Suzuki DR-Z400 2000-2007 Factory Workshop Manual

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Tipo: Motorcycle

Proveedor:

SKU: 51580

Etiquetas: 2000 2001 2002 2003 2004 2005 2006 2007 Consumer Electronics DR-Z400 Drake Electronics Motorcycle Suzuki Transceivers / Land mobile radio

Variantes de producto

Descripción

The Suzuki DR-Z400 is a versatile dual-sport motorcycle renowned for its robust engineering and reliability, produced from 2000 through 2007. This model embodies a strong legacy in off-road and dual-sport motorcycling, offering a balanced blend of on-road usability and off-road prowess. Its 398 cc liquid-cooled engine, coupled with a 5-speed transmission and responsive braking system, makes it a capable machine for diverse riding conditions, from daily commutes to adventurous trail riding. The DR-Z400 is celebrated for its durability and has earned industry recognition as a dependable and adaptable dual-sport choice. This factory workshop manual provides comprehensive coverage for the Suzuki DR-Z400, encompassing essential maintenance, detailed repair procedures, diagnostic information, troubleshooting guides, and technical specifications. It covers critical systems including the engine, fuel system, lubrication, cooling, chassis, suspension, brakes, and electrical systems. The manual is designed to assist DIY enthusiasts, home mechanics, and professional technicians in effectively maintaining and repairing the vehicle, offering factory-level insights and guidance to ensure optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DR-Z400

Model Years Covered:

2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Vehicle Type:

Dual-Sport Motorcycle

Codes

Engine Code Family:

DR-Z400

👋 Introduction

Market Position

Target Audience:

DIY enthusiasts, home mechanics, professional repair shops

Competitive Analysis

Value Proposition:

Provides factory-level information at a fraction of the cost of dealership service, empowering users to perform their own maintenance and repairs with confidence.

Key Features

Key Benefit 1:

Instant download for immediate access to crucial repair information.

Key Benefit 2:

Comprehensive coverage of all major vehicle systems ensures no aspect of maintenance or repair is overlooked.

📋 Manual Details

Coverage Areas

Primary Coverage:

Maintenance, Repair, Diagnostics, Troubleshooting, Specifications

Specific Systems Covered:

Engine, Fuel System, Lubrication System, Cooling System, Chassis, Electrical System, Emission Control

Page Count

Estimated Page Count:

Varies by specific edition, typically 300-500+ pages for comprehensive factory manuals.

Manual Type

Manual Type:

Factory Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Internal Components:

Cylinder head, camshaft, cylinder, piston, crankshaft, connecting rod, valves, valve timing

Fuel And Lubrication:

Fuel tank, fuel lines, carburetor (e.g., Mikuni BSR36/42), fuel pump, oil system, oil pump, oil filter, oil cooler (if equipped)

Cooling System:

Radiator, cooling fan, fan thermoswitch, coolant temperature thermoswitch, thermostat, water pump, coolant specifications

Chassis And Suspension:

Front wheel, front fork (e.g., Kayaba USD), steering head bearings, rear wheel, swingarm, rear shock absorber, linkages, rear suspension adjustments

Braking System:

Front brake caliper, master cylinder, brake fluid specifications, brake pads, rear brake caliper, brake lines, brake discs

Electrical System:

Battery specifications, charging system (stator, regulator/rectifier), starter motor, ignition system (CDI, ignition timing), lighting, relays, switches, fuses, speedometer operation

Emission Control:

Evaporative emission control system (EVAP), canister, carburetor emission components, idle speed control, emissions test procedures

Procedures Included

Periodic Maintenance:

Detailed maintenance schedule, air filter cleaning/replacement, spark plug inspection/replacement, valve clearance adjustment (tappet clearance), fuel line inspection, engine oil change, drive chain adjustment/lubrication, brake system inspection, tire pressure checks, spoke tensioning, steering head bearing adjustment

Engine Repair:

Engine removal/installation, complete engine disassembly, component inspection (e.g., wear limits for piston rings, cylinder bore), engine reassembly, torque specifications for all fasteners

Chassis Repair:

Front fork seal replacement, front fork oil change and level setting, steering head bearing replacement, wheel bearing service, swingarm bearing service, rear shock absorber service/replacement

Electrical Diagnostics:

Troubleshooting electrical faults, testing charging system output, ignition system testing, starter circuit testing, multimeter usage for diagnostics

Fuel System Service:

Carburetor cleaning and adjustment, jetting information, fuel pump testing, fuel filter replacement

Technical Depth

Diagnostic Capabilities:

Advanced diagnostics including component testing, circuit analysis, and troubleshooting flowcharts

