Suzuki Drz 400 2000 Manuel utilisateur

SUZUKI

────────────

DR-Z400

────────────

M.Y 2000-2007

SERVICE MANUAL

http://www.motorcycle.in.th

HOW TO USE THIS MANUAL

TO LOCATE WHAT

YOU

ARE LOOKING

FOR:

The text of this manual is divided into sections.

The section titles are listed in the GROUP INDEX.

3. HOlding the manual as snown at the right will allow

you to find the first page of the section easily.

4. The contents are listed

the first page of each sec-

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

COMPONENT

PARTS AND

WORK

TO BE DONE

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

service information

tightening torque, lubricating points, and locking agent points).

Example: Front wheel

ometer gearb

Bea

rin

g (R)

® From

wneel

® Spacer

(§)

Bearing (L)

Dust seal

ljr

aKe Qi

® Sp

acer

her

t ax

nut

ake d

iSc

unt

ing

ITEM N·m kgf-m

® 42 4.2

® 10 1.0

Ib-ft

30.5

7.0

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SYMBOLS

Listed

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

ing.The meaning

each symbol

also included

the table.

SYMBOL

DEFINI

SYMBO

L DEFINITI

Torque control required.

Apply THREAD LOCK "1342

Data beside

indicates specified torque. 99000-32050

Indicates service data.

Apply or use brake fluid.

Apply oil. Use engine

oil

unless other-

Measure

voltage range.

wise specified.

lir Apply molybdenum

oil

solution.

Measure

resistance range.

(mixture

engine oil

and

SUZUKI

MOLY

PASTE

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.

Measure

diode test rang

99000-25100

Apply SUZUKI

MOLY

PASTE

Measure

continuity test range.

99000-25140

1207

Apply SUZUKI BOND "1207B".

oLi

Use special tool.

99104-31140

(ror

USA)

99000-31140 (For the other countries)

-mm

Apply SUZUKI BOND "1215

-em

Use engine coolant.

99000-31110 (Except USA) 99000-99032-11X (Except USA)

Apply THREAD LOCK SUPER "1303

Use fork oil.

99000-32030 99000-99001-SS5

Apply THREAD LOCK SUPER "1322

99000-32110 (Except USA)

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GENERAL INFORMATION

1-1

GENERAL INFORMATION

,----------------------

CONTENTS

----------------------~

WARNING/CAUTION/NOTE.............................................................................

GENERAL PRECAUTIONS .............................................................................

SUZUKI DR-Z400SY (2000-MODEL) .............................................................. 1- 4

SERIAL NUMBER LOCATION ........................................................................

FUEL, OIL,

AND

ENGINE

COOLANT

RECOMMENDATIONS....................... 1- 4

FUEL.............................................................................................................

ENGINE OIL ................................................................................................. 1- 5

BRAKE

FLUID .............................................................................................1- 5

FRONT FORK OIL ....................................................................................... 1- 5

ENGINE COOLANT..................................................................................... 1- 5

BREAK-IN PROCEDURES ..............................................................................

INFORMATION

LABELS

..................................................................................

SPECIFICATIONS ............................................................................................

COUNTRY

AND

AREA CODES ...................................................................... 1-10

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1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully.

emphasize special informHtinn,

thp.

~ymbol

and the words WARNING, CAUTION and NOTE have special meanings.

Pay

special attention

the mes-

sages highlighted

these signal words.

A WARNING

Indicates a potential hazard

that

could

result

in death

injury.

CAUT

}ON]

Indicates a potential hazard

that

could

result

motorcycle

damage.

NOTE

Indicates special information

make maintenance easier or instructions clearer.

rlease

note, however, that the warnings and

cautiun~

(;untaineu

this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of servicing, of the motorcycle.

addition

the WARN-

and CAUTIONS stated, you must use good judgement and basic mechanical safety principles.

you

are unsure about how to perform a particular service operation, ask a more experienced mechanic for

advice.

