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Suzuki DR-Z400S (2000 - 2012)

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The original Haynes Repair Manual - Based on a complete stripdown and rebuild of a vehicle

Suzuki DR-Z400S (2000 - 2012)

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What's Covered
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This Suzuki DR-Z400 Manual is 344 pages

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Vehicle identification number / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Basic service methods / Storage Specifications

CHAPTER TWO / TROUBLESHOOTING
Engine operating requirements / Engine starting / Engine spark test / Starting system / Engine performance / Engine noise / Motorcycle noise / Engine leakdown test / Clutch / Shift mechanism and transmission / Brakes Steering and handling / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Fuel type / Pre-ride inspection / Engine break-in / Service intervals / Battery / Periodic lubrication / Engine oil and filter change / Fork oil change / Drive chain cleaning and lubrication / Air filter cleaning and oiling / Maintenance and inspection / Muffler cleaning / Carburetor float bowl draining / Coolant change / Drive chain adjustment / Throttle adjustment / Clutch cable adjustment / Tune-up / Valve clearance / Carburetor / Idle speed and mixture adjustment / Ignition timing / Compression test / Spark plugs / Specifications

CHAPTER FOUR / ENGINE TOP END
Exhaust system / Cylinder head cover / Camshafts and cam chain tensioner / Cylinder head / Valves / Cylinder / Piston and piston rings / Specifications

CHAPTER FIVE / ENGINE LOWER END
Engine / Crankcase / Crankcase seals / Crankcase bearings / Engine balancer / Oil strainer / Crankshaft / Specifications

CHAPTER SIX / CLUTCH, EXTERNAL SHIFT MECHANISM AND LUBRICATION SYSTEM
Clutch cover / Clutch / Right crankcase cover / Oil pump / Cam chain and rear guide / Balancer driven gear / Primary and balancer drive gears / Shift lever / External shift mechanism / Clutch cable replacement / Specifications

CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation / Transmission service / Input shaft / Output shaft / Transmission inspection / Shift drum and forks / Specifications

CHAPTER EIGHT / FUEL SYSTEM
Fuel system precautions / Carburetor / Throttle position sensor / Carburetor systems / Fuel valve / Evaporative emissions control system / Throttle cable replacement / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Troubleshooting / Ignition and charging system operation / Upper idle gear cover / Alternator cover / Lower idle gear / Stator assembly / Rotor and starter clutch / Starter / Starting system switches / Ignition system / Charging system / Radiator fan (S and SM models) / Temperature warning circuit (S and SM models) / Headlight / Taillight / Turn signals / Specifications

CHAPTER TEN / COOLING SYSTEM
Safety precautions / Fan and switch (S and SM models) / Radiators and warning light switch / Thermostat (S and SM models) / Water pump / Specifications

CHAPTER ELEVEN / WHEELS, TIRES AND DRIVE CHAIN
Front wheel / Rear wheel / Front and rear hubs / Wheel service / Drive chain / Sprockets / Tires / Specifications

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Handlebar / Steering stem and head / Front fork / Front fork service / Front fork adjustment / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION
Shock absorber / Shock absorber linkage / Swing arm / Swing arm service / Shock absorber adjustment / Specifications

CHAPTER FOURTEEN / BRAKES
Brake service / Front brake pads / Front brake caliper / Front master cylinder / Rear brake pads / Rear brake caliper / Rear master cylinder / Rear brake pedal / Brake system bleeding / Brake disc / Specifications

CHAPTER FIFTEEN / BODY
Side covers / Seat / Radiator covers / Fuel tank / Headlight cowl / Engine covers / Skid plate / Subframe / Specifications

COLOR WIRING DIAGRAMS

Models covered:
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 Suzuki DR-Z400E DRZ400E DRZ 400 400E E
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 Suzuki DR-Z400S DRZ400S DRZ 400S DRZ 400 S
2005 2006 2007 2008 2009 2010 2011 2012 Suzuki DR-Z400SM DRZ400SM DRZ 400SM 400 SM

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Clymer Suzuki DR-Z400S Online Manual
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Dual Sport Dualsport

Print Manual
DR-Z400E (2000-2012)
DR-Z400S (2000-2012)
DR-Z400SM (2000-2012)

Online Manual
DR-Z400E (2000-2009)
DR-Z400S (2000-2009)
DR-Z400SM (2000-2009)

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