Page 1: ...SUZUKI DR Z400SM OWNER S MANUAL This owner s manual contains Important safety information Please read it carefully part No 99011 29F92 03 1 May 2006 Ci K J EN I I...
Page 2: ...easier or instructions clearer WARNINGs and CAUTIONs are manged like this The first part will describe a POTENTIAL HAZARD and WHAT CAN HAPPEN if you ignore the WARNING or CAU TION FOREWORD Motorcycli...
Page 3: ...r sold Suzuki Motor Corporation believes in conservation and pro tection of Earth s natural resources To that end we encourage every vehicle owner to recycle trade in or properly dis pose of as approp...
Page 4: ...RAFFIC 1 5 INSPECTION BEFORE RIDING 1 5 MOTORCYCLE SAFETY FOUNDATION S RIDING TIPS AND PRACTICE GUIDE HANDBOOK BE STREET SMART 1 6 CONCLUSION 1 6 SPECIAL SITUATIONS REQUIRE SPECIAL CARE 1 3 KNOW YOUR...
Page 5: ...elp your skull protect your intelll gence your memory your pel sonality and your life Your eyesight is equally valuable Wearing suitable eye protectior can help keep your visior unblurred by the wind...
Page 6: ...riding practices We lggest that you practice riding your motorcycle in a non traffic tuation until you are thoroughly liuniliar with your machine and its controls Again consider taking IH1e of the MS...
Page 7: ...g gloves strong boots that fit over the ankle long pants and a long sleeve shirt or jacket Experi enced riders often wear a kidney belt and chest or back protector for additional comfort and protec tl...
Page 8: ...pack out what you packed in Don t bothel wildlife Don t make your exhaust system noisier complaints about noise are one of the biggest threats to the future of our sport With every rider projecting a...
Page 9: ...percentage of oxygenate and whether Important additives arE present Such labels may providE enough information for you tc determine if a particular blend ot fuel meets the requirements listeeJ above...
Page 10: ...cy or rust IIIllIlJltlng performance f ngine Coolant I IIqine coolant should be used at III Illnes in your motorcycle s radi 1101 even if the temperature in VI 1111 area does not go down to the III 1...
Page 11: ...TION SWITCH 3 5 STEERING LOCK 3 6 INSTRUMENT PANEL 3 6 LEFT HANDLEBAR 3 14 RIGHT HANDLEBAR 3 15 FUEL TANK CAP 3 17 FUEL VALVE 3 18 CHOKE KNOB 3 19 GEARSHIFT LEVER 3 19 REAR BRAKE PEDAL 3 20 HELMET HOL...
Page 12: ...ndicator light i Instrument panel 6 Front brake fluid reservoir 7 Right handlebar switches 8 Front brake lever 9 Throttle grip 10 Fuel tank cap 3 2 II park plug I I lIel valve IICllOke knob I j IIIrot...
Page 13: ...I hlilse write your key numbers in 11111 box provided for your future 11IllIlllllce Ignition l l y IIl1mber Steering IGNITION SWITCH The ignition tions switch has 3 posi OFF position All electrical c...
Page 14: ...flickers with high tlrllll1ency to warn the rider of the PI stence of a trouble Neutral Indicator Light 2 1110 green light will come on when 1110 transmission is in neutral The 11 1111 will go off whe...
Page 15: ...adjust trip meter clock stop adjustable mode watch and timer SELECT button Push the select button for 3 sec onds to choose km h or mph 3 8 TRIP METER SUBTRACTION MODE SELECTION 1 Ei5 2 SET 3 4 Additio...
Page 16: ...the MODE TIME but ton to return to clock mode NOTE The clock uses battery fJower even though the ignition switch is turned off Remove the Jattery from the motorcycle when the motorcycle is off for mo...
Page 17: ...zero push the SET TIMEITRIP button 2 ffll IWI l lllIHI cv 1 2 IJ 4 TRIP METER ADJUSTMENT I he trip meter mileage changes d pending on front tire wear and qround traction Adjust the correc tion coeffic...
Page 18: ...switch to sound the horn RIGHT HANDLEBAR 2 _l iIJ I Engine Stop Switch position II Hl ignition circuit is off The IHjlne cannot start or run position IIIU ignition circuit is on and the IHjlne can run...
Page 19: ...III cap lock before installing cap Illrn the key clockwise and I nrnove it Only for California II open the fuel tank cap insert 1I1l ignition key into the lock and 1111 n it clockwise With the key st...
