Suzuki DR Dual-Purpose

Suzuki DR-Z400E, DR-Z400S, DR-Z400SM Repair Manual 2000-2012

Item Description Table of Contents Specifications

The 2000-2012 Suzuki DR-Z400E, DR-Z400S, DR-Z400SM repair and service manual by Clymer, covers the following dual-purpose motorcycles:

Suzuki DR-Z400E, 2000-2012

Suzuki DR-Z400S, 2000-2012

Suzuki DR-Z400SM, 2005-2012

Note: All DRZ400 models powered by Dual Overhead Camshaft (DOHC), 4-valve, 4-stroke, single-cylinder, liquid-cooled, dry sump engines.

Book Excerpt: 2000-2012 Suzuki DR-Z400E, DR-Z400S, DR-Z400SM Repair Manual


The drive chain must have adequate free play so it can adjust to swing arm movement. Too little free play can cause the chain to become tight and cause unnecessary wear to the components.

Too much free play can cause the chain to derail.

Support the motorcycle so it is vertical. The rear wheel can be on or off the ground.

Measure the free play in the bottom length of the chain (Figure 39) as follows:

Place a tape measure so it is stable and vertical below the chain midpoint.

Press the chain down and note where a chain link-pin aligns with the tape measure. Note the measurement.

Push the chain up and note where the same link pin aligns with the tape measures. Note the measurement.

The difference between the two measurements is the chain free play. Required free play is 40-50 mm (1.6-2.0 in.).

If necessary, adjust the free play on E and S models as follows:

Remove the cotter pin from the axle nut, and them loosen the nut (Figure 40).

Position both numbered chain adjusters (Figure 41) so the free play is correct. Both adjusters must be set identically and locked against the adjusting post. If increasing free play, push the wheel forward to take the play out of the adjusters.



Lubrication, Maintenance and Tune-up


Clutch and External Gearshift Linkage

Transmission and Internal Shift Mechanism

Fuel and Emission Systems

Exhaust System

Electrical System

Wheels, Tires and Drivetrain

Front Suspension and Steering

Rear Suspension


Body and Frame

Wiring Diagrams

Subject: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 Suzuki DR-Z400E, DR-Z400S, DR-Z400SM service, maintenance, repair. ISBN-10: 1599696169 | ISBN-13: 9781599696164 | Clymer M477-4

Above: Motor Bookstore customer’s 2005 Suzuki DRZ400SM, which he modified to include a full Yoshimura stainless exhaust, KN filter and jet kit, as well as Acerbis hand guards. Rockford,IL.

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