GENERAL

PRECAUTIONS

A WARNING

Proper

service

and repair

procedures

are

important

for

the

safety

the

service

mechanic

and the safety and

reliability

the

motorcycle

When

two

persons

work

together

, pay

attention

the safety

each

other

When it

necessary

run

the

engine

indoors

, make

sure

that

exhaust

gas

forced out-

doors

When

working

with

toxic

flammable

materials, make sure

that

the

area

you

work

in Is well

ventilated and

that

you

all

the

manufacturer

instructions

Never

use

gasoline

as a cleaning

solvent

avoid

getting

burned,

not

touch

the

engine,

engine

oil

, radiator,

and

exhaust

system

until

they have

cooled

After

servicing

the fuel,

oil

engine

coolant

, exhaust

brake

systems

, check all

the

lines

and

fittings

the

system

for

leaks.

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GENERAL INFORMATION 1-3

CAUTION

• If

parts

replacement

necessary,replace the

parts

with

SUZUKI Genuine Parts

their

equiva-

lent.

• When

removing

parts

that

are

be reused, keep

them

arranged in an

orderly

manner

that

they may be reinstalled in

the

proper

order.

• Be sure

use special

tools

when

instructed

• Make sure

that

all

parts

used

reassembly are clean.

Lubricate

them

when

specified

.. Use the

specified

lubricants

bonds

sealants.

• When

removing

the

battery,

disconnect

the

e battery lead wire

first

then

the

EEl

battery lead

wire.

• When

reconnecting

the

battery,

connect

the

EEl

battery lead

wire

first

then

the

battery

lead

wire. Finally,

cover

the

EEl

battery

terminal

with

the terminal

cover

• When

performing

service

electrical

parts

disconnect

the e battery lead

wire

unless

the

service

procedure

requires

the

battery

power

• When

tightening

cylinder

head

and

crankcase

nuts

and

bolts

tighten

the

larger sizes first.

Always

tighten

the

nuts

and

bolts

from

the

inside

working

out

diagonally

and

the

specified

torque

• Whenever

you

remove

oil

seals,

gaskets

packing

O-rings

self-locking

nuts

locking

wash

ers.

cotter

pins.

circlips.

and

other

specified

parts, be

sure

replace

them

with

new

ones

Also

, before

installing

these new

parts

, be

sure

remove any left

over

material

from

the

mating surfaces.

Never reuse a circlip.When

installing

a new

circlip

,take care

not

expand

the

end

gap

larger

than

required

slip

the

circlip

over

the

shaft.

After

installing

circlip

, always

ensure

completely

seated in

its

groove

and

securely

fitted.

Use a

torque

wrench

tighten

fasteners

the

specified

torque. Wipe

off

grease and

oil

thread

smeared

with

them.

•

After

reassembling,

check

parts

for

tightness

and

proper

operation.

•

protect the

environment

not

unlawfUlly

dispose

used

motor

oil

engine

coolant

, all

other

fluids

, batteries, and

tires

• To

protect

the

earth's natural resources,

properly

dispose

used

motorcycles

and

parts.

http://www.motorcycle.in.th

~UZUKI

DR-Z400

·00.·

___

• E

,..,

.....

SERIAL NUMBER LOCATION

Tho

......

"'V!N""""""!E

._1

......

~_OZ

.....

aLEE

...

_.,.,.

Tho

onoo'It

.,..

""'''''_,,,..

....

.....

,,"'

,_""

""'+"

'.1 " "II

.....

, .oo...., "'".,.'"

"",

•

rUCL,

AND

CNGINE

COOLANT

AECOMMI!NDATIONS

FUEL (FOR USA AND CANADA)

.....

, " -

...

Ch"

hid

• SUlIJI(C

...

••

*"'_0

___

""",,

._',0

•

1,Iae<ll"

CCM

......

r.mIf:!PoW>a't....,IIU¥E

....

" - !

• I,Iae

<II'

' '...

""'

...

or,

''"'"_

.............

CCM

"'" _

.....

'<f'.

........ n .....·

......

