Suzuki DR-Z400S / DR-Z400SK1-SK7 / DR-Z400SMK7 / DR-Z400S/SMK8-SMK9 2001–2009 Service Manual Set

The supplements document changes to the base manual and earlier supplements, with references back to those sections for unchanged procedures. Use them together to distinguish the applicable engine, carburetor, suspension and electrical information.

PDF Search, Chapter Bookmarks and Diagram Detail

Search and navigation: Text search works across most technical sections, but several supplement opening pages lack searchable text. Embedded bookmarks cover the main chapters and supplements. Small wiring labels require zooming, and some supplement pages are out of sequence.

Supplied as one printable, English-language PDF with 433 pages total, including the shared supplement index and 14 blank pages. The publication page counts above include those pages.

Engine Overhaul, Carburetor Diagnosis and S/SM Chassis Service

The following selected coverage highlights outline the main workshop content. Other topics include speedometer operation and battery charging.

• Engine repair: Step-by-step procedures for engine removal, crankcase separation, cylinder-head service, piston inspection, camshaft installation and valve timing.

• Clutch and transmission: Clutch-plate inspection, transmission disassembly and reassembly, shift-fork measurement, and bearing and oil-seal replacement.

• Fuel and emissions: MIKUNI BSR36 carburetor overhaul, float-height adjustment, throttle position sensor testing, PAIR valve checks and California evaporative-system inspection.

• Cooling system: Radiator leak testing, thermostat and cooling-fan thermoswitch checks, and water-pump bearing and mechanical-seal replacement.

• Chassis and brakes: Conventional and SM inverted-fork service, steering-bearing replacement, swingarm inspection, brake-caliper overhaul, master-cylinder service and hydraulic bleeding.

• Electrical troubleshooting: Charging and ignition fault charts, stator and regulator/rectifier tests, starter-motor service, interlock checks and market-specific wiring diagrams.

• Periodic maintenance: Inspection schedules and procedures for valve clearances, engine oil, filters, throttle cables, drive-chain adjustment and brake components.

Written for mechanics who have the knowledge, skills and tools—including special tools—needed to service Suzuki motorcycles.

Engine Inspection and Reassembly References

The in-frame service table identifies components that can be removed without taking the engine out, helping mechanics assess the scope of a repair. Internal service extends to valve-guide replacement, valve-seat cutting, crankshaft inspection and transmission assembly.

Intake and exhaust tappet shim selection tables support valve-clearance adjustment. The engine chapter identifies the left-hand-thread primary drive gear nut and specifies THREAD LOCK SUPER “1303” for starter-clutch fasteners; the SK4 supplement adds revised primary-drive tightening information.

The crankshaft installation cautions explain how hammering can disturb crankshaft alignment. The oil-pump section warns that attempted internal overhaul can damage its secured screw and treats the pump as a replacement assembly.

Starter torque limiter: Coverage consists of slip-torque testing and replacement, rather than internal overhaul.

Carburetor, Lubrication and Cooling Diagnosis

Carburetor coverage distinguishes needle-valve leakage from restricted fuel supply and includes piston-valve control-solenoid checks for the applicable markets. Throttle position sensor testing and adjustment accompany the mechanical carburetor procedures.

The Engine Lubrication System Chart traces the oil circuit, while Canister Hose Routing drawings identify the California evaporative-system connections. PAIR coverage includes hose, reed-valve and vacuum-operated valve inspection.

Cooling diagnosis separates radiator-cap and system leak tests from fan-motor, thermoswitch and thermostat checks. Water-pump service includes inspection and replacement of the bearing and mechanical seal.

Suspension Differences and Brake Service

The SK2 supplement updates conventional-fork service, while the SMK5 supplement adds inverted-fork disassembly, damper inspection and separate inner- and outer-chamber oil information. Spring setting tables and variant-specific axle and brake-hose drawings support reassembly.

The SMK5 supplement contains conflicting chain-length entries in its model specifications and service-data table.

Rear-shock coverage includes removal, inspection, adjustment and replacement; the manual identifies the shock as nonserviceable internally. Follow the specified precautions for its pressurized nitrogen charge and for handling DOT 4 brake fluid.

Electrical Fault Isolation and Wiring References

The charging-system troubleshooting chart connects battery-discharge symptoms with current-leakage, regulated-voltage, generator and regulator/rectifier tests. Ignition diagnosis includes coil resistance and peak-voltage checks, with the required tester and adapter identified.

Market-specific wiring diagrams distinguish electrical configurations. Cable and hose routing drawings show the installed paths needed when refitting controls and surrounding components.

A Preview of Engine and Chassis Service Data

Engine inspection: The base DR-Z400S service data lists a standard cylinder bore of 90.000–90.015 mm and an intake tappet clearance of 0.10–0.20 mm with the engine cold.

Chassis assembly: The base manual specifies 90 N·m for the steering stem head nut and 77 N·m for the swingarm pivot nut.

Cooling capacity: The base DR-Z400S specifications list a cooling-system capacity of 1.25 liters; the supplements provide the corresponding model-specific data.