Rebuild Capabilities:

Complete engine and component rebuild procedures with detailed diagrams and specifications

Illustrations And Diagrams:

Clear, step-by-step illustrations and exploded view diagrams for all procedures

📊 Manual Specifications

File Format

File Format Compatibility:

Compatible with all versions of Windows and Mac

Print Quality

Printability:

Printable pages for workshop use

Binding Type

Binding Type Physical:

Not Applicable (Digital Download)

Paper Type

Paper Type Physical:

Not Applicable (Digital Download)

Software Requirements

Required Software:

Adobe PDF Reader (Free)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Single-cylinder, DOHC, 4-valve

Displacement:

398 cc (24.3 cu in)

Bore X Stroke:

90.0 mm x 78.5 mm (3.54 in x 3.09 in)

Cooling System:

Liquid-cooled

Compression Ratio:

11.3:1

Performance

Horsepower Approx:

Approximately 35-40 HP (Varies by market and specific tuning)

Torque Approx:

Approximately 26-30 lb-ft (Varies by market and specific tuning)

Fuel System

Carburetor Type:

Mikuni BSR36 (DR-Z400S/SM) or BSR42 (DR-Z400E/SM - later models) CV carburetor

Fuel Capacity:

Approximately 10.0 L (2.6 US gal)

Lubrication System

Oil Type Specification:

SAE 10W-40 API SG or SH, JASO MA certified motorcycle oil

Oil Capacity With Filter:

Approximately 2.0 L (2.1 US qt)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain (e.g., 520 size)

Features

Gear Ratios Typical:

Specific gear ratios are detailed within the manual.

📐 Dimensions

Exterior

Overall Length:

Approximately 2,255 mm (88.8 in)

Overall Width:

Approximately 825 mm (32.5 in)

Overall Height:

Approximately 1,165 mm (45.9 in)

Weights

Dry Weight Approx:

Approximately 116 kg (255.7 lbs) for DR-Z400S

Curb Weight Approx:

Approximately 132 kg (291 lbs) for DR-Z400S (with all fluids)

Wheelbase:

Approximately 1,460 mm (57.5 in)

Ground Clearance:

Approximately 300 mm (11.8 in)

Seat Height:

Approximately 935 mm (36.8 in)

🛡️ Safety Features

Ratings

Safety Ratings:

As a motorcycle, safety ratings are not comparable to automobiles. Focus is on rider protection and vehicle stability.

Active Features

Active Safety Features:

Responsive braking system (disc brakes front and rear), predictable handling, effective suspension system.

Passive Features

Passive Safety Features:

Sturdy frame construction, rider ergonomics designed for control, protective bodywork.

💡 Technology Features

Infotainment

Infotainment Features:

Basic LCD instrument cluster displaying speedometer, odometer, trip meter, clock, and indicator lights. No advanced infotainment systems.

Driver Assistance

Driver Assistance Features:

N/A (Motorcycle)

Connectivity

Connectivity Features:

N/A (Motorcycle)

Ignition System

Ignition Type:

Electronic ignition (CDI)

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 3,000 km (1,800 miles) or 6 months.

Air Filter Cleaning Interval:

Every 1,000 km (600 miles) or more frequently in dusty conditions.

Spark Plug Inspection Interval:

Every 6,000 km (3,600 miles).

Valve Clearance Check Interval:

Every 6,000 km (3,600 miles).

Drive Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or as needed.

Fluid Specifications

Brake Fluid Type:

DOT 4

Coolant Type:

High-quality ethylene glycol-based antifreeze coolant (50% mixture with distilled water)

Known Issues

Common Wear Items:

Drive chain and sprockets, brake pads, tires, wheel bearings, steering head bearings, fork seals. Carburetor can sometimes require tuning or cleaning due to ethanol fuels.

Common Performance Tips:

Regular cleaning and proper adjustment of the carburetor, ensuring correct air filter maintenance, and proper chain care are crucial for optimal performance.

📚 Vehicle History

Brand Heritage

Suzuki Off Road Legacy:

Suzuki has a long and successful history in off-road and dual-sport motorcycling, building on the performance and durability of models like the DR-Z series.

Model Evolution

Drz400 Introduction:

The DR-Z400 was introduced as a versatile dual-sport motorcycle, offering a balance of off-road capability and on-road usability. It was available in different variants (S, E, SM) catering to different riding preferences.

Production

Manufacturing Location:

Typically manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

The DR-Z400 is widely recognized for its reliability, versatility, and capability as a dual-sport machine, making it a popular choice for both commuting and off-road adventures.