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11, 10 DR-Z400SMK5 (’05-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 Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible. E-03, 28, 33 Fuel tank capacity including reserve 9.5 L (2.5/2.1 US/lmp qt) E-…
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27, Suzuki 2005 DR-Z400SMK5 26 DR-Z400SMK5 (’05-MODEL) COMPRESSION DAMPING FORCE ADJUST- MENT • Turn the adjuster screw clockwise until it stops (full hard posi- tion). • Turn the adjuster screw counterclockwise. 13th position is the standard position. Compression damping force adjuster Standard setting: 13 clicks turn back REBOUND DAMPING FORCE ADJUSTMENT • Turn the adjuster screw clockwise until it stops (full hard posi- tion). • Turn the adjuster screw counterclockwise. 17th position is the standard position. R…
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33, Suzuki 2005 DR-Z400SMK5 32 DR-Z400SMK5 (’05-MODEL) WIRING DIAGRAM E-02, 19 ON OFF ON OFF ON OFF ON OFF L PUSH R OFF ON P HI LO PUSH PUSH FREE PUSH OFF RUN PUSH OFF ON WHNT FRONT TURN SIGNAL LIGHT (R) FRONT TURN SIGNAL LIGHT (L) POSITION LIGHT HEADLIGHT W H N T : WATER TEMP. WARNING LIGHT : HIGH BEAM INDICATOR LIGHT : NEUTRAL INDICATOR LIGHT : TURN SIGNAL INDICATOR LIGHT SPEEDOMETER PILOT LIGHT FRONT BRAKE LIGHT SWITCH ENGINE STOP SWITCH HANDLEBAR SWITCH (R) STARTER BUTTON IGNITION SWITCH WATER TEMP. SWITCH SIDE-STAND SWITCH REAR BRAKE LIGH…
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19, 18 DR-Z400SMK5 (’05-MODEL) INNER TUBE AND OUTER TUBE • Inspect the inner tube for scratches. If it has scratches, replace it with a new one. • Inspect the 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 • Inspect the damper rod assembl…
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32, DR-Z400SMK5 (’05-MODEL) 31 REAR BRAKE HOSE ROUTING Rear brake hose Hose guide 30˚ 21˚ Brake hose After touching the brake hose union to the stopper, tighten the union bolt to the specified torque. Insert the reservior hose until dead end. SAMPLE
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17, Suzuki 2005 DR-Z400SMK5 16 DR-Z400SMK5 (’05-MODEL) INNER TUBE • Separate the inner tube out of the outer tube. • Remove the slide bushing from the inner tube. • Remove the following parts from the inner tube. Guide bushing 1 Seal retainer 2 Oil seal 3 Stopper ring 4 Dust seal 5 • Clamp the bottom (flat part) of the sub-tank with a vise. • Loosen the compression damper unit. Do not clamp the sub-tank too tight. SAMPLE
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29, 28 DR-Z400SMK5 (’05-MODEL) FRONT AXLE 10 N·m (1.0 kgf-m, 7.0 lb-ft) 18 N·m 1.8 kgf-m 13.0 lb-ft 39 N·m 3.9 kgf-m 28 lb-ft ( ) ( ) Clearance 09941-34513: Bearing installer 09913-70210: Bearing installer set SAMPLE
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7, Suzuki 2005 DR-Z400SMK5 6 DR-Z400SMK5 (’05-MODEL) TRANSMISSTION + DRIVE CHAIN Unit: mm (in) Except ratio CARBURETOR ITEM STANDARD LIMIT Primary reduction ratio 2.960 (74/25) — Final reduction ratio * 2.733 (41/15) — Gear ratios Low 2.285 (32/14) — 2nd 1.733 (26/15) — 3rd 1.375 (22/16) — 4th 1.090 (24/22) — Top 0.863 (19/22) — Shift fork to groove clearance 0.1 – 0.3 (0.004 – 0.012) 0.5 (0.020) Shift fork groove width No. 1, No. 2 & No. 3 4.8 – 4.9 (0.189 – 0.193) — Shift fork thickness No. 1, No. 2 & No. 3 4.6 – …
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9, 8 DR-Z400SMK5 (’05-MODEL) TIRE SUSPENSION Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Wheel axle runout Front — 0.25 (0.010) Rear — 0.25 (0.010) Wheel rim size * Front 17M/C × MT 3.50 — * Rear 17M/C × MT 4.50 — ITEM STANDARD/SPECIFICATION LIMIT Cold inflation tire pressure (Solo riding) * Front 175 kPa (1.75 kgf/cm 2 , 25 psi) — * Rear 200 kPa (2.00 kgf/cm 2 , 29 psi) — Cold inflation tire pressure (Dual riding) * Front 175 kPa (1.75 kgf/cm 2 , 25 psi) — * Rear 225 kPa (2.25 kgf/cm 2 , 33 psi) — Tire size …
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10, DR-Z400SMK5 (’05-MODEL) 9 ELECTRICAL Unit: mm (in) WATTAGE Unit: W ITEM SPECIFICATION NOTE Spark plug Type DENSO: U24ESR-N NGK: CR8E Gap 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 mm (0.3 in) at 1 atm. Ignition coil resistance Primary 0.1 – 1.0 Ω Terminal – Ground Secondary 12 – 20 kΩ Plug cap – Terminal Ignition coil primary peak voltage More than 150 V +: B/W, -: B/Y Generator coil resistance Charging 0.5…
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30, DR-Z400SMK5 (’05-MODEL) 29 REAR AXLE 10 N·m (1.0 kgf-m, 7.0 lb-ft) For E-03, 28, 33 100 N·m (10.0 kgf-m, 72.5 lb-ft) The others 110 N·m (11.0 kgf-m, 79.5 lb-ft) RightLeft Right Left Spacer Clearance 09941-34513: Bearing installer set 30 N·m (3.0 kgf-m, 21.5 lb-ft) SAMPLE
