Suzuki 2005 DR-Z400SMK5 Supplementary Service Manual Download Page 1

Page: 1 / 36

9 9 5 0 1 - 4 3 1 1 0 - 0 1 E

No. 10539 99501-43110-01E DR-Z400SM_01E Supply Cover14 for PS printing 2004.12.13

DR-Z400SM

Printed in Japan

USE THIS MANUAL WITH:
DR-Z400S SERVICE MANUAL (99500-43034-01E)

Top

Bottom

Summary of Contents for 2005 DR-Z400SMK5

Page 1: ...9 9 5 0 1 4 3 1 1 0 0 1 E Z400SM USE THIS MANUAL WITH DR Z400S SERVICE MANUAL 99500 43034 01E...

Page 2: ...the Service Manual for details which are not given in this manual SPECIFICATIONS 2 SERVICE DATA 3 FRONT FORK 11 DRIVE CHAIN ADJUSTMENT 26 TIGHTENING TORQUE 27 FRONT AXLE 28 REAR AXLE 29 FRONT BRAKE H...

Page 3: ...spring oil damped Rear suspension Link type coil spring oil damped Front suspension stroke 260 mm 10 2 in Rear wheel travel 276 mm 10 9 in Caster 26 15 Trail 94 mm 3 70 in Steering angle 38 right left...

Page 4: ...5 0 014 Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 Valve stem O D IN 4 975 4 990 0 1959 0 1965 EX 4 955 4 970 0 1951 0 1957 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02...

Page 5: ...002 ITEM STANDARD LIMIT Compression pressure Automatic de comp actuated 950 kPa 9 5 kgf cm2 135 psi Piston to cylinder clearance 0 030 0 040 0 0012 0 0016 0 120 0 0047 Cylinder bore 90 000 90 015 3 5...

Page 6: ...12 Conrod big end side clearance 0 30 0 65 0 012 0 026 1 0 0 04 Conrod big end width 21 95 22 00 0 864 0 866 Crank web to web width 62 0 0 1 2 441 0 004 Crankshaft runout 0 08 0 003 ITEM STANDARD LIM...

Page 7: ...4 8 4 9 0 189 0 193 Shift fork thickness No 1 No 2 No 3 4 6 4 7 0 181 0 185 Drive chain Type RK520KZO Links 110 20 pitch length 319 4 12 57 Drive chain slack 40 50 1 6 2 0 ITEM SPECIFICATION E 02 19...

Page 8: ...radiator mixed with distilled water only at the ratio of 50 50 Engine coolant capacity 1 250 ml 1 3 1 1 US lmp qt ITEM STANDARD SPECIFICATION LIMIT Brake lever play 0 1 0 3 0 004 0 010 Rear brake peda...

Page 9: ...ront 1 6 0 06 Rear 2 0 0 08 ITEM STANDARD SPECIFICATION LIMIT Front fork stroke 260 10 2 Front fork inner tube O D Front fork spring free length 450 17 7 441 17 3 Front fork oil type SUZUKI FORK OIL S...

Page 10: ...ick up coil peak voltage More than 5 0 V Bl G Signal coil peak voltage More than 1 4 V B W Generator no load voltage When engine is cold More than 75 V AC at 5 000 r min Y Y Regulated voltage 13 5 15...

Page 11: ...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 33 10 0 L 2 6 2 2 US lm...

Page 12: ...DR Z400SMK5 05 MODEL 11 FRONT FORK CONSTRUCTION 23 2 3 90 9 0 45 4 5 18 1 8 16 5 65 0 32 5 13 0 25 5 21 5 16 5 50 5 35 3 5 30 3 0 23 2 3 70 7 0 0 N m ITEM kgf m lb ft N m ITEM kgf m lb ft SAMPLE...

Page 13: ...se clamp Remove the front brake caliper Remove the front wheel Remove the handlebars Loosen the front fork cap bolt 1 2 turns to facilitate later dis assembly 09941 53630 Front fork top cap wrench Loo...

Page 14: ...r tube 09941 53630 Front fork top cap wrench Place a drain pan under the front fork and drain fork oil NOTE Face the oil hole A on the sub tank downward Raise the outer tube and temporarily tighten th...

Page 15: ...ench 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...

Page 16: ...eal 8 and the stopper ring 9 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 4 from the inner rod Disassembling...

Page 17: ...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 wi...

Page 18: ...inner rod several strokes INSPECTION CENTER BOLT Inspect the adjuster rod of the center bolt for damage If it is damaged replace it with a new one Replace the O ring with a new one COMPRESSION DAMPER...

Page 19: ...ith 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 bl...

Page 20: ...ust seal Cover the inner tube with a plastic film Install the following parts to the inner tube New dust seal 1 Stopper ring 2 New oil seal 3 NOTE The side of the oil seal that has a mark should face...

Page 21: ...ould allow water mud and the like to enter and cause an oil leak COMPRESSION DAMPER UNIT Clean each threaded part before installing With the damper rod in fully extended position pour the spec ified a...

Page 22: ...mper unit to the specified torque Compression damper unit 30 N m 3 0 kgf m 21 5 lb ft With the damper rod held in vertical position slowly move the inner rod several strokes Tighten the locknut by han...

Page 23: ...he 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...

Page 24: ...the center bolt clockwise until resistance is felt and check the clearance between the locknut and center bolt to provide more than 1 mm 0 04 in Turn the locknut counterclockwise until it contacts wi...

Page 25: ...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 quan...

Page 26: ...o 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 torque 09941 53630 Front fork top cap wrench Fork cap bolt 35 N m 3 5 kgf m...

Page 27: ...andard setting 17 clicks turn back DRIVE CHAIN ADJUSTMENT Remove the cotter pin For E 03 28 33 Loosen the axel nut 1 Loosen the locknuts 2 and adjust the drive chain slack to the specification by turn...

Page 28: ...valve front rear 6 0 6 4 3 Rear brake rod locknut 18 1 8 13 0 Rear brake pedal bolt 29 2 9 21 0 Brake disc mounting bolt front rear 10 1 0 7 0 Front axle nut 39 3 9 28 0 Front axle pinch bolt 18 1 8...

Page 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...

Page 30: ...R 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 Right Left Right Left Spacer Clearance 09941 34513 Bearing installer set 30 N m...

Page 31: ...hose Set the brake hose end between the hose stopper then tighen the brake hose union bolt to the specified torque Set the brake hose in front of the throttle cables Set the brake hose outside of the...

Page 32: ...L 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 unt...

Page 33: ...l Y B B B O W B W B B R B R Br Br B W B W W B W B Gr Gr B W B W W B W B B B W B W B B W B W B B W B W Lg Lg B W B W Br Br B W B W Br Br B W B W B B W B W B B W B W B W Y B R R B W R B W R R W Bl W Y Y...

Page 34: ...W B W O W B W B Bl Bl Y B O W B W B B R B R Br Br B W B W W B W B Gr Gr B W B W W B W B B B W B W B B W B W B B W B W Lg Lg B W B W B B W B W B B W B W B W Y B R R B W R B W R R W Bl W Y Y Y R B W W B...

Page 35: ...Prepared by December 2004 Part No 99501 43110 01E Printed in Japan 36 SAMPLE...

Page 36: ......

Search results

Summary of Contents for 2005 DR-Z400SMK5

Reviews:

Related manuals for 2005 DR-Z400SMK5

Brands by name

Popular brands

Suzuki 2005 DR-Z400SMK5, Supplementary Service Manual

Search results

Summary of Contents for 2005 DR-Z400SMK5

Reviews:

Related manuals for 2005 DR-Z400SMK5

Brands by name

Popular brands