User Manuals: Suzuki drz 400E Offroad Motorcycle

Manuals and User Guides for Suzuki drz 400E Offroad Motorcycle. We have 2 Suzuki drz 400E Offroad Motorcycle manuals available for free PDF download: Service Manual, Manual

Suzuki drz 400E Service Manual (334 pages)

Brand: Suzuki | Category: Motorcycle | Size: 14 MB

Group Index

2
- Table of Contents
  2
- General Information
  5
  - Warning/Caution/Note
    6
  - General Precautions
    6
  - Suzuki Dr-Z400Y/Dr-Z400Ey (2000-Model)
    8
  - Serial Number Location
    8
  - Fuel, Oil, and Engine Coolant Recommendations
    8
    
    Fuel
    8
    
    Engine Oil
    9
    
    Brake Fluid
    9
    
    Front Fork Oil
    9
    
    Rear Shock Absorber Oil
    9
    
    Engine Coolant
    9
  - Break-In Procedures
    10
  - Information Labels
    11
  - Specifications
    12
  - Country and Area Codes
    14
Periodic Maintenance

15
- Periodic Maintenance Schedule
  16
  - Periodic Maintenance Chart
    16
  - Engine
    16
- Maintenance and Tune-Up Procedures
  17
  - Air Cleaner
    17
  - Exhaust Pipe Nut and Bolt and Muffler Nut and Bolts
    18
  - Tappet Clearance
    19
  - Spark Plug
    23
  - Spark Arrester
    24
  - Fuel Line
    24
  - Decompression Lever (Dr-Z400)
    24
  - Engine Oil and Oil Filter
    25
  - Engine Oil Hoses
    26
  - Throttle Cable Play
    27
  - Engine Idle Speed
    28
  - Engine Coolant
    28
  - Radiator Hoses
    29
  - Clutch
    30
  - Drive Chain
    30
  - Brakes
    32
  - Brake Fluid
    33
  - Brake Hoses
    35
  - Tires
    35
  - Spoke Nipples
    36
  - Steering
    37
  - Front Fork
    37
  - Rear Suspension
    37
  - Chassis Nuts and Bolts
    38
  - General Lubrication
    40
- Compression Pressure Check (Dr-Z400E)
  41
  - Compression Test Procedure
    41
- Oil Pressure Check
  42
  - Oil Pressure Test Procedure
    42
Engine

43
- Engine Removal and Remounting
  45
  - Engine Removal
    45
  - Engine Remounting
    50
- Engine Disassembly
  53
- Engine Components Inspection and Service
  64
  - Cylinder Head
    64
  - Camshaft/Automatic Decompression Assembly
    73
  - Cylinder
    75
  - Piston and Piston Ring
    75
  - Conrod
    77
  - Crankshaft
    78
  - Starter Clutch (Dr-Z400E)
    78
  - Starter Torque Limiter (Dr-Z400E)
    79
  - Oil Pump
    79
  - Clutch
    79
  - Gearshift Fork and Gear
    80
  - Transmission
    81
  - Bearings
    84
  - Oil Seals
    87
- Engine Reassembly
  89
  - Crankshaft
    89
  - Gearshift Cam and Fork
    90
  - Crankcase
    91
  - Starter Clutch and Generator Rotor
    92
  - Balancer Shaft
    93
  - Primary Drive Gear
    94
  - Gearshift Cam Driven Gear
    94
  - Gearshift Shaft
    95
  - Oil Pump
    95
  - Kick Starter (Dr-Z400)
    96
  - Cam Chain
    97
  - Clutch
    97
  - Right Crankcase Cover
    99
  - Clutch Cover
    99
  - Generator Rotor Cover
    99
  - Starter Drive Gear Cover (Dr-Z400E)
    100
  - Piston Ring
    100
  - Piston and Cylinder
    101
  - Cylinder Head
    102
  - Camshaft/Automatic Decompression Assembly
    103
  - Cylinder Head Cover
    105
  - Cam Chain Tension Adjuster
    106
Fuel and Lubrication System

107
- Fuel Tank
  108
  - Removal
    108
  - Remounting
    108
- Fuel Valve
  109
  - Removal and Inspection
    109
  - Fuel Strainer
    109
  - Remounting
    109
- Carburetor
  110
  - Construction
    110
  - Specifications
    111
  - I.D. No. Location
    111
  - Slow System
    112
  - Coasting Enrichment System
    112
  - Main System
    113
  - Accelerator Pump System
    114
  - Starter System
    115
  - Float System
    115
  - Removal
    116
  - Disassembly
    116
  - Cleaning
    119
  - Inspection
    120
  - Reassembly
    120
  - Remounting
    121
- Lubrication System
  122
  - Engine Lubrication System Chart
    122
  - Oil Pan
    122
Cooling System

123
- Cooling System
  124
  - Description
    124
  - Construction
    125
- Engine Coolant
  126
- Radiator
  127
  - Inspection
    127
  - Removal
    128
  - Remounting
    128
  - Water Pump
    129
Chassis

