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DR-Z400SM
USE THIS MANUAL WITH:
DR-Z400S SERVICE MANUAL (99500-43034-01E)
9 9 5 0 1 - 4 3 1 1 0 - 0 1 E

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Table of Contents

   Summary of Contents for Suzuki 2005 DR-Z400SMK5

  • Page 1 DR-Z400SM USE THIS MANUAL WITH: DR-Z400S SERVICE MANUAL (99500-43034-01E) 9 9 5 0 1 - 4 3 1 1 0 - 0 1 E...
  • Page 2: Table Of Contents

    EFFECTIVE FRAME NO. E-02 U.K. JS1B8111100100001 – E-19 E.U. JS1B8111200100001 – E-03 U.S.A. (Except for california) JS1SK44A 52100001 – E-28 Canada JS1SK44A 52100001 – E-33 California (U.S.A.) JS1SK44A 52100001 – UE-19 E.U. JS1B8211100100001 – © COPYRIGHT SUZUKI MOTOR CORPORATION 2004...
  • Page 3: Specifications

    2 DR-Z400SMK5 (’05-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................* 2 225 mm (87.6 in) Overall width ..................* 870 mm (34.3 in) Overall height ..................* 1 185 mm (46.7 in) Wheelbase ..................* 1 460 mm (57.5 in) Ground clearance................* 260 mm (10.2 in) Seat height.
  • Page 4: Service Data

    DR-Z400SMK5 (’05-MODEL) 3 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 5 4 DR-Z400SMK5 (’05-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 6: Oil Pump

    DR-Z400SMK5 (’05-MODEL) 5 ITEM STANDARD LIMIT Piston ring thickness 0.71 – 0.76 — (0.0280 – 0.0299) 1.08 – 1.10 — (0.0425 – 0.0433) 0.77 – 0.79 — (0.0303 – 0.0311) Piston pin bore 20.002 – 20.008 20.030 (0.7875 – 0.7877) (0.7886) Piston pin O.D.
  • Page 7 6 DR-Z400SMK5 (’05-MODEL) TRANSMISSTION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.960 (74/25) — Final reduction ratio * 2.733 (41/15) — Gear ratios 2.285 (32/14) — 1.733 (26/15) — 1.375 (22/16) — 1.090 (24/22) —...
  • Page 8 DR-Z400SMK5 (’05-MODEL) 7 THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT ITEM STANDARD/SPECIFICATION LIMIT Thermostat valve opening temper- Approx. 75 °C (167 °F) — ature Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) — Engine coolant temp. switch oper- OFF→ON Approx.
  • Page 9 Front fork inner tube O.D. Front fork spring free length * 450 (17.7) (17.3) Front fork oil type SUZUKI FORK OIL SS-05 — or an equivalent fork oli Front fork oil capacity (each leg) * OUTER 350 ml (11.830/12.324 US/Imp oz) —...
  • Page 10 DR-Z400SMK5 (’05-MODEL) 9 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug DENSO: U24ESR-N Type NGK: CR8E 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 mm (0.3 in) at 1 atm. Ignition coil resistance Terminal – 0.1 – 1.0 Ω Primary Ground Plug cap –...
  • Page 11 10 DR-Z400SMK5 (’05-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane ( R/2 + M/2 ) 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 12: Front Fork

