USE THIS MANUAL WITH: DR-Z400S SERVICE MANUAL (99500
Contents
1. Front axle pinch bot SIMI _ oas no Seat rail mounting nut uppe AIT 885255 _ Seat rail mounting NOT 8 35 255 _ Rear sprocketnut SZ Drive chain roller mounting bolt upper amp lower Spoke front amp rear Swingarm pivot nut Rear shock absorber spring adjuster lock ring 43 5 upper amp lower Cushion lever mounting nut center Cushion lever mounting nut front Cushion rod mounting nut 28 DR Z400SMK5 05 MODEL FRONT AXLE 9 10 1 0 kgf m 7 0 Ib ft DR 2 n 09941 34513 Bearing installer 09913 70210 Bearing installer set DR Z400SMK5 705 MODEL 29 REAR AXLE 9 3 0 kgf m 21 5 Ib ft 4 10 N m AH 1 0 7 0 Ib ft 8 LC lt f 2275 09 d ECT For E 03 28 33 100 N m 10 0 kgf m 72 5 Ib ft The others 110 11 0 kgf m 79 5 Ib ft m gt Right Clearance 09941 34513 Bearing installer set 30 DR Z400SMK5 05 MODEL FRONT BRAKE HOSE ROUTING yoyorsq eui jo episino epin6 esou exeiq 195 Jejeujeip esou exeJq Jaddn duno 9 Ou JO 1u0JJ u exeiq 9U 195 1u04J OU JO episino esou exeiq2. tet ein 12V21Wx4 Brake ol y uti conc tine rr 12V 21 5 W speedometer QI ios ux LED Neutral indicator light LED High beam indicator light LED TRIE SIG Mal Indicator LED Water temperature warning light LED CAPACITIES Fuel tank including reserve 9 5 L 2 5 2 1 US Imp gal E 33 10 0 L 2 6 2 2 US Imp gal Others pce sso eaP eee 2 3 L 0 6 0 5 US Imp gal Engine oil oil change 1 700 ml 1 8 1 5 US Imp qt with filter change 1 800 1 9 1 6 US Imp qt OVERHAUL c E T Y 1 900 ml 2 0 1 7 US Imp qt Goola nti g E DEP 1 3 L 1 4 1 1 US Imp qt These specifications are subject to change without notice DR Z400SMK5 705 MODEL 3 SERVICE DATA VALVE GUIDE Unit mm in Tappet clearance when cold 36 1 42 29 1 14 0 10 0 20 0 0039 0 0079 0 20 0 30 0 0079 0 0118 Valve guide to valve stem clearance 0 010 0 037 0 0004 0 0015 0 030 0 057 0 0012 0 0022
3. Loosen and remove the fork bolt sub tank from the outer tube and slowly slide down the outer tube 09941 53630 Front fork top cap wrench WARNING Face the oil hole on the sub downward e Raise the outer tube and temporarily tighten the fork cap bolt 1 sub tank to the outer tube 14 0 24005 5 05 MODEL e Clamp the axle holder 2 with a vise Protect the axle holder ka surface using a rag Loosen the center bolt 3 completely with a 21 mm socket wrench WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight Compress the outer tube by hands and install the conrod holder special tool between the axle holder bottom 2 and locknut 4 09910 20115 Conrod holder e Hold the locknut with a wrench and remove the center bo e Remove the push rod DR Z400SMK5 705 MODEL 15 e With the outer tube compressed by hands remove the special tool Removing the locknut 4 and pushing the inner rod thread into the damper rod will damage the inner rod oil seal Do not remove the locknut 2 from the inner rod e Loosen the fork cap bolt D sub tank and remove the sub tank along with the damper rod assembly e Remove the fork spring Disassembling the damper rod assembly can lead to trouble Do not disassemble the damper rod assembly Do not separate th
