Suzuki DR-Z400 repair manual (2000-07)

2000–2007 Suzuki DR-Z400 Technical Documentation

• Covers 2000–2007 Suzuki DR-Z400 dual-sport motorcycles across international variants including E-02, E-03, E-19, E-28, E-33, and E-54
• Official Suzuki service publication M.Y 2000-2007, first edition
• Contains over 100 pages of exploded-view diagrams, torque specifications, and internal engine component tolerance charts
• Delivered as a direct download the moment payment clears
• Indexed PDF search covers every chapter and appendix
• Detailed maintenance and chassis tuning values assist in the identification of factory-recommended settings
• This reference documents the essential engine, transmission, electrical, and suspension data required for the 398 cc liquid-cooled DOHC platform

Internal Mechanical and Engine System Scope

The 2000–2007 Suzuki DR-Z400 manual provides a detailed look at engine disassembly, inspection, and reassembly. Chapters are organized to assist with component identification and service limits, covering the cylinder head, piston assembly, crankcase, and transmission gear clusters. The document details valve seat cutting angles, camshaft journal tolerances, and piston ring end gap specifications for the 398 cc single-cylinder engine.

Further technical sections address the chassis and periodic maintenance. Data presented includes front and rear suspension service, drive chain maintenance, and hydraulic brake bleeding procedures. Torque values are listed for major fasteners, including the 100 Nm rear axle nut and 21 Nm crankcase drain plug for the 2000–2007 Suzuki DR-Z400.

Specification and Data Preview

Technical highlights include fluid capacities, with engine oil volume for a filter change specified at 1.8 liters. Valve clearance for the intake is listed at 0.10–0.20 mm in the cylinder head specification table. Compression pressure is documented at 950 kPa (135 psi) with the automatic decompression system actuated. Reference charts provide clear guidance on tappet shim selection and gear ratio values for the 5-speed transmission.

Note: This page is a contents overview for the manual. It does not provide repair or diagnostic instructions. This official 100-page service publication provides authoritative data for the 2000–2007 Suzuki DR-Z400 engine, chassis, and electrical systems.