Suzuki DR-Z400S 2001 Bedienungsanleitung

DR-Z400S

99500-43032-01E

FOREWORD

This manual contains an introductory description on

the SUZUKI DR-Z400S and procedures for its inspec-

tion, service, and overhaul of its main components.

Other information considered as generally known is not

included.

Read the GENERAL INFORMATION section to famil-

iarize yourself with the motorcycle and its maintenance.

Use this section as well as other sections as a guide

for proper inspection and service.

This manual will help you know the motorcycle better

so that you can assure your customers of fast and reli-

able service.

This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent of this manual and the actual motorcycle.

Illustrations in this manual are used to show

the basic principles of operation and work pro-

cedures.They may not represent the actual mo-

torcycle exactly in detail.

This manual is written for persons who have

enough knowledge, skills and tools, including

special tools, for servicing SUZUKI motorcycles.

If you do not have the proper knowledge and

tools, ask your authorized SUZUKI motorcycle

dealer to help you.

Inexperienced mechanics or mechanics with-

out the proper tools and equipment may not

be able to properly perform the services de-

scribed in this manual. Improper repair may

result in injury to the mechanic and may ren-

der the motorcycle unsafe for the rider and

passenger.

Overseas Service Department

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FUEL AND LUBRICATION

SYSTEM

COOLING SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

DR-Z400SK1 (’01-MODEL)

DR-Z400SK2 (’02-MODEL)

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING

FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right will allow

you to find the first page of the section easily.

4. The contents are listed on 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 (e.g., tightening torque, lubricating points, and locking agent points).

Example: Front wheel

1Front axle

2Odometer gearbox

3Bearing (R)

4Front wheel

5Spacer

6Bearing (L)

7Dust seal

8Brake disc

9Spacer

0Washer

AFront axle nut

BBrake disc mounting bolt

ITEM N·m kgf-m lb-ft

A42 4.2 30.5

B10 1.0 7.0

SYMBOLS

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

ing. The meaning of each symbol is also included in the table.

SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified torque.

Indicates service data.

Apply oil. Use engine oil unless other-

wise specified.

Apply molybdenum oil solution.

(mixture of engine oil and SUZUKI

MOLY PASTE in a ratio of 1:1)

Apply SUZUKI SUPER GREASE “A”.

99000-25030 (For USA)

99000-25010 (For the other countries)

Apply SUZUKI SILICONE GREASE.

99000-25100

Apply SUZUKI MOLY PASTE.

99000-25140

Apply SUZUKI BOND “1207B”.

99104-31140 (For USA)

99000-31140 (For the other countries)

Apply SUZUKI BOND “1215”.

99000-31110 (Except USA)

Apply THREAD LOCK SUPER “1303”.

99000-32030

Apply THREAD LOCK SUPER “1322”.

99000-32110 (Except USA)

SYMBOL DEFINITION

Apply THREAD LOCK “1342”.

99000-32050

Apply or use brake fluid.

Measure in voltage range.

Measure in resistance range.

Measure in current range.

Measure in diode test range.

Measure in continuity test range.

Use special tool.

Use engine coolant.

99000-99032-11X (Except USA)

Use fork oil.

99000-99001-SS5

GENERAL INFORMATION 1-1

GENERAL INFORMATION

CONTENTS

WARNING/CAUTION/NOTE............................................................................. 1- 2

GENERAL PRECAUTIONS ............................................................................. 1- 2

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

SERIAL NUMBER LOCATION ........................................................................ 1- 4

FUEL, OIL, AND ENGINE COOLANT RECOMMENDATIONS ....................... 1- 4

FUEL ............................................................................................................. 1- 4

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

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

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

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

BREAK-IN PROCEDURES .............................................................................. 1- 6

INFORMATION LABELS .................................................................................. 1- 7

SPECIFICATIONS ............................................................................................ 1- 8

COUNTRY AND AREA CODES ...................................................................... 1-10

1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol

and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-

sages highlighted by these signal words.

Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motorcycle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-

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

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

advice.

GENERAL PRECAUTIONS

Proper service and repair procedures are important for the safety of the service mechanic

and the safety and reliability of the motorcycle.

When two or more persons work together, pay attention to the safety of each other.

When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-

doors.