4. ONISSVd NYOH l To cam HOLIMS MIS HOLOIN HOLN T19 w lt HOLIMS 3X4VH8 YALYVLS dOLS 3NION3 HO LIMS HYVES 10NVH Y O 9 9 NWA NA Iq1 67 Ig g 1 LHDIT 1VN5IS NYNLLNOYS NOILISOd Na Wa 1g 1g 67 LHDIT TVNDIS LNOtid 51 5 8 Wa 1H917 101ld HILIWOGI3IdS 1 YOLVOIGNI TVNSIS NHNL L LHDIT YOLVOIGNI TVH IQ3N LHDIT YOLVOIGNI INVA 1H917 9NINHVM dIN31 H3 1VM DR Z400SMK5 705 MODEL 33 E 03 28 33 YOLVYANAD ualdiLoad HO1V 1n93H HOLOIN YALYVLS AVTIH xoaasna 9 V 0 2 LL LHDIT 1VN5IS NHNL HV3H m 1 GUT T Mi 15 ig E x Wa d Ig Wa d Ig IHOSITIIVL LHOT1 35 VH8 qr wa 67 EEH med LHSIT 5 NYNL HV3H 8 2220 w lt LINN 1 HOLIAS HOSN3S HOLIMS LHDIT dial HOLIMS NOILISOd H3LVM 31LIOHHL HOLIMS QNVLIS 3GIS HOLIMS LH9I1 NOLLNG HOLIMS INOHJ YALYVLS dOLS ANIDNA 5 HYVES 10NVH HOLIMS HOLIAS 5 TWYULNAN H21f 192 xog 35 4 1 HOLIMS HV831dNVH HOLIMS LHDIT TWNDIS NHNL HOLIMS OJOJOT NOLLN
5. Compression damping force adjuster Standard setting 13 clicks turn back REBOUND DAMPING FORCE ADJUSTMENT e Turn the adjuster screw clockwise until it stops full hard posi tion the adjuster screw counterclockwise 17th position is the standard position Rebound damping force adjuster Standard setting 17 clicks turn back DRIVE CHAIN ADJUSTMEN Remove the cotter pin For E 03 28 e Loosen the axel nut Loosen the locknuts and adj specification by turning the right and left adjuster plates scales 5 With the adjusters 3 held in position tighten the locknuts Push the adjuster plates to the adjusters 3 and tighten the axel nut W Axel nut 100 N m 10 0 kgf m 72 5 Ib ft For E 03 28 33 110 N m 11 0 kgf m 79 5 Ib ft For the other countries Tighten the locknut 2 NOTE After installing the rear axel nut insert a new cotter pin into the rear axel For E 03 28 33 DR Z400SMK5 05 MODEL 2 TIGHTENING TORQUE CHASSIS WEM Nm _ Steeringstemheadnut _ 9o 650 Brake pad mounting pin front amp rear Brake caliper plug front amp rear 25 025 1 8 Brake air bleeder valve front amp rear IEEE Rear brake rod locknut 187 N lt as 130 Rear brake pedal bolt Brake disc mounting bolt front amp rear CF dq 70 Fonaxemt
6. SUZUKI DR Z400SM SUPPLEMEN LAF AR WE b USF 71115 MANUAL WITH UR Z400S SERVICE MANUAL 99500 43034 01E MANUAL DR Z400SMK5 05 MODEL DR Z400SMK5 05 MODEL FOREWORD This manual describes service data service specifications and servicing procedures which dif fer from those of the DR Z400SK5 05 model NOTE Any differences between the DR Z400SK5 05 and DR Z400SMK5 05 model in specifications and service data are indicated with an asterisk mark Please refer to the Service Manual for details which are not given in this manual CONTENTS SPECIFICATIONS u u es SERVICE DATA Dua FRONT FORK DRIVE CHAIN ADJUSTMENT TIGHTENING TORQUE FRONT AXLE REAR AXLE FRONT BRAKE HOSE HEAR BRAKE HOSE RC m WIRING DIA E E E COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s COUNTRY or AREA EFFECTIVE FRAME NO U K JS1B8111100100001 E U JS1B8111200100001 U S A Except for california JS1SK44A 52100001 Canada JS1SK44A 52100001 California U S A JS1SK44A 52100001 E U 5188211100100001 SUZUKI MOTOR CORPORATION COPYRIGHT SUZUKI MOTOR CORPORATION 2004 1 2 DR Z400SMK5 05 MODEL SPECIFICATIONS DIMENSIONS AND DRY MASS Ov ralllength a
7. ae 2 225 mm 87 6 in Overall WIGU ago 870 mm 34 3 in Overall tata eae 1185 mm 46 7 in Mn rene 1460 mm 57 5 in Ground DT 260mm 10 2 in ien 890 mm 35 0 in POV oe ua 134 kg 295 bs E 03 28 33 135kgo 297lbs Others ENGINE ER Four stroke liquid cooled DOHC Number of cylinders s sms cto tapete eid oder obe ELLE 1 slope of 90 0 3 543 1 SOK EEN 62 6 2 465 Displacement 398 cm 24 3 in 510 us a n a 11 3 1 Carburetor re pakana Seen LX e deme SaNay Sa ons MIKUNI BSR36 single AVE eleane OAR OLDEST usq Polyurethane foam element Starter systema Sonn eio SS Electric Lubrication LEE LEDERE Dry sump IGG speed H 1 500 100 r min DRIVE TRAIN MUG LEDE FEDE amana Wet multi plate type SION usu 5 speed constant mesh G arshift p tte aaa A 1 down 4 Primary reduction peuct Fr eater toe exdass edu E Te qur
