Suzuki DR-Z400S 2000–2007 Service & Repair Manual

Suzuki service and repair information for the 2000 DR-Z400S (DR-Z400SY) dual-sport. This is S-model base-manual content; E- and SM-specific service information and later model-year supplements are not included.

PDF Search Limits and Chapter Bookmarks

Finding procedures and circuit details: PDF text search does not cover the technical chapters. Chapter bookmarks are included, but the General Information entry has no working destination. Small circuit and connector labels are readable when enlarged, although some lettering has broken strokes.

The ZIP contains one printable, English-language 232-page PDF, including a separate cover page and two introductory pages explaining manual use and symbols.

Engine, Chassis and Electrical Service

This selection of service topics is not a full contents list. Other sections address fuel-valve inspection and speedometer operation.

• Engine repair: Step-by-step procedures for engine removal, crankcase separation, cam-chain timing, and clutch and transmission disassembly and reassembly.

• Carburetor service: Mikuni BSR36 overhaul, float-height adjustment, and throttle position sensor testing and adjustment, with regional carburetor specifications.

• Cooling system: Leak testing, thermostat and fan-control checks, radiator removal, coolant bleeding, and water-pump bearing and mechanical-seal replacement.

• Chassis repair: Front-fork rebuilding, steering-bearing replacement, swingarm linkage service, and front and rear brake caliper and master-cylinder overhaul.

• Electrical fault-finding: System circuit diagrams, troubleshooting charts, and charging, starter, and CDI ignition tests, including side-stand/ignition interlock checks.

• Maintenance data: Drive-chain wear and adjustment, hydraulic brake bleeding, valve-clearance inspection, torque specifications, fluid capacities, and component wear limits.

This manual suits experienced motorcycle mechanics who can use precision measuring equipment and the specified special tools.

Carburetor Versions and Regional Systems

Carburetor identification separates 29FA, 29FB, and 29FC versions: 29FA serves E-02/E-19/E-54, 29FB serves E-03/E-28, and 29FC serves E-33.

The regional sections cover PAIR air-supply valve testing and carburetor piston-valve control solenoid checks for E-02/E-19/E-54. California coverage addresses the evaporative-emissions canister, fuel-vapor separator, roll-over valve, and associated hoses, including a canister hose-routing diagram.

Internal Engine and Transmission Repair

Component identification and service limits cover the cylinder head, piston assembly, crankcase, and transmission gear clusters. Inspection data include valve-seat cutting angles, camshaft-journal tolerances, and piston-ring end gaps.

Repair coverage extends to valve-guide replacement, crankshaft and connecting-rod inspection, and balancer-shaft timing. Exploded assembly views and a transmission cross-section show gear, washer, and circlip placement, backed by shift-fork clearances and gear ratios.

A chart of components removable with the engine installed helps plan whether a job requires engine removal. Factory tool references include crankcase separator 09920-13120 and crankshaft installer 09910-32812. The installation notes warn that hammering the crankshaft into the case can disturb its alignment.

Starter-clutch checks and a starter torque-limiter slip test are included, but the limiter is treated as a replacement assembly rather than an internal rebuild.

Valve Service, Lubrication and Pressure Tests

The Tappet Shim Selection Tables support shim sizing. Compression testing accounts for the automatic decompression mechanism; oil-pressure testing includes guidance on abnormal readings.

The Engine Lubrication System Chart traces the dry-sump circuit through the frame oil tank, feed and return pumps, and engine oil passages. Fluid-capacity data distinguish routine oil changes, filter changes, and engine overhaul.

Torque data cover engine drain plugs and chassis fasteners, including market-specific rear-axle specifications. An oil-filter installation caution identifies a specific repair risk: incorrect filter orientation can cause serious engine damage.

Fork Adjustment and Rear-Shock Limits

Front-fork service includes oil-level setting, spring preload, and compression-damping adjustment. Rear suspension coverage addresses cushion-lever bearings, shock inspection and replacement, and spring-preload and compression-damping settings.

Internal rear-shock rebuilding is not covered; the manual treats the shock as nonserviceable. Before undertaking extensive mechanical work, use proper lifting support and follow the precautions for hot coolant and the nitrogen-charged rear shock.

Electrical Tests and Wiring Limits

Separate charging-system, starter-system, and ignition-system circuit diagrams accompany fault-isolation charts. Tests cover generator output, regulator/rectifier function, starter relay operation, and ignition-coil, pickup-coil, and signal-coil peak voltage.

Starter-motor repair includes brush, commutator, and armature inspection. Electrical test specifications and switch-continuity tables support diagnosis rather than relying solely on component replacement.

This PDF contains system-level schematics, not a complete motorcycle wiring diagram. Section 8 is absent, including the general wire-harness, cable, and hose-routing pages referenced elsewhere in the text.

Cold Valve-Clearance and Float-Height Preview

For cold-engine valve inspection, the specified tappet clearances are 0.10–0.20 mm on the intake side and 0.20–0.30 mm on the exhaust side.

The BSR36 carburetor data specify a float height of 13.0 ± 1.0 mm with the carburetor inverted and the float arm just contacting the needle valve.