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TROUBLESHOOTING

1. 8 24 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page refer to this chart 7 marked bolt Bolt Diameter Conventional or 4 marked bolt mm N m kgf m lb ft kgf m 1 5 0 15 1 0 0 23 3 0 3 2 0 0 45 5 5 0 55 4 0 1 0 13 1 3 9 5 2 3 29 2 9 21 0 5 0 45 4 5 32 5 8 5 65 6 5 47 0 13 5 10 5 76 0 21 0 16 0 115 5 emm emr 1 4 marked bolt 7 marked bolt Conventional bolt SERVICE DATA VALVE GUIDE ITEM SERVICING INFORMATION 8 25 STANDARD Unit mm in Valve diameter 36 1 42 29 1 14 Tappet clearance when cold 0 10 0 20 0 0039 0 0079 0 20 0 30 0 0079 0 0118 Valve guide to valve stem clearance 0 010 0 037 0 0004 0 0015 0 030 0 057 0 0012 0 0022 Valve stem deflection Valve guide 1 0 5 000 5 012 0 1969 0 1973 Valve stem O D 4 975 4 990 0 1959 0 1965 4 955 4 970 0 1951 0 1957 Valve stem runout Valve stem thickness Valve seat width 0 9 1 1 0 035 0 043 Valve head radial runout Valve spring free length IN amp EX Valve spring tension IN amp EX 56 64 5 6 6 4 kgf 12 3 14 1 Ibs at length 27 4 1 08 in 126 145 12 6 14 5 kgf 27 7 32 0 Ibs
2. 5 Worn bearing Replace Clutch slips 1 Clutch cable out of adjustment Adjust 2 Weak or broken clutch spring Replace 3 Worn or distorted clutch pressure plate Replace 4 Distorted clutch plate Replace Clutch drags 1 Clutch out of adjustment Adjust 2 Some clutch springs are weak while others are not Replace 3 Worn or distorted clutch pressure plate Replace 4 Distorted clutch plate Replace Transmission will not 1 Broken gearshift cam Replace shift 2 Distorted gearshift fork Replace 3 Worn gearshift pawl Replace Transmission will not 1 Broken gearshift shaft return spring Replace shift back 2 Rubbing or stuck gearshift shaft Repair or replace 3 Worn or distorted gearshift fork Replace 8 4 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Transmission jumps 1 Worn gear Replace out of gear 2 Worn or distorted gearshift fork Replace 3 Weakened gearshift stopper spring Replace 4 Worn gearshift pawl Replace Engine idles poorly 1 Tappet clearance out of adjustment Adjust 2 Improper valve seating Repair or replace 3 Worn valve guide Replace 4 Worn camshaft Replace 5 Excessive spark plug gap Adjust or replace 6 Defective ignition coil Replace 7 Defective generator Replace 8 Defective CDI unit Replace 9 Incorrect float chamber fuel level Adjust float height 10 Clogged carburetor jet Clean Engine runs poorl
3. Front fork oil type SUZUKI FORK OIL SS 05 or an equivalent fork oil Front fork oil capacity each leg 720 ml 24 3 US oz 25 4 Imp oz Front fork damping force adjuster Rebound Compression 15 clicks out 12 clicks out Rear shock absorber gas pressure 900 kPa 9 0 kgf cm 128 psi Rear shock absorber oil type SUZUKI REAR SUSPENSION OIL SS 25 or an equivalent suspension oil Rear shock absorber oil capacity 380 ml 12 8 US oz 13 4 Imp oz Rear shock absorber spring pre set length 258 0 10 2 Rear shock absorber damping force ad juster Rebound 13 clicks out Compression 12 clicks out Rear wheel travel 295 11 6 Swingarm pivot shaft runout 8 32 SERVICING INFORMATION ELECTRICAL Unit mm in SPECIFICATION Spark plug NGK CR8E DENSO U24 ESR N 0 7 0 8 0 028 0 031 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance Primary 0 1 1 00 Terminal Ground Secondary 12 20 Plug cap Terminal Ignition coil primary peak voltage More than 150 V B W B Y Generator coil resistance Signal coil 0 05 0 20 0 B W Pickup coil 390 6000 G BI Charging coil 0 50 1 25 Q Y Y Pickup coil peak voltage More than 10 0 V BI G DR Z400 More than 5 0 V G DR Z400E Signal coil peak voltage More than 1 0 V W DR Z400 More than 1 4 V W DR Z400E Genera