8. 195 Se qeo epioJui OU JO u asoy exeJq 195 2 enbJoj 5 yoq UOIUN esou exeiq eui 1 reubis ueuDn ueu Jaddojs esou eui pue esou exeJq 195 e qeo uoinio sou 9XeJq 10014 19158 exelg e qeo 9 HOS DR Z400SMK5 705 MODEL 31 REAR BRAKE HOSE ROUTING After touching the brake hose union to the stopper tighten the union bolt to the specified torque 2 Insert the reservior hose until dead end Hose guide gt Brake hose x CC 32 DR Z400SMK5 05 MODEL WIRING DIAGRAM E 02 19 YOLVYANAD 31411999 IHOLVINDIH HOLIMS TWUHULNAN xog 3514 Acl e xog asna V 0 EE 197 D A 9 Wea d 1 LHD 1VN5IS NHNL HV3H Ma 9 9 Wa Ma 19 Jg IHOITIIVL LH9I1I 3XVH8 am 64 LHDIT TVNDIS NHNL HV3H 5 2 lt e2urSo8o lt 100 gt A A NO LINN 1 2 HOLIMS HOSN3S HOLIMS LHDIT dial HOLIMS NOILISOd HV3H d3lVM NOILINDI GION 10S HOLIMS GNV1S 3qIS HOLIMS LHOI1 1 HO LIMS HYVES 10NVH HOLIMS LHDIT TVWNDIS NYNL HOLIMS ECJEN IO 017 65 7
9. IN amp EX 01 4 Valve guide IN amp EX e mu 0 1959 965 4 9 49707 EXE wees L ee D mem ss I DSE 0 035 0 043 001 Valve spring free length lt 12 3 en E m Valve spring tension 64 N IN amp EX INNER 5 6 6 4 kof 12 3 14 1 at length 27 4 mm 1 08 in 126 145 N OUTER 12 6 14 5 kgf 27 7 32 0 Ibs at length 30 9 mm 1 22 in 4 DR Z400SMK5 05 MODEL CAMSHAFT CYLINDER HEAD Unit mm in Cam height N 36 490 36 540 36 190 1 4366 1 4386 1 4248 35 790 35 840 35 490 X 1 4091 1 4110 1 3972 0 019 0 053 0 150 IN amp EX 0 0007 0 0021 0 0059 22 012 22 025 0 8666 0 8671 21 972 21 993 amp 0 8653 0 8659 Camshaft runout 0 10 0 004 Cam chain pin at arrow 15th pin Camshaft journal oil clearance Camshaft journal holder Camshaft journal O D Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 Eu 0 002 CYLINDER PISTON PISTON RING lt S Unit mm in ITEM STANDARD LIMIT Compression pressure 504 7 ui Piston to cylinder clearance 0 030 40 040 0 120 ae 0 0012 0 0016 0 0047 Cylinder bore X 90 000 90 015 Nicks or oa P 3 5433 3 5439 scratches Piston diam lt 89 965 89 980 3 5419 3 5425 3 5386 c Me
10. NHOH mima HOLIMS HOLON r 00 Doe 2g x Iq1 51 Ig g 1 LHDIT 1VN5IS NYNLLNOYS 61 LHOI11VN5IS NYNL LNOH4 u g 67 5 8 Wa 51 9 0 LO Tld HILIINOGI3IdS 1 YOLVOIGNI TVN9IS NYNL L YOLVOIGNI 1 N HOLVDIGNI INV38 9NINHVM dIN31 H3 LVM M Prepared by SUZUKI MOTOR CORPORATION Printed in Japan x K5
11. 0 6 Drive 9 thickness 2 92 3 08 2 62 No 1 amp No 2 0 115 0 121 0 103 Drive plate claw width 13 7 13 8 13 2 No 1 amp No 2 0 539 0 543 0 520 Driven plate distortion 0 10 0 004 Clutch spring free length 49 9 1 96 6 DR Z400SMK5 705 MODEL TRANSMISSTION DRIVE CHAIN Unit mm in Except ratio Primary reduction ralo 2860748 Final reduction raio Tamm Gear ratios 2 285 32 14 O md 1733900 1 375 22 16 Lm 4h 100Qa4p Tp O809 l2 0 004 0 012 0 020 amp No 3 0 189 0 193 amp No 3 0 181 0 185 Drive chain tpe Rezo length 12 57 Drive chain slack 0 CARBURETOR Pa ATLL USPECIFICATION OS TREY Eo32 Carburetortype 22 MRUNIBSR ee Boese LDNo 26 Nedejt NJ PM lt Pilot air je PAS Pilot screw PS ACE M DR Z400SMK5 05 MODEL 7 THERMOSTAT RADIATOR FAN ENGINE COOLANT Th Sm valve opening temper Approx 75 C 167 F Thermostat valve lift Over 6 mm 0 24 in at 90 194 F Engine coolant temp switch oper OFF ON Approx 117 243 ee as ON OFF Approx 100 C 212 F Radiator cap valve opening pres 95 125 kPa sure 0 95 1 25 kgf cm 13 5 17 8 psi Cooling fan thermo switch operat OFF ON Approx 96 205 F ON OFF App
