suzuki DR-Z400SY
WORKSHOP, SERVICE, REPAIR MANUAL
SUZUKI DR-Z400SY - WORKSHOP, SERVICE, REPAIR MANUAL - English Service Manual to Suzuki DR-Z400SY. CONTENTS: FOREWORD HOW TO USE THIS MANUAL - To locate what you are looking for - Component parts and work to be done - Symbols 01 GENERAL INFORMATION - Warning/caution/note - General precautions - Suzuki dr-z400sy (2000-model) - Serial number location - Fuel, oil, and engine coolant recommendations - Fuel - Engine oil - Brake fluid - Front fork oil - Engine coolant - Break-in procedures - Information labels - Specifications - Country and area codes 02 PERIODIC MAINTENANCE - Periodic maintenance schedule - Periodic maintenance chart - Maintenance and tune-up procedures - Air cleaner - Exhaust pipe nut and bolt and muffler nut and bolts - Tappet clearance - Spark plug - Spark arrester (for e-03, 28, 33) - Fuel line - Engine oil and oil filter - Engine oil hoses - Throttle cable play (carburetor) - Engine idle speed (carburetor) - Engine coolant - Radiator hoses - Clutch - Drive chain - Brakes - Brake fluid - Brake hoses - Tires - Spoke nipples - Steering - Front fork - Rear suspension - Evaporative emission control system (for e-33) - Pair (air supply) system (for e-02, 19, 54) - Chassis nuts and bolts - General lubrication - Compression pressure check - Compression test procedure - Oil pressure check - Oil pressure test procedure 03 ENGINE - Engine components removable with engine in place - Engine removal and remounting - Engine removal - Engine remounting - Engine disassembly - Engine components inspection and service - Cylinder head - Camshaft/automatic decompression assembly - Cylinder - Piston and piston ring - Conrod - Crankshaft - Starter clutch - Starter torque limiter - Oil pump - Clutch - Gearshift fork and gear - Transmission - Bearings - Oil seals - Oil check valve - Engine reassembly - Crankshaft - Gearshift cam and fork - Crankcase - Starter clutch and generator rotor - Balancer shaft - Primary drive gear - Gearshift cam driven gear - Gearshift shaft - Oil pump - Cam chain - Clutch - Right crankcase cover - Clutch cover - Generator rotor cover - Neutral switch - Starter drive gear cover - Piston ring - Piston and cylinder - Cylinder head - Camshaft/automatic decompression assembly - Cylinder head cover - Cam chain tension adjuster - Pair (air supply) system (for e-02, 19, 54) - Removal - Inspection - Remounting 04 FUEL AND LUBRICATION SYSTEM - Fuel tank - Removal - Remounting - Fuel valve - Removal and inspection - Fuel strainer - Remounting - Carburetor - Construction - Specifications - I.d. No. Location - Removal - Disassembly - Cleaning - Inspection - Reassembly - Remounting - Lubrication system - Engine lubrication system chart 05 COOLING SYSTEM - Cooling system - Description - Construction - Engine coolant - Radiator and cooling fan - Inspection - Removal - Remounting - Cooling fan thermoswitch - Removal - Inspection - Installation - Engine coolant temperature thermoswitch - Removal - Inspection - Installation - Thermostat - Removal - Inspection - Installation - Water pump - Removal and disassembly - Inspection - Reassembly 06 CHASSIS - Exterior parts - Removal - Remounting - Front wheel - Construction - Removal and disassembly - Inspection - Reassembly and remounting - Front fork - Construction - Removal and disassembly - Inspection - Reassembly and remounting - Suspension setting - Steering - Construction - Removal and disassembly - Inspection - Reassembly and remounting - Rear wheel - Construction - Removal and disassembly - Inspection - Reassembly and remounting - Rear suspension - Construction - Rear shock absorber removal - Rear shock absorber inspection - Rear shock absorber disposal - Rear shock absorber remounting - Rear shock absorber damping force adjustment - Rear swingarm and cushion lever removal - Inspection and