4. 1 Distorted wheel rim Replace 2 Worn rear wheel bearing Replace 3 Defective or incorrect tire Replace 4 Worn swingarm bearing Replace 5 Loose rear axle nut Tighten 6 Loose rear suspension fastener Tighten Rear suspension too 1 Weak rear shock absorber spring Replace soft 2 Rear shock absorber leaks oil Replace 3 Improper suspension setting Adjust Rear suspension too 1 Improper suspension setting Adjust stiff 2 Bent rear shock absorber shaft Replace 3 Worn swingarm bearing and rear suspension related Replace bearing Rear suspension too 1 Loose rear suspension fastener Tighten noisy 2 Worn swingarm bearing and rear suspension related Replace SERVICING INFORMATION 8 7 BRAKES Complaint Symptom and possible causes Remedy Brake power insuffi 1 Leakage of brake fluid Repair or replace cient 2 Worn brake pad Replace 3 Oil on brake pad surface Clean brake disc and brake pads 4 Worn brake disc Replace Air in hydraulic system Bleed Brake squeaks 1 Carbon adhesion on brake pad surface Clean surface with sandpa per 2 Tilted brake pad Readjust brake pad position or replace 3 Damaged wheel bearing Replace 4 Worn brake pad Replace 5 Foreign material in brake fluid Change brake fluid 6 Clogged return port of master cylinder Disassemble and clean mas ter cylinder 7 Loose front or rear axle nut Tighten Brake lever or pedal 1 Air in hydraulic
5. 31921 Rotor remover set 09930 44913 Rotor holder 09940 14911 Steering stem nut wrench 09940 14960 Steering stem nut wrench socket 09940 34520 T handle 09940 34581 Attachment F 09940 52841 Front fork inner rod 09940 52861 Front fork oil seal installer Ki QN iw i Si 09940 54821 Front fork assem bly tool 09940 94922 Stopper plate 09941 34513 Bearing installer 09941 50111 Bearing remover 09941 54911 Bearing outer race remover 09941 74910 Bearing installer 09943 74111 Fork oil level gauge 8 22 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM Cylinder head cover bolt Spark plug Cylinder head bolt Cylinder head side bolt Cylinder nut Decompression shaft bolt DR Z400 Decompression shaft lever nut DR Z400 Camshaft journal holder bolt Balancer shaft nut Primary drive gear nut Generator rotor nut Clutch sleeve hub nut Gearshift arm stopper Gearshift cam driven gear bolt Cam chain tension adjuster bolt Cam chain tensioner mounting bolt Cam chain tensioner spring holder bolt Engine oil drain plug on the crankcase Engine oil drain bolt on the frame Engine oil lebel bolt Crankcase bolt Oil strainer on the frame Oil hose union bolt Radiator air bleeder bolt TDC plug Engine mounting nut Engine mounting bracket nut Exhaust pipe bolt and nut Muffler connection bolt Muffler mounting bolt Engine sprocket nut I