12. ts 2 960 74 25 Gear n u aS o Dae 2 285 32 14 p mE 1 733 26 15 C M Mm 1 375 22 16 Aaa M d drca EET Final reduction ratio s Drive Chalk tem CHASSIS Front 5 scopic spring oil damped Rear suspension coil spring oil damped Front suspension stroke 280 mm 10 2 in Rear wheel travel irent cux ul en io pine co i 276 mm 10 9 in E CRUS tated Masts Nes rei ome ds 26 15 aec c M 94 mm 3 70 in Steering anglesa AM dc cd e dE 38 right amp left u Rr p eR 2 6 m 8 5 ft Front DESKO accu SSS Disc brake Rear brake eres Disc brake mireig SSS ES SE A 120 70R17M C 58H tube type Rear SIZE etr 140 70R17M C 66H tube type ELECTRICAL qmi io x suu e a ee Electronic ignition CDI NE EP 7 at 1 500 r min Spark OU NGK CR8E or DENSO U24ESR N E Ia EET ENE MDC Three phase generator piii pc RE Ud De 20A sic MCCC mee Pm 12 V 21 6 kC 6 Ah 10 HR Headlight m 12 60 55 W TUurnsignal lig At
13. 1 0 Ib ft 99000 32050 THREAD LOCK 1342 e Loosen and remove the fork cap bolt sub tank from the outer tube and slowly slide down the outer tube 09941 53630 Front fork top cap wrench Pour the specified amount of fork oil into the outer tube Oil quantity 350 ml 11 83 12 32 US Imp oz 99000 99001 SS5 SUZUKI FORK OIL SS 05 e Raise the outer tube and temporarily tighten the fork sub tank 09941 53630 Front fork top cap TN DR Z400SMK5 705 MODEL 25 INSTALLATION Install the front fork with the line D aligned with the upper sur face of the upper bracket e Check that the air valve is positioned at the front Tighten the fork lower clamp bolts to the specified torque 9 Fork lower clamp bolt 23 N m 2 3 kgf m 16 5 Ib ft e Tighten the fork cap bolt sub tank to 09941 53630 Front fork top 9 Fork cap bolt 35 N m 3 5 kc e Install the handlebar Install the front wheel e Install the brake caliper R Z400SY 6 45 e Check that the front fork protectors move smoothly If not loosen and adjust the protector guide INSPECTION AFTER INSTALLATION e Front fork C7 DR Z400SY 2 23 e Steering C77 DR Z400SY 2 23 e Front brake hose routing C7730 26 DR Z400SMK5 05 MODEL COMPRESSION DAMPING FORCE ADJUST MENT e Turn the adjuster screw clockwise until it stops full hard posi tion e Turn the adjuster screw counterclockwise 13th position is the standard position
14. TANDARDISPEGIICATION Front fork stroke d 260 C NE EN Front fork inner tube O D Front fork spring free length 450 441 17 7 17 3 Front fork oil type SUZUKI FORK OIL SS 05 or an equivalent fork oli Front fork oil capacity each leg OUTER 350 ml 11 830 12 324 US Imp oz INNER 182 ml 6 152 6 408 US Imp oz Front fork damping force adjuster 17th clicks turn back Pp 13th clicks turn back Rear shock absorber gas pressure 981 kPa 9 81 kgf cm 139 psi pre set length 10 Rear shock absorber damping 14th clicks turn back High speed 1 and 1 8 turns out Low speed 10th clicks turn back Rear wheel travel 276 10 9 Swingarm pivot shaft runout 0 3 0 01 DR Z400SMK5 705 MODEL 9 ELECTRICAL Unit mm in ITEM SPECIFICATION NOTE 0 7 0 8 Over 8 mm 0 3 in at 1 atm Generator coil resistance 13 5 15 0 5 000 Starter relay resistance BRO Battery Type designation V N YT7B BS ss __ Capacity NM 2 2 6 6 Fuse size WATTAGE CY Unit W Le SPECIFICATION E 02 19 E 03 28 33 Headlight m 215 LED O1 UU U U 10 DR Z400SMK5 705 MODEL FUEL OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or 91 octane or higher rated by the research method Gasoline containing MTBE Methyl T