disassembly - Reassembly and remounting - Final inspection and adjustment - Front brake - Construction - Brake pad replacement - Brake fluid replacement - Brake caliper removal and disassembly - Brake caliper inspection - Brake caliper reassembly and remounting - Brake disc inspection - Master cylinder removal and disassembly - Master cylinder inspection - Master cylinder reassembly and remounting - Rear brake - Construction - Brake pad replacement - Brake fluid replacement - Brake caliper removal and disassembly - Brake caliper inspection - Brake caliper reassembly and remounting - Brake disc inspection - Master cylinder removal and disassembly - Master cylinder inspection - Master cylinder reassembly and remounting 07 ELECTRICAL SYSTEM - Cautions in servicing - Connectors - Couplers - Clamps - Fuse - Semiconductor equipped parts - Battery - Connecting the battery - Wiring procedure - Using the multi circuit tester - Location of electrical components - Charging system - Description - Troubleshooting - Inspection - Starter system - Description - Troubleshooting - Starter motor removal and disassembly - Starter motor inspection - Starter motor reassembly and remounting - Starter relay inspection - Side stand/ignition interlock system parts inspection - Ignition system - Description - Troubleshooting - Inspection - Speedometer - Removal - Parts names - Operating procedure - Lamps - Headlight - Front and rear turn signal light - Brake llght/taillight - Relays - Starter relay - Turn signal/side stand relay - Switches - Battery - Removal - Specifications - Servicing - Recharging operation 08 SERVICING INFORMATION - Troubleshooting - Engine - Carburetor - Chassis - Brakes - Electrical - Battery - Wiring diagram - For e-02, 19, 54 - For e-03, 28, 33 - Wire harness, cable, and hose routing - Wire routing - Cable routing - Oil return tank hose routing - Cooling system hose routing - Front brake hose routing - Rear brake hose routing - Pair (air supply) system hose routing (for e-02, 19, 54) - Special tools - Tightening torque - Engine - Chassis - Tightening torque chart - Service data 09 EMISSION CONTROL INFORMATION - Emission control carburetor components - Evaporative emission control system (for e-33) - Canister hose routing - Inspection 10 DR-Z400SK1 ('01-MODEL) - Specifications - Service data - Battery 11 DR-Z400SK2 ('02-MODEL) - Specifications - Service data - Front fork - Construction - Removal and disassembly - Inspection - Reassembly and remounting - Suspension setting - Rear shock absorber damping force adjustment - Headlight - Canister hose routing 12 DR-Z400SK3 ('03-MODEL) - Specifications - Service data - Cam chain tension adjuster - Cam chain tension adjuster removal - Cam chain tension adjuster installation - Wiring diagram (for e-02, 19, 54) 13 DR-Z400SK4 ('04-MODEL) - Specifications - Service data - Tightening torque - Primary drive gear and nut - Cable routing 14 DR-Z400SK5 ('05-MODEL) - Specifications - Service data 15 DR-Z400MK5 ('05-MODEL) - Specifications - Service data - Front fork - Drive chain adjustment - Tightening torque - Front axle - Rear axle - Front brake hose routing - Rear brake hose routing - Wiring diagram 16 DR-Z400SK6 ('06-MODEL) - Specifications - Service data - Rear combination lamp installation - Wiring diagram 17 DR-Z400SMK6/USMK6 ('06-MODEL) - Specifications - Service data 18 DR-Z400SK7 (’07-MODEL) - Pair (air supply) system hose routing (for e-02, 19, 24) 19 DR-Z400SMK7 (’07-MODEL) - Specifications - Service data 20 DR-Z400S/SMK8 (’08-MODEL) - Wiring diagram for e-03, 28, 33 21 DR-Z400S/SMK9 (’09-MODEL) - Specifications (for dr-z400s) - Specifications (for dr-z400sm) - Service data (for dr-z400s) - Service data (for dr-z400sm)
Suzuki DR-Z400SY Service Manual
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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