6. US qt 1 1 Imp qt 8 30 SERVICING INFORMATION BRAKE WHEEL Unit mm in ITEM STANDARD SPECIFICATION Rear brake pedal height 5 0 2 Brake disc thickness 3 0 0 2 Front 0 118 0 008 4 5 0 2 ear 0 177 0 008 Brake disc runout Front amp Rear 11 000 11 043 SE 0 4331 0 4348 12 700 12 743 Bear 0 5000 0 5017 Master cylinder piston diameter Eroni 10 957 10 984 0 4314 0 4324 12 657 12 684 0 4983 0 4994 Master cylinder bore Brake caliper cylinder bore 27 000 27 050 1 0630 1 0650 27 000 27 050 1 0630 1 0650 Brake caliper piston diameter 26 900 26 950 1 0591 1 0610 26 900 26 950 1 0591 1 0610 Brake fluid type DOT 4 Wheel rim runout Axial Radial Wheel rim size Front 1 60 x 21 Rear 2 15 x 18 Wheel axle runout Front Rear TIRE ITEM SERVICING INFORMATION 8 31 STANDARD SPECIFICATION Unit mm in Cold inflation tire pressure Solo riding Front 100 kPa 1 0 14 psi Rear 100 kPa 1 0 kgf cm 14 psi Tire size Front 80 100 21 51M Rear 110 100 18 64M Tire tread depth SUSPENSION ITEM Front Rear STANDARD SPECIFICATION Front fork stroke 288 11 3 Front fork spring free length 510 6 20 1 Front fork oil level without spring 122 4 8
7. mixture Adjust carburetor Generator does not 1 Open or short in lead wires or loose lead connections Repair replace or connect charge properly 2 Shorted grounded or open generator coil Replace 3 Shorted or punctured regulator rectifier Replace Generator charges 1 Lead wires tend to get shorted or open circuited or Repair or tighten but charging rate is loosely connected at terminal below the specifica 2 Grounded or open circuited stator coils or generator Replace tions 3 Defective regulator rectifier Replace 4 Defective battery cell plates Replace battery Generator over 1 Internal short circuit in the battery Replace battery charges 2 Damaged or defective regulator rectifier Replace 3 Poorly grounded regulator rectifier Repair replace or connect properly Unstable charging 1 Lead wire insulation frayed due to vibration resulting Repair or replace in intermittent shorting 2 Internally shorted generator Replace 3 Defective regulator rectifier Replace Starter button does 1 Run down battery Recharge or replace not work DR Z400E 2 Defective switch contact Replace 3 Brushes do not seat properly on the commutator in the Repair or replace starter motor 4 Defective starter relay Replace 5 Wiring connections loose or disconnected Tighten or repair SERVICING INFORMATION 8 9 BATTERY DR Z400E Complaint Symptom and possible causes Remedy Sulfation o
8. 0 21304 V block set 100 mm 09900 22301 Plastigauge 09900 22302 Plastigauge Thickness gauge 09900 22403 Small bore gauge 18 35 mm Tire depth gauge 09900 25008 Multi circuit tester set 09910 32812 Crankshaft installer 09910 60611 Universal clamp wrench 8 20 09913 50121 Oil seal remover SERVICING INFORMATION 09913 70210 Bearing installer set 09915 63310 Adapter 09915 64510 Compression gauge set 09915 70610 Adapter 09915 74510 Oil pressure gauge 09916 10911 Valve lapper set 09916 14510 Valve lifter 09916 14910 Attachment 09916 20610 Seat cutter N 121 09916 21110 Valve seat Cutter set 09916 22420 Valve seat cutter N 128 09916 22430 Valve seat cutter N 114 09916 24311 Solid pilot N 100 5 0 09916 34542 Reamer handle 09916 34570 Valve guide reamer 09916 34580 Valve guide reamer 10 8 mm 09916 44310 Valve guide remover 09916 53360 Valve guide in staller attachment 09916 84511 Tweezers 09920 13120 Crankcase separating tool 09920 53740 Clutch sleeve hub holder 09921 20210 Bearing remover 09921 20220 Bearing remover set 09923 73210 Bearing remover 09923 74510 Bearing remover 09924 84510 Bearing installer set 09924 84521 Bearing installer SERVICING INFORMATION 09925 18010 Steering bearing installer 8 21 09930 30102 Sliding hammer 09930
