Suzuki drz400e manual free download.Suzuki drz 400E Manuals
Looking for:
Suzuki drz400e manual free download |
Suzuki drz400e manual free download
You need to be a member in order to leave a comment. Share More sharing options Followers 5. Recommended Posts. MIcheyGee Posted October 15, Posted October 15, Link to comment Share on other sites More sharing options Posted October 15, edited.
Edited October 15, by bumtarder. Posted October 16, SwiftTone Posted November 19, Posted November 19, NOTE: If the cylinder head does not come off easily, lightly tap it using a plastic mallet. Remove the cylinder head gasket 1 and dowel pins 2. Remove the cam chain guide 3. DR-Z Remove the starter drive gear cover 1 and starter drive gear 2. DR-ZE Remove the generator rotor cover. DR-ZE Remove the starter driven gear 3 , dowel pins 4 , and gasket 5. Remove the oil filter cap 6 and oil filter 7.
Remove the clutch cover. Remove the right crankcase cover. Remove the dowel pins 1 and gasket 2. Loosen the clutch spring set bolts working in diagonal stages, and then remove them when they are fully loosened. Remove the push rod, spring washer, and spring washer seat.
Flatten the clutch sleeve hub washer. Hold the clutch sleeve hub using the special tool, and then remove the clutch sleeve hub nut. Remove the cam chain tensioner 1 and cam chain 2. Remove the retainer 3, spacer 4 and kick starter driven gear 5. DR-Z Remove the kick starter assembly 6. DR-Z Remove the kick starter guide 7.
Remove the pin 3 and oil pump assembly. Do not remove the circrip A, before separating the crankase to prevent the oil pump idle gear shaft from dropping into the crankcase. Hold the generator rotor using the special tool DR-Z or a mm offset wrench DR-ZE , and then remove the balancer driven gear nut.
Hold the generator rotor using the special tool DR-Z or a mm offset wrench DR-ZE , and then remove the primary drive gear nut. Remove the right crankcase securing bolts.
Separate the crankcase using the special tool. Remove the dowel pins. Remove the balancer shaft. Remove the crankshaft from the crankcase using the spe- cial tool. Organize the parts in their respective groups i.
Remove the intake pipe. Remove the valve spring seat. NOTE: Removal of valves completes ordinary disassembling work. If valve guides have to be removed for replacement after inspect- ing the related parts, carry out the steps shown in the valve guide servicing. If the runout ex- ceeds the service limit, replace the valve with a new one. Only oversized valve guides are available as replacement parts. Refinish the valve guide holes in the cylinder head using the valve guide reamer and handle.
Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.
Seat the pilot snugly. Rotate the cutter one or two turns. Measure the valve seat width W after every cut. Check that no gasoline leaks through the valve seat. If leakage is found, correct the sealing surface. Gasoline is highly flammable and explosive. Apply molybdenum oil solution to each oil seal and press-fit them into position. Do not reuse the oil seals.
Apply molybdenum oil solution to the valve as shown, and then insert them into the valve guides. When inserting each valve into the valve guides, make sure not to damage the lip of the oil seal.
It is not serviceable. If the automatic decompression weight does not operate smoothly, replace it with a new one. Take clearance read- ings at several places. If any clearance reading exceeds the ser- vice limit, replace the cylinder block with a new one. If any clearance reading exceeds the service limit, replace both the piston and piston rings. If the diameter exceeds the service limit, replace the piston with a new one.
If the runout ex- ceeds the service limit, replace the crankshaft with a new one. If an attempt is made to overhaul the oil pump assembly, the screw may be damaged. Only the oil pump unit is available as a replacement.
If any spring is not within the service limit, replace all of the springs with new ones. Pay special attention to the following points: NOTE: Before installing the gears, apply engine oil to the inner surface of each gear and bushing. Never reuse a circlip. After a circlip has been re- moved from a shaft, it should be discarded and a new circlip must be installed. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defec- tive and must be replaced with a new one as follows.
Install the right and left driveshaft bearings using the special tool. Replace the removed bearing with a new one. Install the left gearshift cam bearing. Page Oil Seals Install the oil seals into the crankcase, clutch housing case, and generator rotor cover.
Pay attention to the following points: Replace the removed oil seals with new ones. Pay special attention to the following points: NOTE: Apply engine oil to each running and sliding part before reas- sembling the engine. Page Crankcase Install the dowel pins to the left crankcase. Apply engine oil to the conrod big end and to the transmis- sion gears.