When working with toxic or flammable materials, make sure that the area you work in is well

ventilated and that you follow all of the manufacturer’s instructions.

Never use gasoline as a cleaning solvent.

To avoid getting burned, do not touch the engine, engine oil, radiator, and exhaust system

until they have cooled.

After servicing the fuel, oil, engine coolant, exhaust or brake systems, check all of the lines,

and fittings related to the system for leaks.

GENERAL INFORMATION 1-3

If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equiva-

lent.

When removing parts that are to be reused, keep them arranged in an orderly manner so that

they may be reinstalled in the proper order.

Be sure to use special tools when instructed.

Make sure that all parts used in reassembly are clean. Lubricate them when specified.

Use the specified lubricants, bonds, or sealants.

When removing the battery, disconnect the --

-battery lead wire first, then the ++

+battery lead

wire.

When reconnecting the battery, connect the ++

+battery lead wire first, then the --

-battery lead

wire. Finally, cover the ++

+battery terminal with the terminal cover.

When performing service to electrical parts, disconnect the --

-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 to 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 to replace them with new ones.

Also, before installing these new parts, be sure to remove any left over material from the

mating surfaces.

Never reuse a circlip.When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure it is

completely seated in its groove and securely fitted.

Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a

thread is smeared with them.

After reassembling, check parts for tightness and proper operation.

To protect the environment, do not unlawfully dispose of used motor oil, engine coolant, all

other fluids, batteries, and tires.

To protect the earth’s natural resources, properly dispose of used motorcycles and parts.

1-4 GENERAL INFORMATION

SUZUKI DR-Z400SY (2000-MODEL)

FUEL, OIL, AND ENGINE COOLANT RECOMMENDATIONS

FUEL (FOR USA AND CANADA)

Use only unleaded gasoline of at least 87 pump octane ( ) method or 91 octane or higher rated by

the Research Method.

SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible.

Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted.

Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10%

ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion

inhibitors are present in it.

If the performance of the motorcycle is unsatisfactory while using blended gasoline/alcohol fuel, you

should switch to alcohol-free unleaded gasoline.

Failure to follow these guidelines could possibly void applicable warranty coverage. Check with your fuel

supplier to make sure that the fuel you intend to use meets the requirements listed above.

* Difference between photographs and the actual motorcycle depends on the markets.

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) 1is stamped on the right side of the

steering head pipe. The engine serial number 2is located on the right side of the crankcase. These num-

bers are required especially for registering the machine and ordering spare parts.

RIGHT SIDE LEFT SIDE

R + M

GENERAL INFORMATION 1-5

FUEL (FOR THE OTHER COUNTRIES)

Use unleaded gasoline that is graded 91 octane or higher by the Research Method.

ENGINE OIL

Use a premium quality 4-stroke motor oil to ensure longer ser-

vice life of your motorcycle. Use only oils which are rated SF or

SG under the API service classification. The recommended vis-

cosity is SAE 10W-40. If an SAE 10W-40 motor oil is not avail-

able, select an alternative according to the following chart.

BRAKE FLUID

Specification and classification: DOT 4

This motorcycle uses a glycol-based brake fluid. Do not use or mix other types of brake fluid

such as silicone-based and petroleum-based fluids for refilling the system, otherwise seri-

ous damage will result to the brake system.

Do not use any brake fluid taken from old, used, or unsealed containers.

Do not reuse brake fluid left over from the last servicing or which has been stored for a long

period of time.

FRONT FORK OIL

Use SUZUKI FORK OIL SS-05 or an equivalent fork oil.

ENGINE COOLANT

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

antifreeze, even if the atmospheric temperature does not go below the freezing point.

Use an antifreeze designed for aluminum radiators. SUZUKI recommends the use of SUZUKI COOLANT

antifreeze. If this is not available, use an 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 of 50:50 – 40:60.

For more information, refer to page 5-4 in the Cooling System section.

The percentage of antifreeze in the coolant should be between 50 to 60%. If the percentage of

antifreeze is above or below this range the coolant’s frost protection and rust-inhibiting capa-

bilities will be reduced. Always keep the antifreeze content above 50% even if the atmospheric

temperature does not go below the freezing point.

MULTIGRADE

TEMP.

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