2000-2009 Suzuki DR-Z400S, DR-Z400SM repair manual

The following models are encompassed by this manual: DR-Z400S, DR-Z400SM / Suzuki Motor Corporation 2000 Suzuki DR-Z400SY 2001 Suzuki DR-Z400SK1 2002 Suzuki DR-Z400SK2 2003 Suzuki DR-Z400SK3 2004 Suzuki DR-Z400SK4 2005 Suzuki DR-Z400SMK5 SuperMoto 2005 Suzuki DR-Z400SK5 2006 Suzuki DR-Z400SMK6 SuperMoto 2006 Suzuki DR-Z400SK6 2007 Suzuki DR-Z400SMK7 SuperMoto 2007 Suzuki DR-Z400SK7 2008 Suzuki DR-Z400SMK8 SuperMoto 2008 Suzuki DR-Z400SK8 2009 Suzuki DR-Z400SMK9 SuperMoto 2009 Suzuki DR-Z400SK9 Engine: 398.0 cc (24.29 cubic inches), liquid cooled, single cylinder, four-stroke, 40.0 HP (29.2 kW) @ 8500 RPM, Production year(s): 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 Manual Language: English Printable: Yes (with all printers) # ³ "Download the Manual for Repairs: 2000-2009 Suzuki DR-Z400S, DR-Z400SM" If you're a proud owner of a 2000-2009 Suzuki DR-Z400S or DR-Z400SM and you're looking for a comprehensive manual to assist you with repairs, maintenance, and modifications, your search ends here. We have compiled a detailed guide that provides engine specs, maintenance intervals, common issues and their solutions, popular tuning tips, available accessories, owner reviews, and much more. Whether you're an off-road enthusiast or a street rider, this manual will be your go-to resource for keeping your Suzuki DR-Z400S or DR-Z400SM in top-notch condition. Engine Specs/Technical Specifications: • The 2000-2009 Suzuki DR-Z400S and DR-Z400SM are powered by a 398cc, liquid-cooled, single-cylinder engine. • The engine features a bore and stroke of 90.0mm x 62.6mm, delivering a balanced power output. • These models utilize a Keihin FCR39 carburetor for efficient fuel delivery. • The engine has a compression ratio of 11.3:1, ensuring optimal combustion. • The DR-Z400S and DR-Z400SM are equipped with a five-speed constant mesh transmission for smooth gear changes. • An electric starter system provides convenient and reliable starting. • The motorcycles feature a CDI ignition system for consistent spark delivery. • A steel frame provides robustness and durability while keeping the weight in check. • The DR-Z400S and DR-Z400SM have a telescopic front fork with adjustable compression and rebound damping. • At the rear, a link-type suspension with adjustable preload and rebound damping enhances stability and comfort. • Both models are equipped with a front disc brake and a rear disc brake for reliable stopping power. • The motorcycles have a fuel tank capacity of 2.6 gallons (9.8 liters) for extended riding range. • A comfortable two-piece seat accommodates both the rider and passenger. • The DR-Z400S and DR-Z400SM have a wheelbase of 58.5 inches (1,486mm) for stability. • Ground clearance measures at 11.6 inches (295mm), facilitating off-road capabilities. • The DR-Z400S weighs approximately 291 lbs (132 kg), while the DR-Z400SM weighs around 322 lbs (146 kg). • These models are equipped with a 21-inch front wheel and an 18-inch rear wheel for versatile performance. • The DR-Z400SM features street-oriented tires for enhanced on-road grip and handling. • The motorcycles are designed with compact dimensions and agile geometry for maneuverability. • Both models feature a stylish design that showcases their dual-sport versatility. Facts and Details: - The DR-Z400S is a versatile off-road-oriented model, while the DR-Z400SM is a supermoto variant designed for street use. - Both models share the same engine and frame, with variations in wheels, tires, and suspension settings. - The DR-Z400S comes with larger wheels and knobby tires suitable for off-road adventures. - The DR-Z400SM features smaller wheels and street tires, delivering sportier performance on paved surfaces. - These motorcycles offer a balanced power-to-weight ratio, making them agile and responsive. - The DR-Z400S and DR-Z400SM are known for their excellent suspension travel, providing smooth rides over rough terrains. - Riders appreciate the comfortable and upright riding position, ideal for long rides or spirited off-road escapades. - These models boast a reliable and durable engine that can handle various riding conditions with ease. - The motorcycles' compact size allows riders to navigate tight trails and urban environments effortlessly. - The DR-Z400S and DR-Z400SM have a reputation for easy maintenance, making them popular choices among DIY enthusiasts and adventure riders. Maintenance Intervals, General Maintenance Tips, and Common Issues: + Oil and filter changes are typically recommended every 1,000-2,000 miles (1,600-3,200 kilometers) or as specified by the manufacturer. + Regularly clean and lubricate the chain to maintain optimal performance and prevent premature wear. + Check tire pressure regularly and replace tires if they are worn or damaged. + Keep the air filter clean and replace it as necessary to ensure proper airflow to the engine. + Valve adjustments should be performed as per the manufacturer's recommendations to maintain proper engine operation. Common issues reported by owners include carburetor-related problems, such as clogged jets or improper fuel delivery. Cleaning or replacing the affected components usually resolves these issues. + Electrical system problems, such as a faulty ignition coil or wiring issues, can sometimes occur. Thorough inspections and necessary repairs are recommended. + Routine checks of the cooling system and coolant levels are important to prevent overheating. Popular Tuning Tips or Modifications: * Upgrading the exhaust system to an aftermarket option can enhance both the performance and sound of the motorcycle. * Installing a high-flow air filter and rejetting the carburetor or adjusting the fuel injection system can improve throttle response and overall engine performance. * Upgrading the suspension components, such as adding stiffer springs or adjustable shocks, can enhance the motorcycle's off-road capabilities. * Adding handguards or skid plates can provide additional protection during off-road riding. * Installing a larger front brake rotor can improve stopping power, especially in more demanding riding conditions. Available Accessories and Aftermarket Options: - Skid plates, engine guards, and frame sliders for enhanced protection. - Handguards to shield the rider's hands from debris and branches. - Luggage racks and saddlebags for increased carrying capacity during long trips. - Performance exhaust systems for improved power and sound. - High-performance air filters for increased airflow and engine performance. - LED lighting kits and auxiliary lights for enhanced visibility. - Upgraded suspension components, such as springs and shocks, for customized riding preferences. - Aftermarket seats for improved comfort during extended rides. - Off-road footpegs for better grip and control. Owner Reviews and Opinions: Strengths: Agile and versatile performance on various terrains. Reliable engine with ample power for off-road and street riding. Comfortable riding position for extended adventures. Easy maintenance and DIY-friendly features. Strong aftermarket support for customization options. Weaknesses: Limited fuel capacity for longer journeys. The stock suspension may require upgrades for more aggressive off-road use. Some owners may find the stock seat uncomfortable during extended rides. Repairs That Need to Be Carried Out Most Frequently: - Regular oil and filter changes for optimal engine performance and longevity. - Chain maintenance, including cleaning, lubrication, and occasional replacement. - Valve adjustments to ensure proper engine operation. - Starter motor replacement in case of failure. - Routine inspection and replacement of worn brake pads and discs. - Carburetor cleaning or fuel injection system maintenance. Initiate the download of your comprehensive Suzuki service manual by clicking the green button. Purchase the PDF manual securely through the RepairLoader marketplace using PayPal. Upon completing your payment via PayPal, the official Suzuki OEM shop manual/parts list download link will be displayed on the checkout page. 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