15. asure at 15 mm 0 6 in from the skirt end Cylinder distortion ud 0 05 0 002 Piston ring free end gap 151 6 9 0 27 5 5 0 22 2 RC Approx 11 5 0 45 0 36 Piston ring end gap 151 0 08 0 20 0 50 0 003 0 008 0 020 2nd 0 08 0 20 0 50 0 003 0 008 0 020 Piston ring to groove clearance ist 0 180 0 007 0 150 9 68 Piston ring groove width 0 78 0 80 er 0 0307 0 0315 d 1 30 1 32 0 0512 0 0520 __ 0 81 0 83 0 0319 0 0327 2 01 2 03 0 0791 0 0799 DR Z400SMK5 05 MODEL 5 STANDARD UMT Piston ring thickness 0 71 0 76 0 0280 0 0299 0 0425 0 0433 0 77 0 79 Piston pin bore 20 002 20 008 20 030 0 7875 0 7877 0 7886 Piston pin O D 19 995 20 000 0 7872 0 7874 CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT Conrod small end 20 010 20 018 20 040 0 7878 0 7881 0 7890 Conrod deflection 3 0 2 E 2 big side clearance 0 6 30 0 6 0 012 0 02 0 04 Conrod big end width 22 00 866 Crank web to web width m Crankshaft runout 503 OIL PUMP STANDARD NE Oil pump reduction ratio Coe 2 220 74 25 x 20 16 x 12 20 Oil pressure at 60 C 140 F Above 40 kPa 0 4 5 7 psi Below 140 kPa 1 4 kgf cm 19 9 psi at 3 000 r min CLUTCH Unit mm in Clutch cable play 10 15 0 4
16. e outer tube for dent If it is dented all the way to the inner side replace it with a new one Measure the inner tube runout using the V blocks and dial gauge Inner tube runout Service Limit 0 4 mm 0 02 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block DAMPER ROD e Inspect the damper rod assembly for scratches or b it has scratches or is bent replace it with a new o FORK SPRING Measure the free length of front fork spring Service Limit 441 mm 17 36 in DR Z400SMK5 705 MODEL 19 SLIDE BUSHING AND GUIDE BUSHING Inspect the teflon coating metals slide bushing and guide bushing for wear or damage If they are worn or damaged replace them with new ones PFN N Inspect the metal particles on the teflon coating metals If they are not clean clean them with a nylon brush and fork oil us qu REASSEMBLY NOTE Clean all fork parts before reassembling Replace the O rings oil seal and dust seal with the new ones Apply specified front fork oil when installing the O rings slide bushing guide bushing damper unit and other sliding parts INNER TUBE Apply front fork oil to the oil seal lip and the dust seal Cover the inner tube with a plastic film e Install the following parts to the inner tube New dust seal 7 Stopper ring 2 New oil seal p MN Scratches on the oil sea anccause oil leaks When installing the s
17. e sub tank and damper rod assem bly Remove the dust seal 8 and the stopper ring 9 9 k Scratches on the inner tube could cause oil leaks Avoid scratching when removing 16 DR Z400SMK5 05 MODEL INNER TUBE Separate the inner tube out of the outer tube Remove the slide bushing from the inner tube Hemove the following parts from the inner tube Guide bushing Seal retainer 2 Oil seal 3 Stopper ring Dust seal e Clamp the bottom flat part of the sub tank with a vise Do not clamp the sub tank too tight Loosen the compression damper unit DR Z400SMK5 05 MODEL Remove the compression damper unit from the sub tank NOTE Slowly compress the inner rod until it stops so that the compres sion damper unit can be removed easily e Drain the fork oil from the damper rod assembly by moving the inner rod several strokes INSPECTION CENTER BOLT e Inspect the adjuster rod of the center age If it is COMPRESSION DAMPER UNIT Inspect the compression damper unit for damage If it is dam aged replace it with a new one Replace the O ring with a new Disassembling the compression damper unit can lead to trouble Do not disassemble the compression damper unit 17 18 DR Z400SMK5 705 MODEL INNER TUBE AND OUTER TUBE Inspect the inner tube for scratches If it has scratches replace it with a new one e Inspect th