132
- Exterior Parts
  133
  - Removal
    133
  - Remounting
    133
- Front Wheel
  134
  - Construction
    134
  - Removal and Disassembly
    136
  - Inspection
    137
  - Reassembly and Remounting
    139
- Front Fork
  141
  - Construction
    141
  - Removal and Disassembly
    142
  - Inspection
    144
  - Reassembly and Remounting
    145
  - Suspension Setting
    148
- Steering
  149
  - Construction
    149
  - Removal and Disassembly
    150
  - Inspection
    152
  - Reassembly and Remounting
    153
- Rear Wheel
  156
  - Construction
    156
  - Removal and Disassembly
    158
  - Inspection
    159
  - Reassembly and Remounting
    159
- Rear Suspension
  162
  - Construction
    162
  - Rear Shock Absorber Removal
    164
  - Rear Shock Absorber Inspection and Disassembly
    166
  - Rear Shock Absorber Disposal
    166
  - Oil Replacement Procedure
    167
  - Rear Shock Absorber Reassembly and Remounting
    169
  - Rear Shock Absorber Damping Force Adjustment
    170
  - Rear Swingarm and Cushion Lever Removal
    171
  - Inspection and Disassembly
    172
  - Reassembly and Remounting
    174
  - Final Inspection and Adjustment
    175
- Front Brake
  176
  - Construction
    176
  - Brake Pad Replacement
    177
  - Brake Fluid Replacement
    178
  - Brake Caliper Removal and Disassembly
    178
  - Brake Caliper Inspection
    179
  - Brake Caliper Reassembly and Remounting
    180
  - Brake Disc Inspection
    181
  - Master Cylinder Removal and Disassembly
    182
  - Master Cylinder Inspection
    183
  - Master Cylinder Reassembly and Remounting
    183
- Rear Brake
  185
  - Construction
    185
  - Brake Pad Replacement
    186
  - Brake Fluid Replacement
    187
  - Brake Caliper Removal and Disassembly
    188
  - Brake Caliper Inspection
    189
  - Brake Caliper Reassembly and Remounting
    189
  - Brake Disc Inspection
    190
  - Master Cylinder Removal and Disassembly
    191
  - Master Cylinder Inspection
    192
  - Master Cylinder Reassembly and Remounting
    192
Electrical System

194
- Cautions in Servicing
  195
  - Connectors
    195
  - Couplers
    195
  - Clamps
    195
  - Fuse (Dr-Z400E)
    195
  - Semiconductor Equipped Parts
    195
  - Battery (Dr-Z400E)
    196
  - Connecting the Battery (Dr-Z400E)
    196
  - Wiring Procedure
    196
  - Using the Multi Circuit Tester
    197
- Location of Electrical Components
  198
- Charging System (Dr-Z400E)
  200
  - Description
    200
  - Troubleshooting
    201
  - Inspection
    202
- Starter System (Dr-Z400E)
  205
  - Description
    205
  - Troubleshooting
    205
  - Starter Motor Removal and Disassembly
    206
  - Starter Motor Inspection
    207
  - Starter Motor Reassembly and Remounting
    208
  - Starter Relay Inspection
    209
- Ignition System (Dr-Z400)
  210
  - Description
    210
  - Troubleshooting
    210
  - Inspection
    212
- Ignition System (Dr-Z400E)
  215
  - Description
    215
  - Troubleshooting
    215
  - Inspection
    217
- Odometer
  219
  - Removal
    219
- Lamps
  220
  - Headlight
    220
  - Taillight
    221
- Switches
  222
- Battery (Dr-Z400E)
  223
  - Removal
    223
  - Specifications
    223
  - Servicing
    223
  - Recharging Operation
    224
Servicing Information

225
- Troubleshooting
  226
  - Engine
    226
  - Carburetor
    229
  - Chassis
    230
  - Brakes
    231
  - Electrical
    232
  - Battery (Dr-Z400E)
    233
- Wiring Diagram
  234
  - Dr-Z400
    234
  - Dr-Z400E
    235
- Wire Harness, Cable, and Hose Routing
  236
  - Wire Routing
    236
  - Cable Routing
    238
  - Fuel Hose and Fuel Tank Mounting
    239
  - Oil Return Tank Hose Routing
    240
  - Cooling System Hose Routing
    241
  - Front Brake Hose Routing
    242
  - Rear Brake Hose Routing
    242
- Special Tools
  243
- Tightening Torque
  246
  - Engine
    246
  - Chassis
    247
  - Tightening Torque Chart
    248
- Service Data
  249
Dr-Z400Ey (E-24 Model)

258
- Specifications
  259
- Service Data
  261
- Battery
  267
- Brake Light/Taillight
  267
- Fuse
  267
- Headlight
  267
- High Beam Indicator Light
  267
- Neutral Indicator Light
  267
- Speedometer Light
  267
- Turn Signal Indicator Light
  267
- Turn Signal Light
  267
- Side-Stand/Ignition Interlock System
  269
- Switches
  270
- Speedometer
  271
- Wiring Diagram
  274
- Wire, Cable and Hose Routing
  275
Dr-Z400/Ek1 ('01-Model)