Page 20: ...the engine This can cause a fire or cause severe damage when you start the engine Always leave the fuel valve in the ON or RES position CHOKE KNOB Irl o c JRP Illl carburetor is equipped with a lloke...
Page 21: ...lIln stand is down and the trans IIllssion is in any gear other than rII lltral III side stand ignition interlock Witch works as follows 1 If the side stand is down and the transmission is in gear th...
Page 22: ...The com pression damping force is set on 13 clicks position at the factory The rebound damping force is set on 17 clicks position at the factory Unequal suspension adjust ment can cause poor handling...
Page 23: ...y and turn it out Fully turned In position provides stiffest damping force and turning out the adjuster will soften damp ing force Count the number 01 clicks from the fully turned in posi tion The low...
Page 24: ...f II OJ z c en m C m 0 n t z 0 z OJ m n 0 c m 2 z j j W N r OJ JJ m OJ m I TI Z 0 JJ Z m C JJ Z c en Z C G m I 0 Z...
Page 25: ...ve During break in opera tion all of the engine components will have mated together and seated Maintenance required as part of the initial service includes correction of all adjustments tightening of...
Page 26: ...Engine stop Correct level Engine oil Enough coolant in radiator system Cooling No leaks or damage Throttle Proper play Smootll response Quick retUnl to idle position Gearshift No damage lever Smooth o...
Page 27: ...s Warm 1 Confirm that the choke knob I in the OFF position 2 With the throttle grip in the fully closed position PUS the electric starter button NOTE Operation of the carburE tor choke system is not n...
Page 28: ...ble below shows ing point for each gear Shifting up schedule Gear position km h 1st 7 2nd 20 2nd 3rd 30 3rd 4th 40 4th 5th 50 Shifting down schedule miles h 12 19 25 31 Downshifting when engine speed...
Page 29: ...flat surface where it will not fal over 6 Turn the ignition key to thE OFF position I 7 Remove the keys A hot muffler can burn you The muffler will be hot enough to burn you for some time after stopp...
Page 30: ...6 4 maneuver the motorcycle and deal with quickly changing off road conditions and a passen ger or cargo may interfare with your movement If you lose control of the motorcycle both I you and the pass...
Page 31: ...ynamic affecting accessories are installed they should be mounted as low as possible as close to the motorcycle and as near the center of gravity as is feasible The mounting brackets and other attachm...
Page 32: ...ed the full length of the seat to change position to maneuver the motorcycle and deal with quickly changing off road conditions and a passen ger or cargo may interfere with your movement If you lose c...
Page 33: ...mechanic to do the mainte nance items marked with an asterisk You may perform the unmarked maintenance items by referring to the instructions in this section if you have mechanical experi ence If you...
Page 34: ...PAtH Air supply system I NOTE NOTE 1 Inspect and clean adjust replace or lubricate as nee essary R Replace T Tighten C Clean NOTE California model only and CA ONLY means that the items 0 the maintenan...
Page 35: ...t go to the neg ative terminal AIR CLEANER fhe air cleaner element must be kept clean to provide good engine power and gas mileage If you use your motorcycle under normal low stress conditions you sho...
Page 36: ...gine Carefully examine the air cleaner element for tears dur ing cleaning Replace it with a new one if it is torn f Clean any dirt or debris from inside the air cleaner case Be sure no dirt enters the...
Page 37: ...seat 4 I 1 m S Turn the fuel valve to the ON or RES position Ii Disconnect the fuel hose 7 Fuel spilled from the fuel hose can catch on fire Stop the engine before discon necting the fuel hose Keep fl...
Page 38: ...s motorcycle useE resistor type spark plug to avoio jamming electronic parts Improper spark plug selectior may cause electronic interfer ence with your motorcycle s igm tion system resulting ir motorc...
Page 39: ...cle on level ground on the side stand 2 Start the engine and allow it to idle for three minutes 3 Stop the engine and wait three minutes 4 Remove the oil filler cap The engine oil dipstick i 1I comes...
Page 40: ...d drain the engine oil into a drain pan Engine oil and exhaust pipes can be hot enough to burn you Wait until the oil drain plug and exhaust pipes are cool enough t o touch with bare hands efore drain...
Page 41: ...ly you need a tachometer If you do not have one ask your Suzuki dealer or a qualified mechanic to perform this adjust ment To adjust the idle speed r r j E r L 0 o CD 1 Start the engine and warm it up...
Page 42: ...to be replaced The condition and adjustment of the drive chain should be checked before each lise of the motorcycle Always fol low the guidelines below for inspecting and servicing the chain Riding wi...
