Comprehensive Maintenance Schedule for Suzuki DR-Z400
The Suzuki DR-Z400, in production since 2000, is a popular dual-sport motorcycle known for its versatility, reliability, and off-road capability. Featuring a liquid-cooled 398cc single-cylinder engine, the DR-Z400 is available in several variants, including the DR-Z400S (street legal), DR-Z400SM (supermoto), and DR-Z400E (off-road only).
Technical Specifications
First Generation (2000-2007)
- Engine: 398cc liquid-cooled single-cylinder 4-stroke
- Power: 39 hp @ 7,600 rpm
- Torque: 29 lb-ft @ 6,600 rpm
- Transmission: 5-speed
- Fuel Capacity: 2.6 US gal (10 L)
- Dry Weight: 291 lb (132 kg)
Second Generation (2008-present)
- Engine: 398cc liquid-cooled single-cylinder 4-stroke
- Power: 39 hp @ 7,500 rpm
- Torque: 29 lb-ft @ 6,500 rpm
- Transmission: 5-speed
- Fuel Capacity: 2.6 US gal (10 L)
- Curb Weight: 317 lb (144 kg)
Fluid Specifications
- Engine Oil:
- Type: SAE 10W-40 meeting API SF/SG or SH/SJ specs
- With Filter Change: 1.8 US qt (1.7 L)
- Without Filter Change: 1.6 US qt (1.5 L)
- Coolant:
- Type: Ethylene glycol antifreeze + distilled water (1:1 mix)
- Capacity: 1.3 US qt (1.2 L)
- Brake Fluid: DOT 4
- Fork Oil:
- Type: Suzuki SS-05 or equivalent
- Capacity: 16.2 oz (480 ml) per fork leg
Maintenance Schedule
| Item | Interval |
|---|---|
| Engine Oil & Filter | Change every 3,500 mi (5,600 km) or 6 months |
| Air Filter | Clean every 1,500 mi (2,400 km), replace if damaged |
| Spark Plug | Check every 4,000 mi (6,400 km), replace every 11,000 mi (18,000 km) |
| Valve Clearance | Check/adjust every 15,000 mi (24,000 km) |
| Coolant | Change every 2 years |
| Brake Fluid | Change every 2 years |
| Brake Pads | Check every 4,000 mi (6,400 km), replace if worn to limit |
| Drive Chain | Clean & lubricate every 500 mi (800 km), adjust slack if needed |
| Sprockets | Check for wear every 4,000 mi (6,400 km), replace if worn |
| Wheel Bearings | Check every 6,000 mi (9,600 km), repack if needed |
| Steering Head Bearings | Check every 6,000 mi (9,600 km), adjust if needed |
| Chassis Bolts & Nuts | Check tightness every 6,000 mi (9,600 km) |
Frequently Asked Questions
1. What type of oil does a DR-Z400 use?
- The DR-Z400 uses SAE 10W-40 oil that meets API SF/SG or SH/SJ specifications. The oil capacity with filter change is 1.8 US qt (1.7 L).
2. How often should I change the oil on my DR-Z400?
- Suzuki recommends changing the engine oil and filter every 3,500 miles (5,600 km) or 6 months, whichever comes first.
3. What is the valve clearance spec for the DR-Z400?
- The intake valve clearance should be 0.10-0.20 mm (0.004-0.008 in) and the exhaust valve clearance should be 0.20-0.30 mm (0.008-0.012 in). Valve clearance should be checked and adjusted every 15,000 miles (24,000 km).
4. How much coolant does a DR-Z400 hold?
- The DR-Z400 cooling system capacity is 1.3 US qt (1.2 L). Use a 1:1 mix of ethylene glycol antifreeze and distilled water.
5. What type of spark plug does the DR-Z400 use?
- The DR-Z400 uses an NGK CR8E or Denso U24ESR-N spark plug. The gap should be set to 0.024-0.028 in (0.6-0.7 mm).
6. How often should I clean the air filter?
- The air filter should be cleaned every 1,500 miles (2,400 km) and replaced if damaged. Clean more frequently if riding in dusty conditions.
7. What is the chain slack spec?
- The drive chain slack should be 1.6-2.0 in (40-50 mm) when measured at the midpoint between the sprockets. Adjust if needed.
8. How do I adjust the chain on my DR-Z400?
- Loosen the axle nut, turn the adjuster bolts evenly on both sides until the proper slack is achieved, then retighten the axle nut to 65 lb-ft (88 Nm).
9. What type of brake fluid does the DR-Z400 use?
- The DR-Z400 uses DOT 4 brake fluid. Fluid should be changed every 2 years.
10. How often should I repack the wheel bearings?
- Wheel bearings should be checked every 6,000 miles (9,600 km) and repacked with grease if needed. Inspect for any roughness, noise, or excessive play.
Following this maintenance schedule and using the proper fluids and parts will help keep your Suzuki DR-Z400 running reliably for many miles of on and off-road adventures. Consult your owner’s manual for more detailed information.
Sources of this Blog Post
General Information and Introduction
- Suzuki Motorcycles Australia – DR-Z400E: Provides an overview and specifications of the Suzuki DR-Z400E, highlighting its versatility and off-road capabilities.
- Wikipedia – Suzuki DR-Z400: Comprehensive information on the Suzuki DR-Z400, including its history, variants, and technical details.
- RevZilla – 2015 Suzuki DR-Z400SM Review: A review focusing on the Suzuki DR-Z400SM variant, discussing its features and performance.
Technical Specifications
- Suzuki Cycles – DR Series: Detailed technical specifications for various models in the Suzuki DR-Z400 series.
- ADV Rider – DR-Z400S Model Year Differences: Discussion on the differences between model years for the DR-Z400S.
- Autoevolution – Suzuki DR-Z: Specifications and information on different models within the Suzuki DR-Z series.
- Webike Japan – Suzuki DR-Z400SM: Specifications and maintenance information for the Suzuki DR-Z400SM.
Maintenance Schedule and FAQs
- Maintenance Schedule – Suzuki DR-Z400: Detailed maintenance schedule for the Suzuki DR-Z400, including service intervals and parts.
- ThumperTalk – DR-Z400S Oil Capacity: Community discussion on oil capacity and maintenance tips for the DR-Z400S.
- ADV Rider – DR-Z400 Maintenance: Forum discussion on maintenance practices and tips for the DR-Z400.
- YouTube – DR-Z400 Maintenance: Video guide on maintenance procedures for the Suzuki DR-Z400.
- Mad or Nomad – Suzuki DR-Z400S Review: Detailed review and maintenance tips for the Suzuki DR-Z400S.
- Vince Strang Motorcycles – DR-Z400E Service Manual: Official service manual providing detailed maintenance and repair procedures for the DR-Z400E.
- Reddit – DRZ400 Maintenance Schedule: Community discussion on the maintenance schedule for the DR-Z400.
These sources were used to compile an accurate and comprehensive maintenance schedule and specifications for the Suzuki DR-Z400, ensuring reliable information for owners and enthusiasts.