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  4. 2005 DR-Z400SMK5
  5. Supplementary Service Manual

Suzuki 2005 DR-Z400SMK5 Supplementary Service Manual

Summary of 2005 DR-Z400SMK5

  • Page 1

    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 k5 use this manual with: dr-z400s service manual (99500-43034-01e) top bottom.

  • Page 2: Dr-Z400Smk5 (’05-Model)

    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 (’...

  • Page 3: Specifications

    2 dr-z400smk5 (’05-model) specifications dimensions and dry mass overall length ......................................................................................* 2 225 mm (87.6 in) overall width .......................................................................................* 870 mm (34...

  • Page 4: Service Data

    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 – 0.00...

  • Page 5

    4 dr-z400smk5 (’05-model) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 36.490 – 36.540 (1.4366 – 1.4386) 36.190 (1.4248) ex. 35.790 – 35.840 (1.4091 – 1.4110) 35.490 (1.3972) camshaft journal oil clearance in. & ex. 0.019 – 0...

  • Page 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...

  • Page 7

    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...

  • Page 8

    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 t...

  • Page 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 ...

  • Page 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 k Ω plug ...

  • Page 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 wit...

  • Page 12: Front Fork

    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 sa mp le.

  • Page 13

    12 dr-z400smk5 (’05-model) removal • place a block under the chassis tubes. • remove the fork protectors, brake hose guide and brake hose 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- ...

  • Page 14

    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 ...

  • Page 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 locknu...

  • Page 16

    Dr-z400smk5 (’05-model) 15 • with the outer tube compressed by hands, remove the special tool. • loosen the fork cap bolt 1 (sub-tank) and remove the sub-tank 5 along with the damper rod assembly 6. • remove the fork spring 7. • remove the dust seal 8 and the stopper ring 9. Removing the locknut 4 a...

  • Page 17

    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-tan...

  • Page 18

    Dr-z400smk5 (’05-model) 17 • 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. • drain the fork oil from the damper rod assembly by moving the inner rod several strokes. Inspection cen...

  • Page 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...

  • Page 20

    Dr-z400smk5 (’05-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. Inspect the metal particles on the “teflon coating metals”. If they are not clean, clean them ...

  • Page 21

    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 • attach the stopper ring securely to the stopper ring groove of the outer tube. • attach the dust seal 1. Note:...

  • Page 22

    Dr-z400smk5 (’05-model) 21 • apply fork oil to the o-rings and bushing on the compression damper unit. • with the damper rod held immovable in fully extended posi- tion, gently install the compression damper unit to the sub-tank. • clamp the bottom (flat part) of the sub-tank with a vise. • tighten ...

  • Page 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 (po...

  • Page 24

    Dr-z400smk5 (’05-model) 23 • clamp the axle holder with a vise. Protect the axle holder with a rag when using a vise. • 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 • insert the push rod into ...

  • Page 25

    24 dr-z400smk5 (’05-model) • apply thread lock “1342” to the center bolt. • tighten the center bolt to the specified torque.  center bolt: 70 n·m (7.0 kgf-m, 51.0 lb-ft)  99000-32050: thread lock “1342” • loosen and remove the fork cap bolt (sub-tank) from the outer tube and slowly slide down the ...

  • Page 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, 1...

  • Page 27: Drive Chain Adjustment

    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 ...

  • Page 28: Tightening Torque

    Dr-z400smk5 (’05-model) 27 tightening torque chassis item n·m kgf-m lb-ft handlebar clamp bolt 23 2.3 16.5 front fork upper clamp bolt * 23 * 2.3 * 16.5 front fork lower clamp bolt * 23 * 2.3 * 16.5 steering stem head nut 90 9.0 65.0 front fork cap bolt * 35 * 3.5 * 25.5 front fork center bolt * 70 ...

  • Page 29: Front Axle

    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 sa mp le.

  • Page 30: Rear Axle

    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) right left right left spacer clearance ) 09941-34513: bearing installer set 30 n·m (3.0 kgf-m, 21.5 lb-ft) sa mp le.

  • Page 31: Front Brake Hose Routing

    30 dr-z400smk5 (’05-model) front brake hose routing ! " # $ master cylinder t ur n signal (l) clutch cab le br ak e hose f ront br ak e hose f ront f or k protector clutch cab le f ront br ak e hose f ront br ak e hose set the br ak e hose end betw een the hose stopper then tighen the br ak e hose u...

  • Page 32: Rear Brake Hose Routing

    Dr-z400smk5 (’05-model) 31 rear brake hose routing rear br ak e hose hose guide 30 ˚ 21 ˚ br ak e hose after touching the br ak e hose union to the stopper , tighten the union bolt to the specified torque . Inser t the reser vior hose until dead end. Sa mp le.

  • Page 33: Wiring Diagram

    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 ru n push off on wh nt fr ont turn signal light (r) fr ont turn signal light (l) position light headlight w h n t : w a ter temp . W arning light : high beam indica t or lig...

  • Page 34

    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 ru n off on wh nt fr ont turn signal light (r) fr ont turn signal light (l) headlight w h n t : w a ter temp . W arning light : high beam indica t or light : neutral indica t or light ...

  • Page 35

    Prepared by december, 2004 part no. 99501-43110-01e printed in japan 36 sa mp le.

  • Page 36

    Printed in japan k5 use this manual with: dr-z400s service manual (99500-43034-01e) top bottom.