Segment:
Dual-sport / Enduro motorcycle segment.
Target Audience:
Owners seeking to perform their own maintenance and repairs, enthusiasts, workshops.
Competitors:
Yamaha WR250F/WR450F, Honda CRF series, Kawasaki KLX series.
Benefit To Owner:
Significant cost savings on repairs and maintenance, empowers owners with knowledge for self-sufficiency.
Ease Of Use:
Step-by-step instructions and pictures make complex tasks accessible.
Versatility:
Covers all models and variations within the specified production years.
Engine:
Full coverage of the 398cc liquid-cooled, four-stroke, DOHC, single-cylinder engine.
Transmission:
Complete coverage of the 5-speed constant mesh transmission, clutch, and shifting mechanisms.
Chassis And Suspension:
Detailed sections on frame, front forks (including adjustment procedures), rear shock absorber (including linkage and adjustment), swingarm, and steering system.
Brakes:
Comprehensive coverage of front and rear disc brake systems, including hydraulic components, caliper service, and fluid replacement.
Electrical System:
In-depth coverage of ignition system, lighting, charging system (stator, rectifier/regulator), battery, starting system, and wiring diagrams.
Fuel System:
Detailed information on the fuel tank, fuel pump, fuel injection system (for applicable models), and carburetor (for applicable models).
Cooling System:
Complete instructions for the liquid cooling system, including radiator, hoses, water pump, and coolant specifications.
Exhaust System:
Information on the exhaust system, including muffler and pipe maintenance.
Bodywork And Plastics:
Guidance on the removal, installation, and maintenance of body panels, fenders, and seat.
Wheels And Tires:
Information on wheel bearing service, tire mounting, and recommended tire pressures.
Troubleshooting:
Extensive troubleshooting guide for diagnosing and resolving common and uncommon issues.
Periodic Maintenance:
Detailed procedures for all scheduled maintenance tasks.
Torque Specifications:
All essential torque specifications for fasteners and critical components.
Wiring Diagrams:
Clear and comprehensive wiring diagrams for electrical system diagnostics.
Special Tools:
Identification of specialized tools required for specific procedures.
Cleaning And Storage:
Recommended procedures for cleaning and long-term storage.
Estimated Pages:
Comprehensive (specific page count not provided, but implied to be extensive based on 'Complete Workshop Service Repair Manual' and 'A-Z' coverage).
Type:
Workshop Service Repair Manual
Format:
Downloadable Digital File (PDF)
Accessibility:
Printable, Viewable on PC, MAC, tablets, and smartphones.
Software Requirement:
Adobe Reader (free download)
Powertrain:
Engine, transmission, clutch, final drive (chain).
Chassis:
Frame, subframe, steering, suspension (front and rear), swingarm, wheels, tires.
Braking System:
Front and rear hydraulic disc brakes, brake fluid.
Electrical And Ignition:
Ignition system, CDI unit, spark plug, charging system (alternator, rectifier/regulator), battery, starter motor, lighting system, instrumentation, wiring harness.
Fuel And Air Induction:
Fuel tank, fuel pump, fuel filter, carburetor (Mikuni BSR36-1A for early models, potential fuel injection for later variants not explicitly detailed but implied by 'All Models/Engines/Trim/Transmissions Types Are Covered'), air filter, intake manifold.
Cooling System:
Radiator, cooling fan, coolant pump, hoses, coolant type and capacity.
Exhaust And Emission:
Exhaust pipes, muffler, catalytic converter (if applicable), emission control systems.
Body And Frame:
Body panels, seat, handlebars, footpegs, plastics, frame inspections.
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly procedures.
Transmission Service:
Gearbox disassembly, inspection, and reassembly; clutch service.
Suspension Fork Rebuild:
Front fork oil changes, seal replacement, and internal component service.
Rear Shock Service:
Rear suspension linkage maintenance and shock absorber adjustments.
