Suzuki DR-Z400S 2001 Motorcycle Manuals

Manuals and User Guides for Suzuki DR-Z400S 2001 Motorcycle. We have 1 Suzuki DR-Z400S 2001 Motorcycle manual available for free PDF download: Service Manual

Suzuki DR-Z400S 2001 Service Manual

Suzuki DR-Z400S 2001 Service Manual (310 pages)

Brand: Suzuki | Category: Motorcycle | Size: 13 MB

Table of Contents

General Information 1

6
- Table of Contents
  6
- Warning/Caution/Note
  7
- General Precautions
  7
- Suzuki Dr-Z400Sy (2000-Model)
  9
- Serial Number Location
  9
- Fuel, Oil, and Engine Coolant Recommendations
  9
- Fuel
  9
- Engine Oil
  10
- Brake Fluid
  10
- Front Fork Oil
  10
- Engine Coolant
  10
- Break-In Procedures
  11
- Information Labels
  12
- Specifications
  13
- Country and Area Codes
  15
Periodic Maintenance

16
- Periodic Maintenance Chart
  17
- Periodic Maintenance Schedule
  17
- Air Cleaner
  18
- Maintenance and Tune-Up Procedures
  18
- Exhaust Pipe Nut and Bolt and Muffler Nut and Bolts
  19
- Tappet Clearance
  20
- Spark Plug
  24
- Fuel Line
  25
- Spark Arrester (for E-03, 28, 33)
  25
- Engine Oil and Oil Filter
  26
- Engine Oil Hoses
  27
- Throttle Cable Play (Carburetor)
  28
- Engine Coolant
  29
- Engine Idle Speed (Carburetor)
  29
- Radiator Hoses
  30
- Clutch
  31
- Drive Chain
  31
- Brakes
  33
- Brake Fluid
  34
- Brake Hoses
  36
- Tires
  36
- Spoke Nipples
  37
- Evaporative Emission Control System (for E-33)
  38
- Front Fork
  38
- Pair (Air Supply) System (for E-02, 19, 54)
  38
- Rear Suspension
  38
- Steering
  38
- Chassis Nuts and Bolts
  39
- General Lubrication
  41
- Compression Pressure Check
  42
- Compression Test Procedure
  42
- Oil Pressure Check
  43
- Oil Pressure Test Procedure
  43
Engine

44
- Engine Removal
  46
- Engine Removal and Remounting
  46
- Engine Remounting
  51
- Engine Disassembly
  54
- Cylinder Head
  65
- Engine Components Inspection and Service
  65
- Camshaft/Automatic Decompression Assembly
  74
- Cylinder
  76
- Piston and Piston Ring
  76
- Conrod
  78
- Crankshaft
  79
- Starter Clutch
  79
- Oil Pump
  80
- Starter Torque Limiter
  80
- Clutch
  81
- Gearshift Fork and Gear
  82
- Transmission
  83
- Bearings
  86
- Oil Seals
  89
- Oil Check Valve
  90
- Crankshaft
  91
- Engine Reassembly
  91
- Gearshift Cam and Fork
  92
- Crankcase
  93
- Starter Clutch and Generator Rotor
  94
- Balancer Shaft
  95
- Gearshift Cam Driven Gear
  96
- Primary Drive Gear
  96
- Gearshift Shaft
  97
- Oil Pump
  97
- Cam Chain
  98
- Clutch
  98
- Clutch Cover
  100
- Generator Rotor Cover
  100
- Neutral Switch
  100
- Right Crankcase Cover
  100
- Piston Ring
  101
- Starter Drive Gear Cover
  101
- Piston and Cylinder
  102
- Cylinder Head
  103
- Camshaft/Automatic Decompression Assembly
  104
- Cylinder Head Cover
  106
- Cam Chain Tension Adjuster
  107
- Inspection
  108
- Removal
  108
- Remounting
  109
Fuel and Lubrication System

110
- Fuel Tank
  111
- Remounting
  111
- Removal
  111
- Fuel Strainer
  112
- Fuel Valve
  112
- Remounting
  112
- Removal and Inspection
  112
- Carburetor
  113
- Construction
  113
- I.D. No. Location
  114
- Specifications
  114
- Disassembly
  115
- Removal
  115
- Cleaning
  119
- Inspection
  119
- Reassembly
  121
- Remounting
  121
- Engine Lubrication System Chart
  122
- Lubrication System
  122
Cooling System

