Suzuki DR-Z400S / DR-Z400SK1-SK7 / DR-Z400SMK7 / DR-Z400S/SMK8-SMK9 2001-2009 Service Manual
Provides comprehensive procedures for the DR-Z400S series, covering engine disassembly, fuel system, chassis components, and electrical systems. Ref: 99500-43090-03E
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Sample pages from the Suzuki DR-Z400S / DR-Z400SK1-SK7 / DR-Z400SMK7 / DR-Z400S/SMK8-SMK9 2001-2009 Service Manual manual
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Models Covered & Key Technical Specifications
Suzuki DR-Z400S / DR-Z400SK1-SK7 / DR-Z400SMK7 / DR-Z400S/SMK8-SMK9 (2001-2009) Service Manual
Service procedures | Documentation Division.
- Verified Enclosure Specs: 288 mm (11.3 in) is the standard front fork stroke Measurement.
- Key Addressable Resolution: For optimal operation, 300 mm (11.8 in) defines the ground clearance Metric.
- Principal Clamp Forces: The swingarm pivot nut requires 77 N-m (7.7 kgf-m, 55.5 lb-ft) for secure fastening.
- Advanced Spacing Data: The rear sprocket nut requires 30 N-m (3.0 kgf-m, 21.5 Ib-ft) for proper installation Standards.
- Design Electrical Load: A 20 A fuse protects the electrical system Functionality.
- Designated Footprint Data: The steering stem head nut is specified as 90 N-m (9.0 kgf-m, 65.0 Ib-ft) Tightening Protocol.
Professional Workshop Service Manual & Technical Specifications
Functional Installation Technical Manual: Suzuki DR-Z400S, DR-Z400SK1, DR-Z400SK2, DR-Z400SK3, DR-Z400SK4, DR-Z400SK5, DR-Z400SK6, DR-Z400SK7, DR-Z400SMK7, DR-Z400S/SMK8, DR-Z400S/SMK9 Manual (2001-2009) System-Standards
Application-Range: DR-Z400S / DR-Z400SK1-SK7 / DR-Z400SMK7 / DR-Z400S/SMK8-SMK9 // Technical-Scope: Motorcycle / Engine Logic // Application-Range: 2001-2009.
| Performance-Element | System-Path | Calibration-Spec |
|---|---|---|
| Engine Type | DOHC | Four-stroke |
| Ignition Type | CDI | Electronic |
| Fuel Capacity | L | 9.5 / 10.0 |
| Engine Oil Capacity | ml | 1700 / 1800 / 1900 |
Cataloging major assemblies into distinct sections for clarity and ease of use. This manual outlines procedures for the engine, fuel and lubrication systems, chassis components, cooling system, and electrical system.
Engine Procedures
This manual details engine disassembly, inspection, and reassembly, including camshafts, pistons, crankshafts, and more. It provides specific torque values and technical guidance for each step.
Chassis Components
Covers the front and rear suspension, wheels, brakes, steering, and swingarm. It includes detailed instructions for disassembly, inspection, and reassembly of these critical motorcycle systems.
Fuel and Lubrication Systems
This section provides guidance on the fuel tank, fuel valve, fuel strainer, and carburetor. It includes maintenance procedures for cleaning, inspection, and reassembly of the carburetor, as well as lubrication system charts.
Electrical System
Details the battery, charging system, starter system, ignition system, lights, relays, and switches. It offers troubleshooting tips and inspection procedures for electrical components.
This manual documents torque specifications for various components to ensure proper thread engagement security.
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