Brake Bleeding And Service:
Proper procedures for bleeding brake lines and servicing brake calipers and master cylinders.
Electrical Diagnostics:
Troubleshooting charging system, ignition faults, and starter circuit issues using wiring diagrams.
Carburetor Cleaning And Adjustment:
Detailed instructions for cleaning, rebuilding, and adjusting the carburetor for optimal performance.
Cooling System Maintenance:
Coolant flushing, replacement, and leak testing.
Tire And Wheel Maintenance:
Tire changing, wheel balancing, and bearing service.
Valve Clearance Adjustment:
Precise instructions for checking and adjusting valve clearances.
Oil And Filter Change:
Step-by-step guide for routine engine oil and filter replacement.
Chain Adjustment And Lubrication:
Guidance on proper chain tension and maintenance.
Diagnostic Troubleshooting Flowcharts:
Systematic approaches to identify and resolve issues.
Depth:
Comprehensive from basic maintenance and fluid checks to complete engine and transmission rebuilds, including electrical system diagnostics.
Engine Type:
Liquid-cooled, four-stroke, DOHC, 1-cylinder
Bore X Stroke:
83.0 mm x 74.4 mm
Compression Ratio:
11.3:1 (typical, check specific model variant)
Horsepower:
Approximately 40-45 hp (at crank, varies by tuning and model variant)
Torque:
Approximately 3.4 kgf-m @ 6500 rpm (approx. 33.3 Nm or 24.6 lb-ft)
Carburetor Type:
Mikuni BSR36-1A (single slide, constant velocity) for carbureted models. Fuel injection for later or specific variants may be covered, but the manual's focus implies detailed carburetor service.
Fuel Type:
Unleaded gasoline (minimum 91 octane recommended).
Ignition Type:
Electronic ignition (CDI).
Oil Capacity:
Approximately 2.0 L (with filter change), 1.8 L (without filter change). Check manual for exact specification.
Oil Type:
SAE 10W-40 motorcycle oil, API SG or higher, JASO MA certified. Consult manual for precise recommendations.
Engine Oil Change:
Every 3,000 km (1,865 miles) or 6 months. Consult manual for exact interval and specific conditions.
Oil Filter Replacement:
Every 3,000 km (1,865 miles) or 6 months (concurrent with oil change).
Air Filter Cleaning:
Every 1,000 km (620 miles) or 3 months. More frequently in dusty conditions.
Spark Plug Inspection:
Every 3,000 km (1,865 miles) or 6 months.
Valve Clearance Check:
Every 6,000 km (3,730 miles) or 12 months. Crucial for engine longevity.
Chain Lubrication And Adjustment:
Every 500 km (310 miles) or weekly if riding frequently, and after washing.
Brake Fluid Replacement:
Every 2 years or as recommended in the manual.
Coolant Replacement:
Every 2 years or as recommended in the manual.
Engine Oil:
SAE 10W-40, API SG or higher, JASO MA.
Coolant:
Permanent type antifreeze coolant (ethylene glycol base) mixed with distilled water at a 50:50 ratio.
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, fork seals, and brake pads are common wear items that require regular inspection and replacement.
Carburetor Issues:
Carburetor needle jet wear, float bowl sealing issues, and jet clogging can occur, especially with age and varying fuel quality.
Suspension Performance:
Front fork dive and rear shock fade can occur with hard use or aging components, requiring maintenance or upgrades.
Manufacturer:
Suzuki Motor Corporation, a long-standing Japanese manufacturer known for its motorcycles and automotive products.
Introduction Year:
The DR-Z400 was introduced around 2000, replacing earlier DR models and establishing itself as a capable and versatile dual-sport machine.
Variants:
Over its production run, the DR-Z400 saw variations like the E (off-road focused), S (street-legal), and SM (Supermoto) models, each with subtle differences in suspension, tires, and engine tuning, all of which are implied to be covered by this comprehensive manual.
Manufacturing Location:
Japan (primary manufacturing location for Suzuki motorcycles).
