Suzuki DR-Z400E/S/SM 2000-2006 Service Manual | Clymer Edition
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
Model 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
- Official Clymer publication M477 (2006 edition) for the 2000–2006 Suzuki DR-Z400 series
- Covers DR-Z400E, DR-Z400S, and DR-Z400SM variants equipped with liquid-cooled 398 cc engines
- Contains 79 detailed photographic figures and 7 maintenance specification tables
- Includes full-color electrical schematics for accurate circuit troubleshooting
- 342-page professional reference covering mechanical, electrical, and fuel injection documentation
Engine and Maintenance Overview
Inside this resource, mechanics and dedicated DIY enthusiasts will find a complete breakdown of major mechanical components. It details the teardown and inspection processes for the engine top and lower ends, clutch, transmission, and cooling systems. Rather than generic advice, the sections are segmented by model variant to provide precise diagnostic procedures and maintenance schedules. Proper service techniques and parts identification are heavily emphasized to keep the DR-Z400 platform running smoothly. Before beginning any teardown, ensure you review all workshop safety protocols and verify your mechanical skill level, as working on engine internals and high-voltage systems requires strict precautions.
Specification Highlights and Data
Performance tuning and assembly require exact metrics. This manual documents engine oil pressure at 40–140 kPa (5.8–20.3 psi) at 3000 rpm. Fastener tables list the camshaft cap bolt torque at exactly 10 Nm (7 ft.-lb.). For the intake valve clearance, the tune-up specification table indicates 0.10–0.20 mm. It also outlines the distinct maintenance intervals, clearly separating the hour-based service for the E-model from the mileage-based schedules for the S and SM versions. All chassis, electrical, and cooling specifications for the entire production run are covered in depth.
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