Page 43: ...1 6 2 0 in of slack as shown Too much chain slack can I cause the chain to come off the sprockets resulting in an acci dent or serious damage to the motorcycle InSpect and adjust the drive chain slac...
Page 44: ...TION section Engine coolant must be fille up to the bottom of the infe hole 4 Tighten the radiator ca securely and then tighten th screw securely BRAKES This motorcycle has front and rear disk brakes...
Page 45: ...the reservoir Wipe up spills immediately Spilled brake fluid can damage painted surfaces and plastic parts Brake Pads FRONT I I J I i C REAR G G 11 Grooved wear limit line Inspect the front and rear b...
Page 46: ...d the road Follow these instructions Check tire condition and pressure and adjust pres sure before each ride Avoid overloading your motorcycle Replace a tire when worn to the specified limit or if you...
Page 47: ...repair replace ment and balancing because proper tools and experience are required Install tires according to the rotation direction shown by arrows on the sidewall of each tire SPOKE NIPPLE TIGHTNESS...
Page 48: ...burn you The muffler will be hot enough to burn you for some time after stopping the engine Wait until the muffler cools to avoid burns II 1 Ji_ j 1 Remove the bolts 1 and spark arrester 2 Use a brush...
Page 49: ...ilure to torque bolts and nuts properly could lead to an acci dent Torque bolts and nuts to the proper specifications If you are not sure of the proper pro cedure have your authorized SUZUKI dealer or...
Page 50: ...ke pads after installing the wheel can cause poor braking perfor mance and may result in an accident Before riding pump the brake repeatedly until the brake pads are pressed against the brake disks an...
Page 51: ...s to crack Tighten the screws only until they are snug Brake LightlTaillight FUSE To replace the brake light taillight 01 bulb follow the procedure below i o1 y U if If there is any electrical system...
Page 52: ...TI G lc z m 3 0 zen en t m en s t n m I s m nn I m n co co W I JJ o C OJ r m en I o o I Z G...
Page 53: ...m the drain hole c Turn the fuel valve lever to the ON position d Drain the fuel and tighten the drain screw e Push the electric starter but ton for several sec onds to crank the engine referring to t...
Page 54: ...STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE 9 2 PROCEDURE FOR RETURNING TO SERVICE 9 3 CORROSION PREVENTION 9 3 MOTORCYCLE CLEANING 9 5 INSPECTION AFTER CLEANING 9 6 9 1...
Page 55: ...ill1d crank the engine a few times 2 Drain the engine 011 thorouCJllly and refill the crankcase Wlttl fresh engine oil all thp WilY IIp to the filler hole 3 Cover the air cleaner Intake and the muffle...
Page 56: ...garage or if you frequently park it inside when wet your garage may be damp The high humidity may cause or accelerate corrosion A wet motorcycle may corrode even in a heated garage if the venti latio...
Page 57: ...ith wet brakes can be hazardous Wet brakes may not provide as much stopping power as dry brakes This could lead to an I accident I Test your brakes after washing I the motorcycle while riding at I slo...
Page 58: ...7 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seventh Street Sw Washington DC 20590 You can also obtain other information about motor vehicle safety from ht...
Page 59: ...educed Read owner s manual care fully J LOCATION OF LABELS Read and follow all of the warn ings labeled on your motorcycle Make sure you understand all of the labels Keep the labels on your motorcycle...
Page 60: ...CHASSIS Front suspension Inverted telescopic coil spring oil damped Rear suspension Link type coil spring oil damped Front suspension stroke 260 mm 10 2 in Rear wheel travel 276 mm 109 in 15 Trail 94...
Page 61: ...N AFTER RIDING TIPS AND PRACTICE CONSCIOUS ON F CLEANING 9 G c UIDE HANDBOOK 1 5 BAD WEATHER DAyS 1 4 FRONT SUSPENSION 3 22 INSPECTION BEFORE BESTREETSMART 1 FRONT WHEEL RIDING 1 5 4 3 N BRAKES 7 25 R...
Page 62: ...SIDE STAND IGNITION INTERLOCK SWiTCH 7 31 SPARK ARRESTER 7 32 SPARK PLUG 7 10 SPECIAL SITUATIONS REQUIRE SPECIAL CARE 1 SPOKE NIPPLE TIGHTNESS 7 31 STARTING OFF AND SHIFTING 5 3 STARTING THE ENGINE 5...
Page 63: ...hing Don t ride after consuming alcohol or other drugs Slow down on slippery sur faces unfamiliar terrain or when visibility is reduced Read owner s manual care fully 1 1 1 1 1111111111111111111111111...
