This service manual provides service, repair and maintenance information for the following motorcycles: 2000 Suzuki DR-Z400Y
2000 Suzuki DR-Z400SY
2000 Suzuki DR-Z400EY
2001 Suzuki DR-Z400SK1
2001 Suzuki DR-Z400K1
2001 Suzuki DR-Z400EK1
2002 Suzuki DR-Z400SK2
2002 Suzuki DR-Z400K2
2002 Suzuki DR-Z400EK2
2003 Suzuki DR-Z400SK3
2003 Suzuki DR-Z400K3
2003 Suzuki DR-Z400EK3
2004 Suzuki DR-Z400SK4
2004 Suzuki DR-Z400EK4
2005 Suzuki DR-Z400SMK5
2005 Suzuki DR-Z400SK5
2005 Suzuki DR-Z400EK5
2006 Suzuki DR-Z400SMK6
2006 Suzuki DR-Z400SK6
2006 Suzuki DR-Z400EK6
This service manual includes 331 pages of text containing color wiring diagrams and hundreds of photos and illustrations. The chapter breakdown for this new title is as follows:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Basic service methods / Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING
Engine operating requirements / Engine starting / Engine spark test / Starting system / Engine performance / Engine noise / Motorcycle noise / Engine leakdown test / Clutch / Shift mechanism and transmission / Brakes / Steering and handling
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Fuel type / Pre-ride inspection / Engine break-in / Service intervals / Battery / Periodic lubrication / Maintenance and inspection / Tune-up / Valve clearance / Carburetor / Ignition timing / Compression test / Spark plugs / Specifications
CHAPTER FOUR / ENGINE TOP END
Exhaust system / Cylinder head cover / Camshafts and cam chain tensioner / Cylinder head / Valves / Cylinder / Piston and piston rings / Specifications
CHAPTER FIVE / ENGINE LOWER END
Engine / Crankcase / Crankcase seals / Crankcase bearings / Engine balancer / Oil strainer / Crankshaft / Specifications
CHAPTER SIX / CLUTCH, EXTERNAL SHIFT MECHANISM AND LUBRICATION SYSTEM
Clutch cover / Clutch / Right crankcase cover / Oil pump / Cam chain and rear guide / Balancer driven gear / Primary and balancer drive gears / Shift lever / External shift mechanism / Clutch cable replacement / Specifications
CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation / Transmission service / Input shaft / Output shaft / Transmission inspection / Shift drum and forks / Specifications
CHAPTER EIGHT / FUEL SYSTEM
Fuel system precautions / Carburetor / Throttle position sensor / Carburetor systems / Fuel valve / Evaporative emissions control system / Throttle cable replacement / Specifications
CHAPTER NINE / ELECTRICAL SYSTEM
Troubleshooting / Ignition and charging system operation / Upper idle gear cover / Alternator cover / Lower idle gear / Stator assembly / Rotor and starter clutch / Starter / Starting system switches / Ignition system / Charging system / Radiator fan (S and SM models) / Temperature warning circuit (S and SM models) / Headlight / Taillight / Turn signals / Specifications
CHAPTER TEN / COOLING SYSTEM
Safety precautions / Fan and switch (S and SM models) / Radiators and warning light switch / Thermostat (S and SM models) / Water pump / Specifications
CHAPTER ELEVEN / WHEELS, TIRES AND DRIVE CHAIN
Front wheel / Rear wheel / Front and rear hubs / Wheel service / Drive chain / Sprockets / Tires / Specifications
CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Handlebar / Steering stem and head / Front fork / Front fork service / Front fork adjustment / Specifications
CHAPTER THIRTEEN / REAR SUSPENSION
Shock absorber / Shock absorber linkage / Swing arm / Swing arm service / Shock absorber adjustment / Specifications
CHAPTER FOURTEEN / BRAKES
Brake service / Front brake pads / Front brake caliper / Front master cylinder / Rear brake pads / Rear brake caliper / Rear master cylinder / Rear brake pedal / Brake system bleeding / Brake disc / Specifications
CHAPTER FIFTEEN / BODY
Side covers / Seat / Radiator covers / Fuel tank / Headlight cowl / Engine covers / Skid plate / Subframe / Specifications
INDEX
DR-Z400 WIRING DIAGRAMS
DR-Z400 DRZ400 Repair Manual Suzuki 2000-2006 Clymer