280
- Specifications
  281
  - DR-Z400/E (for E-01, 03 and 28)
    281
  - DR-Z400E (for E-24)
    283
- Service Data
  285
  - DR-Z400/E (for E-01, 03 and 28)
    285
  - DR-Z400E (for E-24)
    293
- Battery (Dr-Z400E)
  301
- Initial Charging
  301
Dr-Z400/Ek2 ('02-Model)

304
- Specifications
  305
  - DR-Z400/E (E-01, 03 and 28)
    305
  - Dr-Z400E (E-24)
    306
  - Brake Disc
    306
- PERIODIC MAINTENANCE SCHEDULE (for E-24)
  309
- Service Data
  310
  - DR-Z400/E (E-01, 03 and 28)
    310
  - Dr-Z400E (E-24)
    313
- Rear Shock Absorber
  326
  - Oil Replacement Procedure
    326
  - Reassembly and Remounting
    328
  - Damping Force Adjustment
    329
- Wiring Diagram
  330
- Cooling System Hose Routing
  332

Suzuki drz 400E Manual (117 pages)

Brand: Suzuki | Category: Motorcycle | Size: 3 MB

Break-In (Running-In) Information for Your Motorcycle
2
Table of Contents
4
Consumer Information
6
Accessory Use and Motorcycle Loading
7
Accessory Installation Guidelines
7
Loading Limit
8
Loading Guidelines
8
Safe Riding Recommendation for Motorcycle Riders
9
Ride Defensively
10
Labels
10
Serial Number Location
11
Controls
12
Location of Parts
13
Key
16
Ignition Switch
16
"Off" Position
16
Steering Lock
17
Instrument Panel
18
Turn Signal Indicator Light
18
High Beam Indicator Light
18
Left Handlebar
29
Clutch Lever
29
Dimmer Switch
29
Turn Signal Light Switch
30
Horn Switch
30
Right Handlebar
30
Engine Stop Switch
30
Front Brake Lever
30
Throttle Grip
31
Brake Lever Play Adjustment
31
Fuel Tank Cap
32
Fuel Valve
33
Gearshift Lever
35
Rear Brake Pedal
35
Helmet Holder
36
Side Stand
36
Suspension Adjustment
37
Rear Suspension
39
Fuel, Engine Oil and Coolant Recommendations
42
Fuel Octane Rating
43
Oxygenated Fuel Recommendation
43
Engine Oil
44
Engine Coolant Solution
46
Break-In (Running-In) and Inspection before Riding
48
Maximum Engine Speed Recommendation
49
Observe Your First and most Critical Service
49
Inspection before Riding
50
Riding Tips
52
Engine Starting
53
Starting off
54
Using the Transmission
55
Riding on Hills
56
Stopping and Parking
57
Carrying a Passenger
58
Inspection and Maintenance
60
Maintenance Schedule
61
Maintenance Chart
63
Tools
64
Lubrication Points
64
Battery
65
Battery Removal
66
Air Cleaner
67
Spark Plug
70
Installation
73
Fuel Hose
73
Engine Oil
74
Engine Oil and Filter Change
75
Carburetor
78
Idle Speed Adjustment
78
Throttle Cable Adjustment
79
Clutch
80
Drive Chain
80
Drive Chain Cleaning and Oiling
81
Drive Chain Adjustment
82
Engine Coolant
83
Radiator Hose Inspection
84
Brakes
85
Brake Fluid
86
Brake Pad
87
Rear Brake Pedal Adjustment
88
Tires
89
Spoke Nipple Tightness
91
Side Stand/Ignition Interlock System
91
Spark Arrester
92
Front Wheel Removal
93
Rear Wheel Removal
95
Light Bulb Replacement
96
Headlight Beam Adjustment
98
Turn Signal Light
98
Brake Light/Taillight
99
Fuse
99
Troubleshooting
102
Fuel System Check
103
Ignition System Check
104
Engine Stalling
104
Storage Procedure and Motorcycle Cleaning
106
Storage Procedure
107
Procedure for Returning to Service
108
Corrosion Prevention
109
Motorcycle Cleaning
110
Plastic Parts
111
Inspection after Cleaning
112
Specifications
113
Dimensions and Curb Mass
113
Drive Train
113

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User Manuals: Suzuki drz 400E Offroad Motorcycle

Suzuki drz 400E Service Manual (334 pages)

Table of Contents

Group Index

Periodic Maintenance

Engine

Fuel and Lubrication System

Cooling System

Chassis

Electrical System

Servicing Information

Dr-Z400Ey (E-24 Model)

Dr-Z400/Ek1 ('01-Model)

Dr-Z400/Ek2 ('02-Model)

Suzuki drz 400E Manual (117 pages)

Table of Contents

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