    DR-Z400SMK5 (’05-MODEL) 11 FRONT FORK CONSTRUCTION kgf-m lb-ft kgf-m lb-ft ITEM N·m ITEM N·m 65.0 21.5 16.5 25.5 32.5 16.5 13.0 50.5...
  • Page 13 12 DR-Z400SMK5 (’05-MODEL) REMOVAL • Place a block under the chassis tubes. • Remove the fork protectors, brake hose guide and brake hose clamp. • Remove the front brake caliper. • Remove the front wheel. • Remove the handlebars. • Loosen the front fork cap bolt 1 – 2 turns to facilitate later dis- assembly.
  • Page 14 DR-Z400SMK5 (’05-MODEL) 13 DISASSEMBLY • Set rebound and compression damper settings to the mini- mum settings (softest) before disassembling. Record the set- ting before turning the adjuster. • Thoroughly clean the fork before disassembly.  Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.
  • Page 15 14 DR-Z400SMK5 (’05-MODEL) • Clamp the axle holder 2 with a vise. Protect the axle holder surface using a rag. • Loosen the center bolt 3 completely with a 21 mm socket wrench.  Clamping the axle holder too tight can damage it which will affect riding stability.
  • Page 16 DR-Z400SMK5 (’05-MODEL) 15 • With the outer tube compressed by hands, remove the special tool.  Removing the locknut 4 and pushing the inner rod thread into the damper rod will damage the inner rod oil seal. Do not remove the locknut 4 from the inner rod. •...
  • Page 17 16 DR-Z400SMK5 (’05-MODEL) INNER TUBE • Separate the inner tube out of the outer tube. • Remove the slide bushing from the inner tube. • Remove the following parts from the inner tube. Guide bushing 1 Seal retainer 2 Oil seal 3 Stopper ring 4 Dust seal 5 •...
  • Page 18 DR-Z400SMK5 (’05-MODEL) 17 • Remove the compression damper unit from the sub-tank. NOTE: Slowly compress the inner rod until it stops so that the compres- sion damper unit can be removed easily. • Drain the fork oil from the damper rod assembly by moving the inner rod several strokes.
  • Page 19 18 DR-Z400SMK5 (’05-MODEL) INNER TUBE AND OUTER TUBE • Inspect the inner tube for scratches. If it has scratches, replace it with a new one. • Inspect the outer tube for dent. If it is dented all the way to the inner side, replace it with a new one.
  • Page 20 DR-Z400SMK5 (’05-MODEL) 19 SLIDE BUSHING AND GUIDE BUSHING Inspect the “teflon coating metals” (slide bushing and guide bushing) for wear or damage. If they are worn or damaged, replace them with new ones. Inspect the metal particles on the “teflon coating metals”. If they are not clean, clean them with a nylon brush and fork oil.
  • Page 21 • Clean each threaded part before installing. • With the damper rod in fully extended position, pour the spec- ified amount of fork oil.  Fork oil quantity (Inside the damper rod): 182 ml (6.152/6.408 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05...
  • Page 22 DR-Z400SMK5 (’05-MODEL) 21 • Apply fork oil to the O-rings and bushing on the compression damper unit. • With the damper rod held immovable in fully extended posi- tion, gently install the compression damper unit to the sub-tank. • Clamp the bottom (flat part) of the sub-tank with a vise. ...
  • Page 23 22 DR-Z400SMK5 (’05-MODEL) • Force out the remaining oil (discharged oil) using compressed air completely. • With the damper rod in horizontal position, move the inner rod by hand to inspect it if operating smoothly. If the inner rod is not extend, repeat the “COMPRESSION DAMPER UNIT”...
  • Page 24 DR-Z400SMK5 (’05-MODEL) 23 • Clamp the axle holder with a vise. Protect the axle holder with a rag when using a vise.  Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight. •...
  • Page 25  09941-53630: Front fork top cap wrench • Pour the specified amount of fork oil into the outer tube.  Oil quantity: 350 ml (11.83/12.32 US/lmp oz)  99000-99001-SS5: SUZUKI FORK OIL SS-05 • Raise the outer tube and temporarily tighten the fork cap bolt (sub-tank).
  • Page 26 DR-Z400SMK5 (’05-MODEL) 25 INSTALLATION • Install the front fork with the line T aligned with the upper sur- face of the upper bracket. • Check that the air valve A is positioned at the front. • Tighten the fork lower clamp bolts to the specified torque. ...
  • Page 27: Drive Chain Adjustment

    26 DR-Z400SMK5 (’05-MODEL) COMPRESSION DAMPING FORCE ADJUST- MENT Soft Hard • Turn the adjuster screw clockwise until it stops (full hard posi- tion). • Turn the adjuster screw counterclockwise. 13th position is the standard position.  Compression damping force adjuster Standard setting: 13 clicks turn back REBOUND DAMPING FORCE ADJUSTMENT •...
  • Page 28: Tightening Torque

    DR-Z400SMK5 (’05-MODEL) 27 TIGHTENING TORQUE CHASSIS ITEM N·m kgf-m lb-ft Handlebar clamp bolt 16.5 Front fork upper clamp bolt * 23 * 2.3 * 16.5 Front fork lower clamp bolt * 23 * 2.3 * 16.5 Steering stem head nut 65.0 Front fork cap bolt * 35...
  • Page 29: Front Axle

    28 DR-Z400SMK5 (’05-MODEL) FRONT AXLE 10 N·m (1.0 kgf-m, 7.0 lb-ft) 18 N·m 1.8 kgf-m 13.0 lb-ft 39 N·m 3.9 kgf-m 28 lb-ft 09941-34513: Bearing installer 09913-70210: Bearing installer set Clearance...
  • Page 30: Rear Axle

    DR-Z400SMK5 (’05-MODEL) 29 REAR AXLE 30 N·m (3.0 kgf-m, 21.5 lb-ft) 10 N·m (1.0 kgf-m, 7.0 lb-ft) For E-03, 28, 33 100 N·m (10.0 kgf-m, 72.5 lb-ft) The others 110 N·m (11.0 kgf-m, 79.5 lb-ft) Left Right Left Right Spacer Clearance 09941-34513: Bearing installer set...
  • Page 31: Front Brake Hose Routing

    30 DR-Z400SMK5 (’05-MODEL) FRONT BRAKE HOSE ROUTING...
  • Page 32: Rear Brake Hose Routing

    DR-Z400SMK5 (’05-MODEL) 31 REAR BRAKE HOSE ROUTING...
  • Page 33: Wiring Diagram

    32 DR-Z400SMK5 (’05-MODEL) WIRING DIAGRAM E-02, 19...
  • Page 34 DR-Z400SMK5 (’05-MODEL) 33 E-03, 28, 33...
  • Page 35 Prepared by December, 2004 Part No. 99501-43110-01E Printed in Japan...
  • Page 36 Printed in Japan...

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