18. eals place a plastic film over the bushing attachment groove and edges of the inner tube to avoid damaging the seals lip NOTE The side of the oil seal that has a mark should face the dust seal e Remove the plastic film and install the seal retainer 4 guide bushing and slide bushing 6 e Clean the parts and keep them free from dust NOTE Inspect the bushings for burrs If there is a burr remove it with a knife taking care not to peel off the teflon coating If the bush ings have a large crack or excessive play after installing them replace them with new ones e Insert the inner tube into the outer tube 20 DR Z400SMK5 05 MODEL Install the new oil seal 3 with the special tool until the stopper ring groove of the outer tube can be seen 09940 52861 Front fork oil seal installer set e Attach the stopper ring securely to the stopper ring groove of the outer tube Attach the dust seal D NOTE After attaching the dust seal make sure that there are no cracks around the circumference of the seal Cracks could allow water mud and the like to enter and cause an oil leak Use of grease as a substitute fork oil when installing the oil seal can result in an oil leak Applying grease to the dust seal and oil seal can cause dirt to accumulate and damage the dust seal lip and oil seal lip lt Use only a thin coat of fork oil on the oil seal Pi COMPRESSION DAMPER UNIT e Cl
19. ean each threaded part before inst Wing e With the damper rod in fully extended position pour the spec ified amount of fork oil Fork oil quantity Inside the damper rod 182 ml 6 152 6 408 US Imp oz 99000 99001 SS5 SUZUKI FORK OIL SS 05 DR Z400SMK5 05 MODEL 21 Apply fork oil to the O rings and bushing on the compression damper unit e With the damper rod held immovable in fully extended tion gently install the compression damper unit to the sub tank al e Clamp the bottom flat part of the sub tank with a vise Do not clamp the sub tank too tight Tighten the compression damper unit to the specified torque Q Compression damper unit 30 N m 3 0 kgf m 21 5 Ib ft With the damper rod held in vertical position slowl inner rod several strokes Tighten the locknut by hand completely With the damper rod held in vertical position compress the damper rod fully to discharge an excess of oil Protect the inner rod end with a rag when compress ing the damper rod NOTE Set the compression damper setting to the softest 22 DR Z400SMK5 05 MODEL Force out the remaining oil discharged oil using compressed air completely With the damper rod in horizontal position move the inner rod by hand to inspect it if operating smoothly If the inner rod is not extend repeat the COMPRESSION DAMPER UNIT procedures Pour the specified amount fork