124
- Cooling System
  125
- Description
  125
- Construction
  126
- Engine Coolant
  127
- Inspection
  128
- Radiator and Cooling Fan
  128
- Removal
  129
- Remounting
  130
- Cooling Fan Thermoswitch
  131
- Removal
  131
- Inspection
  132
- Installation
  132
- Engine Coolant Temperature Thermoswitch
  133
- Inspection
  133
- Installation
  133
- Removal
  133
- Inspection
  134
- Removal
  134
- Thermostat
  134
- Installation
  135
- Removal and Disassembly
  136
- Water Pump
  136
- Inspection
  137
- Reassembly
  137
Chassis

140
- Exterior Parts
  141
- Remounting
  141
- Removal
  141
- Construction
  142
- Front Wheel
  142
- Removal and Disassembly
  144
- Inspection
  145
- Reassembly and Remounting
  147
- Construction
  149
- Front Fork
  149
- Removal and Disassembly
  150
- Inspection
  152
- Reassembly and Remounting
  153
- Suspension Setting
  155
- Construction
  156
- Steering
  156
- Removal and Disassembly
  157
- Inspection
  160
- Reassembly and Remounting
  160
- Construction
  163
- Rear Wheel
  163
- Removal and Disassembly
  165
- Inspection
  166
- Reassembly and Remounting
  166
- Construction
  169
- Rear Suspension
  169
- Rear Shock Absorber Removal
  171
- Rear Shock Absorber Disposal
  172
- Rear Shock Absorber Inspection
  172
- Rear Shock Absorber Remounting
  173
- Rear Shock Absorber Damping Force Adjustment
  174
- Rear Swingarm and Cushion Lever Removal
  175
- Inspection and Disassembly
  176
- Reassembly and Remounting
  178
- Final Inspection and Adjustment
  179
- Construction
  180
- Front Brake
  180
- Brake Pad Replacement
  181
- Brake Caliper Removal and Disassembly
  182
- Brake Fluid Replacement
  182
- Brake Caliper Inspection
  183
- Brake Caliper Reassembly and Remounting
  184
- Brake Disc Inspection
  185
- Master Cylinder Removal and Disassembly
  186
- Master Cylinder Inspection
  187
- Master Cylinder Reassembly and Remounting
  187
- Construction
  189
- Rear Brake
  189
- Brake Pad Replacement
  190
- Brake Fluid Replacement
  191
- Brake Caliper Removal and Disassembly
  192
- Brake Caliper Inspection
  193
- Brake Caliper Reassembly and Remounting
  193
- Brake Disc Inspection
  194
- Master Cylinder Removal and Disassembly
  194
- Master Cylinder Inspection
  195
- Master Cylinder Reassembly and Remounting
  196
Electrical System

198
- Cautions in Servicing
  199
- Clamps
  199
- Connectors
  199
- Couplers
  199
- Fuse
  199
- Semiconductor Equipped Parts
  199
- Battery
  200
- Connecting the Battery
  200
- Wiring Procedure
  200
- Using the Multi Circuit Tester
  201
- Location of Electrical Components
  202
- Charging System
  204
- Description
  204
- Troubleshooting
  205
- Inspection
  206
- Description
  209
- Starter System
  209
- Troubleshooting
  209
- Starter Motor Removal and Disassembly
  210
- Starter Motor Inspection
  211
- Starter Motor Reassembly and Remounting
  212
- Starter Relay Inspection
  213
- Side Stand/Ignition Interlock System Parts Inspection
  214
- Description
  216
- Ignition System
  216
- Troubleshooting
  216
- Inspection
  218
- Removal
  221
- Speedometer
  221
- Operating Procedure
  222
- Parts Names
  222
- Headlight
  226
- Lamps
  226
- Front and Rear Turn Signal Light
  227
- Brake Light/Taillight
  228
- Relays
  229
- Starter Relay
  229
- Turn Signal/Side Stand Relay
  229
- Switches
  230
- Battery
  231
- Removal
  231
- Servicing
  231
- Specifications
  231
- Recharging Operation
  232
Servicing Information

234
- Engine
  235
- Troubleshooting
  235
- Carburetor
  238
- Chassis
  239
- Brakes
  240
- Electrical
  241
- Battery
  242
- Wiring Diagram
  243
- Wire Routing
  245
- Oil Return Tank Hose Routing
  250
- Front Brake Hose Routing
  252
- Rear Brake Hose Routing
  252
- Pair (Air Supply) System Hose Routing
  253
- Special Tools
  254
- Engine
  257
- Tightening Torque
  257
- Chassis
  258
- Tightening Torque Chart
  259
- Service Data
  260
- Specifications
  285
- Service Data
  287
- Construction
  295
- Front Fork
  295
- Removal and Disassembly
  296
- Inspection
  298
- Reassembly and Remounting
  299
- Suspension Setting
  304
- Rear Shock Absorber Damping Force Adjustment
  305
- Headlight
  306

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