Suzuki DR-Z400 Repair Shop Manual 2000-2010 Haynes 2933

20 Мар 2015 | Author: | Комментарии к записи Suzuki DR-Z400 Repair Shop Manual 2000-2010 Haynes 2933 отключены
Suzuki DR Dual-Purpose

Suzuki DR-Z400, DR-Z400E, DR-Z400SM Repair Manual by Haynes

Item Description of Contents Specifications

The 2000-2010 DR-Z400 DIY repair manual by covers the following models:

DR-Z400 (Kick Start),

Suzuki DR-Z400E (Electric 2000-2009

Suzuki DR-Z400S

Suzuki DR-Z400SM 2005-2010

dual-purpose bikes are powered by single-cylinder, liquid-cooled, 4-…

Book Excerpt: 2000-2010 DR-Z400, DR-Z400E, DR-Z400S, Repair Manual


Before installing the new rings, the ring end gaps be checked.

Insert the top (No. 1) into the bottom of the first and square it up with the cylinder by pushing it in with the top of the piston. The should be about one-half above the bottom edge of the

To measure the end gap, slip a gauge between the ends of the (see illustration) and compare the to the Specifications.

If the gap is larger or smaller specified, double check to sure that you have the rings before proceeding.

If the gap is too it must be enlarged or the ring may come in contact with other during engine which can cause serious

The end gap can be increased by filing the ring very carefully with a file (see illustration). performing this operation, only from the outside in.

the procedure for the second compression (ring gap is not specified for the oil ring or spacer).

Once the ring end gaps been checked/corrected, the rings can be on the piston.

The oil control ring on the piston) is installed first. It is of three separate components. the spacer into the groove, install the upper side (see illustrations).

Do not use a piston installation tool on the oil ring rails as they may be damaged. place one end of the side rail the groove between the spacer and the ring land.

Hold it in place and slide a finger the piston while pushing the into the groove (taking not to cut your fingers on the sharp

Next, install the lower rail in the same manner.


motorcycles use a one-piece handlebar, to the upper triple clamp by and lower brackets.

On all except models, the lower brackets are with the upper triple The SM lower brackets are secured to the triple clamp by mounting which are threaded on the bottom and to the upper triple clamp by

Before removing the handlebars, for a punch mark indicating the of the handlebar in the brackets and another one which end of the bracket faces (see illustration). Make own mark if you can’t see one.

If the must be removed for access to components, such as the forks or the head, remove the bracket (see illustration) and lift off the and remove the handlebar.

It’s not necessary to disconnect the wires or hoses, but it is a good to support the assembly with a of wire or rope, to avoid strain the cables, wires and (on the side) the brake hose.

the handlebar for cracks and distortion and it if any undesirable conditions are found.

is the reverse of removal, with the additions:

If you removed the lower from a DR-Z400SM model, the bracket nuts to the torque in this Chapter’s Specifications.

all four bracket bolts to one-half of the torque listed in Chapter’s Specifications. Then the forward bolt on each to the torque listed in this Specifications, then tighten the bolts to the specified torque. will leave a gap at the rear of the (see illustration).

Don’t try to close the gap by tightening the further or the brackets will



Identification numbers

Buying parts

Pre-ride checks

oil level

Brake fluid

Suzuki DR Dual-Purpose


Bike specs

Routine maintenance and servicing

Lubricants and fluids


Component locations



Engine, and transmission

Cooling system

and exhaust systems

Ignition and systems

Wiring diagrams


Tools and workshop




2000, 2001, 2002, 2004, 2005, 2006, 2008, 2009, 2010 DR-Z400 off-road bike maintenance, repair. ISBN-10: | ISBN-13: 9781563929335 | Haynes

Suzuki DR Dual-Purpose
Suzuki DR Dual-Purpose
Suzuki DR Dual-Purpose
Suzuki DR Dual-Purpose
Suzuki DR Dual-Purpose
Suzuki DR Dual-Purpose

Interesting articles

Other articles of the category "Suzuki":

Our partners
Follow us
Contact us
Our contacts

Born in the USSR


About this site

For all questions about advertising, please contact listed on the site.

Motorcycles catalog with specifications, pictures, ratings, reviews and discusssions about Motorcycles.