If a large resistance is felt to rotation, try to free the shafts by tapping them with a plastic mallet. When installing the balancer driven gear, align the pin 3 with the groove 4. Hold the generator rotor using the special tool DR-Z or a mm offset wrench DR-ZE , and then tighten the primary drive gear nut to the specified torque. Tighten the cam chain tensioner mounting bolt 2 to the speci- fied torque. Page 98 ENGINE Hold the clutch sleeve hub using the special tool, and then tighten the clutch sleeve hub nut to the specified torque.
Install the spring washer seat 1 and spring washer 2 onto the clutch sleeve hub correctly. Use a new gasket to prevent oil leakage. Tighten the right crankcase cover bolts securely. NOTE: The 1st 1 and 2nd 2 piston rings differ in shape.
The spacer and side rails do not have a designated top and bottom. They can be installed in any position. When installing the spacer, be careful not to allow its two ends to overlap in the groove. Hold each piston ring with the piston ring sections positioned correctly and put it into the cylinder.
Make sure that the piston rings are caught by the cylinder skirt. Tighten the cylinder head bolts to the specified torque. Also, apply engine oil to the camshaft journal holders. Place each camshaft into the correct position. Pay special attention to the following points: Apply engine oil to the push rod. Turn the adjusting screw clockwise with a flat-bladed screw- driver until the push rod is locked.
Fit a new gasket to the chain tension adjuster body. Disconnect the fuel hose. Keep heat, sparks, and flames away from gasoline. Remove the fuel valve. Replace the removed O-ring with a new one to pre- vent fuel leakage.
The fuel from the float chamber 2 is metered by the pilot jet 3 where it mixes with air coming in through the pilot air jet 4. The fuel in the float chamber 2 is metered by the main jet 3. The metered fuel enters the needle jet 4, mixes with the air admitted through the main air jet 5, and then forms an emulsion.
When the rider opens the throttle grip quickly, the intake air volume increases and air velocity at the bottom of the piston valve is slow and sucking volume of fuel is less.
The starter jet 2 meters this fuel, which then flows into the fuel passage 3 and mixes with the air coming from the float chamber. Disconnect the throttle cables. Disconnect the coasting richer pump hose. Loosen the carburetor clamp screws, and then remove the carburetor assembly. DR-Z Remove the throttle position sensor. Remove the accelerating pump assembly.
Replace the removed O-ring with a new one to prevent fuel leakage. Remove the throttle valve. Remove the intake joint. Replace the removed O-ring with a new one to prevent air leakage. Remove the float chamber. If any damages are found, replace the damaged parts with new ones. A high-capacity centrifugal pump is used for the water pump and a tube-and-fin type aluminum radiator, which is characterized by lightness in weight and good heat dissipation, is used.
Check the cooling system for leaks with a radiator tester 1. Remove the radiator cap and connect the radiator tester to the filler. Pressurize the cooling system with kPa 1.
The engine must be cool before servicing the cool- ing system. Rotate the inner race by hand to inspect it for abnormal noise and smooth rotation. If ab- normal noise occurs or if rough movement is noted, replace the water pump bearing with a new one. Remove the front axle nut 1 and loosen the front axle pinch bolts 2. Support the motorcycle with a jack or wooden block and re- move the front axle 3 and front wheel 4. Do not operate the brake lever during or after front wheel removal.
If any dam- age is found, replace the odometer gearbox with a new one. If any damage is found, replace the wheel hub dust seal with a new one. Insert the wedge bar 2 from the opposite side and lock it into the slit of the bearing remover attachment.
Drive out the wheel bearing by striking the wedge bar. Page Reassembly And Remounting First, install the left wheel bearing, and then install the right wheel bearing. Remove the front fork after loosening the front fork upper clamp bolts 3 and lower clamp bolts 4.
NOTE: Hold the fork inverted for a few minutes to drain the oil. Remove the push rod 1, needle 2, and return spring 3. Slowly pull out the inner tube. NOTE: Be careful not to damage the inner tube. Remove the oil seal 2 , oil seal retainer 3 , outer tube antifriction metal 4 inner tube antifriction metal 5, and oil lock piece 6. Pour the specified fork oil into the inner tube. Install the fork spring. Log in or Join. Adventure Rider.
Adrian V , Dec 8, Just got a DRZ and want to pick up a repair manual. Which is the best one to get and what's a good place to get it in Oz or overseas? Cheers, Adrian. PBee , Dec 8, Joined: Jun 4, Oddometer: 12, Location: Kersbrook. Aussie Trev , Dec 8, If you want I can copy off one for you and post it.
❿ ❿
Comments
Post a Comment