Suzuki DR-Z400E, DR-Z400S, DR-Z400SM Repair Manual 2000-2008

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Item # M477-2  ISBN: 9781599692500




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This repair and service manual covers Suzuki DR-Z400E, DR-Z400S, and DR-Z400SM 4-stroke models, 2000-2008.

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 andD 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 | COLOR WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Suzuki DR-Z400E, DR-Z400S, DR-Z400SM Repair Manual 2000-2008