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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Sample pages from the 2000-2006 Suzuki DR-Z400E, S & SM Service Manual (Clymer Edition) manual
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Suzuki Models Covered & Key Technical Specifications
Models: Suzuki DR-Z400E, Suzuki DR-Z400S, Suzuki DR-Z400SM
Sub-models / Variants: 2000 DR-Z400EY, 2001 DR-Z400EK1, 2002 DR-Z400EK2, 2003 DR-Z400EK3, 2004 DR-Z400EK4, 2005 DR-Z400EK5, 2006 DR-Z400EK6, 2000 DR-Z400SY, 2001 DR-Z400SK1, 2002 DR-Z400SK2, 2003 DR-Z400SK3, 2004 DR-Z400SK4, 2005 DR-Z400SK5, 2006 DR-Z400SK6, 2005 DR-Z400SMK5, 2006 DR-Z400SMK6
Build Years: 2000–2006
Serial Numbers: JS1DK433 Y2100001–On, JS1DK433 12100001–On, JS1DK433 22100001–On, JS1DK433 32100001–On, JS1DK433 42100001–On, JS1DK433 52100001–On, JS1DK433 62100001–On, JS1SK43A Y2100001–On, JS1SK43A 12100001–On, JS1SK43A 22100001–On, JS1SK43A 32100001–On, JS1SK43A 42100001–On, JS1SK43A 52100001–On, JS1SK43A 62100001–On, JS1SK44A 52100001–On, JS1SK44A 62100001–On
Technical Data:
- Engine displacement: 398 cc
- Compression ratio (E models): 12.2:1 (standard)
- Idle speed (E models): 1700–1900 rpm
- Ignition timing: 7° BTDC at 1800 rpm (E models)
- Oil pressure: 40–140 kPa (5.8–20.3 psi) at 3000 rpm
- Camshaft cap bolt torque: 10 Nm (7 ft.-lb.)
Suzuki Manual Features & Content Preview
Suzuki DR-Z400E, S & SM Technical Scope
- Covers 2000–2006 Suzuki DR-Z400E, DR-Z400S, and DR-Z400SM variants with liquid-cooled 398 cc engines
- Official Clymer publication M477, 2006 edition
- Contains 79 detailed photographic figures and 7 maintenance specification tables
- Includes full-color electrical schematics for accurate circuit troubleshooting
- Laid out for standard letter and A4 printing
- Full-text search finds any part number in seconds
- This 342-page manual is the specific reference for the entire 2000–2006 DR-Z400 series mechanical, electrical, and fuel injection documentation
Engine and Maintenance Overview
This Clymer publication provides detailed information for the 2000–2006 Suzuki DR-Z400E, S and SM motorcycles. The content covers the complete disassembly of major mechanical components, including the engine top and lower ends, clutch, transmission, and cooling systems. Every section is organized for the home enthusiast, offering diagnostic procedures and system-specific maintenance schedules tailored to each model variant. The text focuses on proper service techniques, parts identification, and inspection standards to maintain the DR-Z400 platform effectively.
Specification Highlights and Data
The 2000–2006 Suzuki DR-Z400E, S & SM manual documents key metrics for performance tuning and assembly. Engine oil pressure is listed at 40–140 kPa (5.8–20.3 psi) at 3000 rpm in the engine data section. The camshaft cap bolt torque is specified at 10 Nm (7 ft.-lb.) within the fastener tables. Intake valve clearance for the Suzuki DR-Z400 is documented at 0.10–0.20 mm in the tune-up specification table. The manual serves as an authentic record for maintenance intervals, covering both the E-model hour-based service and the S/SM mileage-based how factory workshop documentation is structured. Reference only — always consult a certified technician before performing service on this equipment. This official Clymer edition is the professional reference used for the 2000–2006 Suzuki DR-Z400E, S, and SM line, documenting engine, chassis, electrical, and cooling specifications for the entire production range.
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