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8, Suzuki 2005 DR-Z400SMK5 DR-Z400SMK5 (’05-MODEL) 7 THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Thermostat valve opening temper- ature Approx. 75 °C (167 °F) — Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) — Engine coolant temp. switch oper- ating temperature OFF→ON Approx. 117 °C (243 °F) — ON→OFF Approx. 100 °C (212 °F) — Radiator cap valve opening pres- sure 95 – 125 kPa (0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi) — Cooling fan thermo-switch operat- ing temperatur…
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6, DR-Z400SMK5 (’05-MODEL) 5 CONROD + CRANKSHAFT Unit: mm (in) OIL PUMP CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Piston ring thickness 1st 0.71 – 0.76 (0.0280 – 0.0299) — 1.08 – 1.10 (0.0425 – 0.0433) — 2nd 0.77 – 0.79 (0.0303 – 0.0311) — Piston pin bore 20.002 – 20.008 (0.7875 – 0.7877) 20.030 (0.7886) Piston pin O.D. 19.995 – 20.000 (0.7872 – 0.7874) 19.980 (0.7866) ITEM STANDARD LIMIT Conrod small end I.D. 20.010 – 20.018 (0.7878 – 0.7881) 20.040 (0.7890) Conrod deflection — 3.0 (…
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14, Suzuki 2005 DR-Z400SMK5 DR-Z400SMK5 (’05-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. • Thoroughly clean the fork before disassembly. • Clamp the outer tube with a vise. Protect the outer tube sur- face using a rag. • Loosen and remove the fork cap bolt (sub-tank) from the outer tube and slowly slide down the outer tu…
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15, 14 DR-Z400SMK5 (’05-MODEL) • Clamp the axle holder 2 with a vise. Protect the axle holder surface using a rag. • Loosen the center bolt 3 completely with a 21 mm socket wrench. • 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 • Hold the locknut with a wrench and remove the center bolt. • Remove the push rod. Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder to…
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1, 99501-43110-01E No. 10539 99501-43110-01E DR-Z400SM_01E Supply Cover14 for PS printing 2004.12.13 DR-Z400SM Printed in Japan K5 USE THIS MANUAL WITH: DR-Z400S SERVICE MANUAL (99500-43034-01E) Top Bottom
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23, 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 oil and discharge an excess of oil). (21) • Make sure approx. 10 mm (0.39 in) of inner rod thread is exposed on the end. • Completely wipe off…
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26, DR-Z400SMK5 (’05-MODEL) 25 INSTALLATION • Install the front fork with the line T aligned with the upper sur- face of the upper bracket. • Check that the air valve A is positioned at the front. • Tighten the fork lower clamp bolts to the specified torque. Fork lower clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Tighten the fork upper clamp bolts to the specified torque. Fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Tighten the fork cap bolt (sub-tank) to the specified to…
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3, 2 DR-Z400SMK5 (’05-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ......................................................................................* 2 225 mm (87.6 in) Overall width .......................................................................................* 870 mm (34.3 in) Overall height ......................................................................................* 1 185 …
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2, DR-Z400SMK5 (’05-MODEL) 1 CONTENTS DR-Z400SMK5 (’05-MODEL) © COPYRIGHT SUZUKI MOTOR CORPORATION 2004 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-model) 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 …
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4, DR-Z400SMK5 (’05-MODEL) 3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. IN. 36 (1.42) — EX. 29 (1.14) — Tappet clearance (when cold) IN. 0.10 – 0.20 (0.0039 – 0.0079) — EX. 0.20 – 0.30 (0.0079 – 0.0118) — Valve guide to valve stem clearance IN. 0.010 – 0.037 (0.0004 – 0.0015) — EX. 0.030 – 0.057 (0.0012 – 0.0022) — Valve stem deflection IN. & EX. — 0.35 (0.014) Valve guide …
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34, Suzuki 2005 DR-Z400SMK5 DR-Z400SMK5 (’05-MODEL) 33 E-03, 28, 33 ON OFF ON OFF ON OFF ON OFF L PUSH R OFF ON P HI LO PUSH PUSH FREE PUSH OFF RUN OFF ON WHNT FRONT TURN SIGNAL LIGHT (R) FRONT TURN SIGNAL LIGHT (L) HEADLIGHT W H N T : WATER TEMP. WARNING LIGHT : HIGH BEAM INDICATOR LIGHT : NEUTRAL INDICATOR LIGHT : TURN SIGNAL INDICATOR LIGHT SPEEDOMETER PILOT LIGHT FRONT BRAKE LIGHT SWITCH ENGINE STOP SWITCH HANDLEBAR SWITCH (R) STARTER BUTTON IGNITION SWITCH WATER TEMP. SWITCH SIDE-STAND SWITCH REAR BRAKE LIGHT SWITCH IGNITION COIL CDI UNIT THR…
