Suzuki DR-Z400S 2001 User Manual

CHASSIS 6-1
CHASSIS
CONTENTS
EXTERIOR PARTS ......................................................................................................................................... 6- 2
REMOVAL ................................................................................................................................................. 6- 2
REMOUNTING .......................................................................................................................................... 6- 2
FRONT WHEEL .............................................................................................................................................. 6- 3
CONSTRUCTION .....................................................................................................................................6- 3
REMOVAL AND DISASSEMBLY ............................................................................................................. 6- 5
INSPECTION ............................................................................................................................................ 6- 6
REASSEMBLY AND REMOUNTING ....................................................................................................... 6- 8
FRONT FORK ................................................................................................................................................6-10
CONSTRUCTION ....................................................................................................................................6-10
REMOVAL AND DISASSEMBLY ............................................................................................................ 6-11
INSPECTION ........................................................................................................................................... 6-13
REASSEMBLY AND REMOUNTING ......................................................................................................6-14
SUSPENSION SETTING ......................................................................................................................... 6-16
STEERING ..................................................................................................................................................... 6-17
CONSTRUCTION ....................................................................................................................................6-17
REMOVAL AND DISASSEMBLY ............................................................................................................ 6-18
INSPECTION ........................................................................................................................................... 6-21
REASSEMBLY AND REMOUNTING ......................................................................................................6-21
REAR WHEEL ............................................................................................................................................... 6-24
CONSTRUCTION ....................................................................................................................................6-24
REMOVAL AND DISASSEMBLY ............................................................................................................ 6-26
INSPECTION ........................................................................................................................................... 6-27
REASSEMBLY AND REMOUNTING ......................................................................................................6-27
REAR SUSPENSION .................................................................................................................................... 6-30
CONSTRUCTION ....................................................................................................................................6-30
REAR SHOCK ABSORBER REMOVAL ................................................................................................6-32
REAR SHOCK ABSORBER INSPECTION ............................................................................................6-33
REAR SHOCK ABSORBER DISPOSAL ...............................................................................................6-33
REAR SHOCK ABSORBER REMOUNTING ......................................................................................... 6-34
REAR SHOCK ABSORBER DAMPING FORCE ADJUSTMENT ......................................................... 6-35
REAR SWINGARM AND CUSHION LEVER REMOVAL ....................................................................... 6-36
INSPECTION AND DISASSEMBLY .......................................................................................................6-37
REASSEMBLY AND REMOUNTING ......................................................................................................6-39
FINAL INSPECTION AND ADJUSTMENT ............................................................................................ 6-40
FRONT BRAKE ............................................................................................................................................. 6-41
CONSTRUCTION ....................................................................................................................................6-41
BRAKE PAD REPLACEMENT ................................................................................................................ 6-42
BRAKE FLUID REPLACEMENT ............................................................................................................ 6-43
BRAKE CALIPER REMOVAL AND DISASSEMBLY ............................................................................. 6-43
BRAKE CALIPER INSPECTION ............................................................................................................ 6-44
BRAKE CALIPER REASSEMBLY AND REMOUNTING .......................................................................6-45
BRAKE DISC INSPECTION ....................................................................................................................6-46
MASTER CYLINDER REMOVAL AND DISASSEMBLY ........................................................................ 6-47
MASTER CYLINDER INSPECTION .......................................................................................................6-48
MASTER CYLINDER REASSEMBLY AND REMOUNTING .................................................................. 6-48
REAR BRAKE ............................................................................................................................................... 6-50
CONSTRUCTION ....................................................................................................................................6-50
BRAKE PAD REPLACEMENT ................................................................................................................ 6-51
BRAKE FLUID REPLACEMENT ............................................................................................................ 6-52
BRAKE CALIPER REMOVAL AND DISASSEMBLY ............................................................................. 6-53
BRAKE CALIPER INSPECTION ............................................................................................................ 6-54
BRAKE CALIPER REASSEMBLY AND REMOUNTING .......................................................................6-54
BRAKE DISC INSPECTION ....................................................................................................................6-55
MASTER CYLINDER REMOVAL AND DISASSEMBLY ........................................................................ 6-55
MASTER CYLINDER INSPECTION .......................................................................................................6-56
MASTER CYLINDER REASSEMBLY AND REMOUNTING .................................................................. 6-57
6

Suzuki DR-Z400S 2001 Specifications

General

Bore x Stroke	90.0 mm x 62.6 mm
Compression Ratio	11.3:1
Ignition	Electronic ignition (CDI)
Transmission	5-speed constant mesh
Final Drive	Chain
Front Suspension	Telescopic, coil spring, oil damped
Rear Suspension	Link type, coil spring, oil damped
Front Tire	80/100-21
Rear Tire	120/90-18
Seat Height	935 mm (36.8 in)
Engine Type	398cc, 4-stroke, liquid-cooled, DOHC
Front Brakes	Single hydraulic disc
Rear Brakes	Single hydraulic disc
Ground Clearance	300 mm (11.8 in.)
Wheelbase	1, 485 mm (58.5 in)
Fuel Tank Capacity	10.0 L (2.6 US gal.)
Fuel System	Mikuni BSR36, single carburetor