fork spring. NOTE: The end of the fork spring with the smaller inside diameter should be at the bottom of the front fork. •...
  • Page 303 10-20 DR-Z400SK2 (’02-MODEL) • Install the boot holder and the boot to the front fork. • Align the right boot holder’s mating surface A with the center of axle clamp on the right fork. • Align the left boot holder’s B with the center of axle clamp on the left fork.

  • Page 304: Suspension Setting

    DR-Z400SK2 (’02-MODEL) 10-21 • Fix the boot to the boot holder with a new clamp. NOTE: Make sure that the boot is not twisted. • Install the brake hose clamp and odometer cable guide. (Front brake hose routing: "8-19, Cable routing :"8-16) •...

  • Page 305: Rear Shock Absorber Damping Force Adjustment

    10-22 DR-Z400SK2 (’02-MODEL) REAR SHOCK ABSORBER DAMPING FORCE ADJUSTMENT After installing the rear suspension, adjust the rebound and com- pression damping force as follows. NOTE: Do not turn the adjust screws more than the given position or the adjuster may be damaged. REBOUND DAMPING FORCE ADJUSTMENT Fully turn the damping force adjuster 1 clockwise.

  • Page 306: Headlight

    DR-Z400SK2 (’02-MODEL) 10-23 HEADLIGHT Headlight bulb : 12 V 60/55 W Position light : 12 V 4 W (Except for E-03, 28, 33) BULB REPLACEMENT • Remove the headlight over 1. • Remove the headlight bracket mounting bolts.
  • Page 307 10-24 DR-Z400SK2 (’02-MODEL) • Remove the turn signal/side stand relay 2. • Disconnect the position light coupler (For E-02, 19, 54) and the headlight coupler. • Remove the headlight assembly. • Remove the rubber cap. • Remove the bulb. • Install the new bulb in the reverse order of removal. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
  • Page 309 Prepared by Overseas Service Department 3rd Ed. October, 2001 1st Ed. March, 2000 Part No. 99500-43032-01E Printed in Japan...
  • Page 310 Printed in Japan Y K1 K2...

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