.............

...

_.,,'CO_

_.-.

'''.

•....

_.......,.

.....

""*"'

....

""00

....

"""'"

1',

"EI

.................

)<'0

" '

..........

.....

...

•

......

_ goAa'

...

""""'..,..oy....:

.............

~."

...

CZ!oa

won,.,.,.

tuo!

,,'

'.,-..

..........

Il10

.....

)<'0_.,

.....

..-

...

..,

....

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GENERAL INFORMATION 1-5

FUEL (FOR THE OTHER COUNTRIES)

Use unleaded gasoline Ihat

graded

octane or higher

the Research Method.

ENGINE OIL

MULnGRADE

, ., .,

, ,

lOW

·c

4 0

SUZUKI recommends the use of SUZUKI PERFORMANCE 4

MOTOR OIL to ensure longer service life

your motorcycle.

Use only oils which are rated SF or

under the

API

service

classification. The recommended viscosity

SAE 10W-40.

SAE 10W-40 motor

oil

not available, select

alternative ac-

cording

the following chart. TEMP

_4 14

104

BRAKE FLUID

Specification

and

classification:

DOT 4

A WARNING

This

motorcycle

uses

glycol-based

brake fluid. Do

not

use

mix

other

types

brake

fluid

such as silicone-based

and

petroleum-based

fluids

for

refilling

the

system

otherwise

seri-

ous

damage

will

result

tne

Orake

system

* Do

not

use any brake

fluid

taken

from

old, used,

unsealed

containers

* Do

not

reuse brake

fluid

left

over

from

the

last

servicing

which

has been stored

for

long

period

time.

FRONT FORK OIL

Use SUZUKI FORK OIL SS-05 or

equivalent fork oil.

ENGINE COOLANT

Since antifreeze also has corrosion- and rust-inhibiting properties, always use engine coolant containing

antifreeze, even

the atmospheric temperature does not go below the freezing point.

Use

antifreeze designed for aluminum radiators. SUZUKI recommends the use

SUZUKI COOLANT

antifreeze.

this is not available, use

equivalent antifreeze for aluminum radiators.

Mix

only distilled water with the antifreeze, Other types of water can corrode and clog the aluminum radiator.

Mix

distilled

water

and

antifreeze at a

ratio

50:50 -40:60.

For more information, refer

page 5-4

the Cooling System section.

rA CAUTION .

The percentage

antifreeze in the

coolant

should

be between

If the percentage

antifreeze Is aOove

Oelow

tnls

range the

coolant's

frost

protection

and rust-inniOiting capa-

bilities

will

be reduced. Always keep the antifreeze

content

above 50% even

the

atmospheric

temperature

does

not

below

the freezing point.

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1-6 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.

is still necessary

allow the moving parts

"BREAK-IN" before subjecting the engine

maximum stresses. The future periormance and reliability of the engine depends

the care and restraint

exercised during its early life. Refer to the following break-in engine speed recommendations.

• Keep to these brake-in throttle positions during the break-in period.

Break-in

throttle

position

Initial 800

(500 miles): Less

than

112

thrott

1 600 km (1 000 m

): Less

than

3/4

throttle

• Upon reaching

odometer reading

1 600

000 miles) you can subject the motorcycle to full

throttle operation for short periods of time.

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GENERAL INFORMATION 1-7

INFORMATION LABELS

LAO[L

[,LAT[

NAM[

APPLIED SPECIFICATION

E-02 E-03 E-19 E

-2B

E-33

E-S

Engine starting label 0 0 0 0 0 0

® Noise label -0 --0 -

@ Inlormat

n la

bel

0 0 -

@ IC

Canada label - - - 0 - -

el caution label 0 - - ---

® Manual no

ce label 0 0 -

(J)

Tir

e a

ess

e lab

0 0 0 0 0 0

® Warning

fet

y label 0 0 0 0 0 0

plate 0 -0 - - 0

@ Safe

ate -0 --0 -

@ Compliance label - - - 0 --

'" '"

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