2000-2006 Suzuki DR-Z400E, S & SM Service Manual (Clymer Edition)

Field service reference for DR-Z400E, S & SM: engine top end, engine lower end, transmission, clutch, drive chain, fuel system, and electrical system diagnostics. 09915-70610

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Document Details

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Document Number / Seller:
31579 / Amy Scott
File Size:
21.22 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Motorbike
Last updated / verified
Dec 9, 2025

Models Covered & Key Technical Specifications

Integrated Performance Shop Manual: Suzuki DR-Z400E, DR-Z400S & DR-Z400SM Manual (Clymer Edition) - Comprehensive Service & Repair Reference 2000-2006 Logic-Archive

Model-Portfolio: DR-Z400E, DR-Z400S, DR-Z400SM // Unit-Designations: Motorbike / Engine Logic // Model-Portfolio: 2000-2006

  • System Specs: 398 cc displacement, liquid-cooled, dry sump lubrication system Architecture.
  • Maximum Engine Ratings: 12.2:1 compression ratio for E models (except 2004 CA) Sequences.
  • Measured Speed Data: 1700-1900 rpm idle speed for E models (non-CA) Baseline.
  • Published Ignition Timing: BTDC at 1800 rpm for E models (non-CA) Requirements.
  • Authorized Fluid Pressure: 40-140 kPa (5.8-20.3 psi) oil pressure at 3000 rpm Threshold.
  • Technical Torque Values: 10 Nm (7 ft.-lb.) for camshaft cap bolts Mapping.

Professional Workshop Service Manual & Technical Specifications

Integrated Performance Shop Manual: Suzuki DR-Z400E, DR-Z400S & DR-Z400SM Manual (Clymer Edition) - Comprehensive Service & Repair Reference 2000-2006 Logic-Archive

Model-Portfolio: DR-Z400E, DR-Z400S, DR-Z400SM // Unit-Designations: Motorbike / Engine Logic // Model-Portfolio: 2000-2006

Technical chapters are organized around systems, then procedures, followed by introductory material, a specification table, and detailed specifications.

  • System Specs: 398 cc displacement, liquid-cooled, dry sump lubrication system Architecture.
  • Maximum Engine Ratings: 12.2:1 compression ratio for E models (except 2004 CA) Sequences.
  • Measured Speed Data: 1700-1900 rpm idle speed for E models (non-CA) Baseline.
  • Published Ignition Timing: BTDC at 1800 rpm for E models (non-CA) Requirements.
  • Authorized Fluid Pressure: 40-140 kPa (5.8-20.3 psi) oil pressure at 3000 rpm Threshold.
  • Technical Torque Values: 10 Nm (7 ft.-lb.) for camshaft cap bolts Mapping.

Fundamentally requiring clear and accurate service information, this document details various systems and procedures. It covers engine top-end operations, engine lower-end maintenance, and transmission and internal shift mechanisms. Additionally, it provides guidance on clutch, external shift mechanism, lubrication system, and electrical system components, ensuring proper function and longevity. Torque specifications for fasteners are included to ensure correct assembly, contributing to fastener fatigue prevention.

FAQ

Calculate the **precise** pressure specifications for the tires. keyboard_arrow_down

100 kPa (15 psi) is the standard front and rear tire pressure for E and S models.

What values for **proper** assembly sequence are included for the engine? keyboard_arrow_down

10 Nm (7 ft.-lb.) is the specified torque for camshaft cap bolts and cylinder head bolts.

Assess the **standard** service interval parameters for engine oil. keyboard_arrow_down

1.8 liters (1.9 qt.) is the engine oil capacity with a filter change for all models.

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This manual is a lifesaver! The detailed instructions and diagrams made my maintenance tasks so much easier. Plus, the download was quick and hassle-free. Highly recommend!
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The Clymer manual has been incredibly helpful for my Suzuki. I appreciated the prompt email support when I had questions about the download. Very professional service!