TABLE OF CONTENTS QUICK REFERENCE DATA CHAPTER ONE / GENERAL INFORMATION Manual organization / Warnings, cautions and notes / Safety / Serial numbers / 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 CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP Fuel type / Pre-ride inspection / Engine break-in / Service intervals / Battery / Periodic lubrication / Maintenance and inspection / Tune-up / Valve clearance / Carburetor / 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 INDEX WIRING DIAGRAMS
MODELS COVERED
2000-2008 SUZUKI DR-Z400S
2005-2008 SUZUKI DR-Z400SM