Model Variants:
DR-Z400, DR-Z400S, DR-Z400E, DR-Z400SM (Supermoto)
Production Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Segment:
Dual-Sport / Supermoto motorcycle segment
Competitors:
Honda CRF450L/X, Yamaha WR450F, Kawasaki KLX400 (rebadged DR-Z400)
Appeal:
Versatile platform for off-road, commuting, and light trail riding (S and E models), with the SM variant offering street-focused supermoto capability.
Engine:
Top End, Bottom End, Lubrication System, Cooling System, Fuel Delivery System (Carburetor/EFI depending on sub-model), Ignition System, Exhaust System
Transmission:
Clutch, Gearbox, Shift Mechanism, Final Drive (Chain)
Chassis:
Frame, Swingarm, Bearings, Front Forks (Conventional/Inverted), Rear Shock Absorber, Linkages
Brakes:
Front and Rear Brake System (Hydraulic Disc), Calipers, Master Cylinders, Hoses, Pads, Fluid Maintenance
Electrical System:
Wiring Diagrams, Lighting, Ignition Switch, Starter System, Battery, Charging System (Stator/Regulator/Rectifier), Fuses, Switches, Sensors
Bodywork And Trim:
Seat, Fenders, Fuel Tank, Side Covers, Handlebars, Controls
Maintenance:
Routine Service, Oil Changes, Filter Replacements, Chain Adjustment, Valve Clearance Checks, Spark Plug Replacement, Brake Bleeding
Diagnostics:
Troubleshooting Guides, Symptom-Based Diagnostics, Component Testing
Repair:
Engine Rebuild (Top-End and Bottom-End), Transmission Overhaul, Suspension Overhaul, Brake System Repairs, Electrical Component Replacement
Assembly Disassembly:
Detailed step-by-step instructions with torque specifications for all major components and sub-assemblies.
Depth:
Comprehensive, suitable for home mechanics and professional technicians. Covers basic maintenance to full engine rebuilds.
File Type:
PDF (Portable Document Format)
Printability:
Print-friendly, high-resolution images and text for clear reproduction.
Binding:
Not Applicable (Digital Product)
Paper Type:
Not Applicable (Digital Product)
Reader:
Adobe Acrobat Reader or compatible PDF viewer required.
Engine Type:
Liquid-cooled, four-stroke, SOHC, 4-valve
Bore X Stroke:
89.0 mm x 62.6 mm
Compression Ratio:
12.2:1
Horsepower:
~39 HP @ 7,500 RPM (varies slightly by model/tuning)
Torque:
~28 lb-ft @ 6,000 RPM (varies slightly by model/tuning)
Fuel Delivery:
Carburetor (Keihin FCR39 on E/S models), Mikuni BSR36 on early models. SM models may have different carburetors or early EFI versions depending on region.
Fuel Type:
Unleaded gasoline, 91 octane (AKI) or higher recommended
Oil Type:
SAE 10W-40 API SG or higher, JASO MA rated motorcycle oil
Coolant Type:
Permanent antifreeze solution, 50% mixture of ethylene glycol and distilled water
Spark Plug Type:
NGK CR9E (or equivalent)
Engine Serial Number Location:
Typically stamped on the crankcase, near the transmission output shaft.
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet, multi-plate
Gear Ratios:
1st: 2.571 (36/14), 2nd: 1.777 (32/18), 3rd: 1.333 (32/24), 4th: 1.142 (32/28), 5th: 1.041 (30/29)
Final Drive:
Chain drive, 15/44 tooth sprocket ratio (stock)
Fluid Type:
Suzuki 4-stroke motorcycle gear oil or equivalent API GL-4, SAE 80
Length:
Approx. 2,255 mm (88.8 in) for DR-Z400S
Width:
Approx. 805 mm (31.7 in) for DR-Z400S
Height:
Approx. 1,205 mm (47.4 in) for DR-Z400S
Dry Weight:
Approx. 122 kg (269 lbs) for DR-Z400S
Wet Weight:
Approx. 133 kg (293 lbs) for DR-Z400S (with fluids)
Gvwr:
Not typically specified for this class of motorcycle, but refers to maximum safe operating weight including rider and cargo.
Front Tire Size:
80/90-21 (Spoke wheel) for S/E, 120/70-17 (Cast wheel) for SM
Rear Tire Size:
100/90-18 (Spoke wheel) for S/E, 160/60-17 (Cast wheel) for SM
Wheelbase:
Approx. 1,460 mm (57.5 in) for DR-Z400S
Ground Clearance:
Approx. 330 mm (13.0 in) for DR-Z400E
Oil Change Interval:
Every 2,000 km (1,200 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
At every oil change.
Air Filter Cleaning:
Every 1,000 km (600 miles) or more frequently in dusty conditions.
Chain Lubrication Adjustment:
Every 500 km (300 miles) or as needed.
Valve Clearance Check:
Every 4,000 km (2,500 miles)
Engine Oil Capacity:
1.7 L (1.8 US qt) without filter change; 1.8 L (1.9 US qt) with filter change.
Transmission Oil Capacity:
0.6 L (0.63 US qt)
Coolant Capacity:
1.1 L (1.2 US qt)
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, swingarm bushings, chain and sprockets.
Potential Concerns:
Some owners report cam chain tensioner noise (can be addressed with aftermarket manual tensioners). Carburetor tuning can be sensitive to altitude and temperature changes. Early models might have slightly less refined suspension than later iterations.
Manufacturer:
Suzuki Motor Corporation, a Japanese manufacturer with a long history of producing motorcycles, automobiles, and marine engines.
Platform Basis:
Developed from the successful RM-Z motocross line, adapted for dual-sport and supermoto use.
Manufacturing Location:
Japan (primarily)
Key Updates Within Period:
Minor updates in suspension tuning, color schemes, and minor component revisions across the years. Significant changes were minimal during this specific generation.