20. ertiary Butyl 03 28 33 Ether less than 1096 ethanol or less than 596 methanol with appropriate cosolvents and corro sion inhibitor is permissible Fuel tank capacity including 9 5L reserve 2 5 2 1 US Imp qt 10 0L 2 6 2 2 US Imp qt The others 2 3 L SAE 10W 40 API SF SG or SH SJ with JASO MA DR Z400SMK5 05 MODEL 11 FRONT FORK CONSTRUCTION 12 DR Z400SMK5 05 MODEL REMOVAL e Place a block under the chassis tubes Remove the fork protectors brake hose guide and brake hose clamp e Remove the front brake caliper e Remove the front wheel e Remove the handlebars e Loosen the front fork cap bolt 1 2 turns to facilitate latera assembly 09941 53630 Front fork top cap TN Loosen the front fork upper clamp bolts D Hold the fork body and loosen the fork lower clamp bolts 2 Remove the front fork DR Z400SMK5 705 MODEL 13 DISASSEMBLY Set rebound and compression damper settings to the mini mum settings softest before disassembling Record the set ting before turning the adjuster e Thoroughly clean the fork before disassembly Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak Avoid scratching or damaging the inner tube or the oil seal Use a mild detergent or car wash soap and sponge out dirt with plenty of water e Clamp the outer tube with a vise Protect the outer tube sur face using a rag TOOL
21. oil and discharge an excess of oil C 5 21 e Make sure approx 10 mm 0 39 in of inner rod thread exposed on the end Approx 10 mm 0 39 in Completely wipe off the fork oil from the spring and damper rod assembly e Insert the spring and damper rod assembly into the fork Temporarily tighten the fork cap bolt sub tank 09941 53630 Front fork top cap wrench TOOL e Clamp the axle holder with vise Protect the axle holder with a rag when using a vise WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight Compress the outer tube by hands and install the conrod holder special tool between the axle holder bottom and lock nut 09910 20116 Conrod holder e Insert the push rod into the inner rod Insert the AA shaped projection of center bolt into the push rod e Turn the locknut counterclockwise until it contacts with the center bolt e With the locknut held immovable using a wrench tighten the locknut center bolt to the specified torque V Locknut center bolt 23 N m 2 3 kgf m 16 0 Ib ft e With the outer tube compressed by hands remove the special tool DR Z400SMK5 05 MODEL 23 o 1 24 DR Z400SMK5 05 MODEL Apply THREAD LOCK 1342 to the center bolt Tighten the center bolt to the specified torque 9 Center bolt 70 N m 7 0 kgf m 5
22. rox 91 C 196 F Engine coolant type Use an anti freeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50 Engine coolant capacity 1 250 ml 1 3 1 1 US Imp qt pe BRAKE WHEEL Unit mm in me E Brake lever play Brake disc thickness Brake disc runout 12 700 12 743 0 5000 0 5017 12 700 12 743 ned 0 5000 0 5017 12 657 12 684 Front 0 4983 0 4994 12 657 12 684 Rear 0 4983 0 4994 27 000 27 050 Front 1 0630 1 0650 27 000 27 050 1 0630 1 0650 26 918 26 968 1 0598 1 0617 26 900 26 950 peat 1 0591 1 0610 Brake fluid type DOT 4 Wheel runout 0 08 20 Master cylinder bore Master cylinder piston diam Brake caliper cylinder bore Brake caliper piston diam 8 DR Z400SMK5 705 MODEL 0 010 Hear 0 010 Wheel rim size Rom mesmas oo Rer i7MWCxMT450 TIRE Cold inflation tire pressure 175 kPa 1 75 25 psi Pp 0291920910 200 kPa 2 00 kgf cm 29psi Cold inflation tire pressure 175 kPa 1 75 25 psi Pp Pua Nang 225 kPa 2 25 33 ps Tire size Front 1207ORIAMCSBH _ Rear 140 70R17WC 66H Tire type Rom DUNLOPDAOFSM 1 U o S S uM 68 SUSPENSION aa NNNM Unit mm in TEM T 1 S
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