9. 1410 e 007Z HQ ajqeo asoy 3 ejqeo ao ejqe5 e qeo epouu r SERVICING INFORMATION 8 15 FUEL HOSE AND FUEL TANK MOUNTING Cushion Fuel hose To the carburetor 8 16 SERVICING INFORMATION OIL RETURN TANK HOSE ROUTING Breather hose Oil return tank To air cleaner q H Breather hose Breather hose Face the tip of clip to the front Face the tip of clip to the bottom 8 17 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING epis y Jo peeu eui 2224 apis xoeq eui 5 peau 2224 1u0JJ OU JO peeu eui 4 7 epis eui oi dijo jo 4 dij jo dy ayy eoe4 doi eui dijo jo dy e e4 emo1u esou esou EN X Se qeo Jo pessed snu esou 900 2 peel amp MIIA Joes asoy 2804 e qeo uoinio eui edid eui yono oq 8 18 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING After touching the bra
10. 2 505 E Boo w lt H m 5 z YOSNAS LINN 109 1109 HOLIMS NOILISOd 31LLOUHL NOILINDI 9015 SNIDNS 8 11 SERVICING INFORMATION DR Z400E 41123 01 10938 30194339 HOLIMS 49984 MOIISA 13921 SHUM 30101 1 15 0 49981 162 UUM JJA MOJI A e 431415 lt lt lt o 9 on Keay 5 uea 5 m EJ 8 m SHO109 SHIM puc a E E E 2 2 lt 2 2 5 D A e DU Na 19 lt 2 3 5 lt o 55 55 DH T e lt SE OO 557 mE E 30 35 LINN 109 1102 HOLIMS NOLLISOd H31V1S HOLIMS NOILISOd 31LLOUHL NOILINDI 83 31 HOLNTO 8015 SNIDNA SERVICING INFORMATION 8 12 30077 euw 5 apoase n oy peaj Ayed duet M3IA duer duer 300vZ HQ durej5 9Sn pue ueejeq Jejdnoo 195 plod uoua oi Jojjered euiuue 18S YOUMS uo
11. 8 2 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start 1 Worn cylinder Replace 2 Worn piston ring Replace 3 Worn valve guide or improper valve seating Repair or replace 4 Loose spark plug Tighten 5 Broken cracked or damaged piston Replace 6 Slow cranking starter motor DR Z400E See electrical section 7 Mistimed valves Adjust 8 Tappet clearance out of adjustment Adjust Spark plug not sparking 1 Damaged spark plug Replace 2 Damaged spark plug cap Replace 3 Fouled spark plug Clean or replace 4 Wet spark plug Clean and dry or replace 5 Defective ignition coil Replace 6 Open or short in high tension cord Replace 7 Defective generator Replace 8 Defective CDI unit Replace No fuel reaching the carburetor 1 Clogged fuel tank vent hose Clean or replace 2 Clogged or defective fuel valve Clean or replace 3 Defective carburetor needle valve Replace 4 Clogged fuel hose Clean or replace 5 Clogged fuel filter Clean or replace Engine stalls easily 1 Fouled spark plug Clean or replace 2 Defective generator Replace 3 Defective CDI unit Replace 4 Clogged or defective fuel valve Clean or replace 5 Clogged carburetor jet Clean 6 Tappet clearance out of adjustment Adjust SERVICING INFORMATION 8 3 Complaint Symptom and possible causes R
12. Primary reduction ratio 2 960 74 25 Final reduction ratio 3 357 47 14 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 Gearshift fork to gearshift fork groove 0 1 0 3 clearance 0 004 0 012 Gearshift fork groove width No 1 No 2 4 8 4 9 amp 3 0 189 0 193 Gearshift fork thickness No 1 2 4 6 4 7 amp No 3 0 181 0 185 Drive chain Type RK520KZO Links 112 20 pitch length Drive chain slack CARBURETOR ITEM SERVICING INFORMATION 8 29 SPECIFICATION DR Z400 DR Z400E E 01 E 03 28 E 01 E 03 28 Carburetor type KEIHIN FCR39H Bore size 39 mm 1 5 in 1 0 No 29F0 Idle r min 1800 100 r min Float height 9 0 1 0 mm 0 35 0 04 in Main jet 165 Main air jet Jet needle 200 OBDXP 4th Needle jet 2 9 mm 0 11 in Slow jet 45 Slow air jet 60 Air jet 90 Pilot screw 1 1 2 turns out RADIATOR ENGINE COOLANT ITEM STANDARD SPECIFICATION Radiator cap valve opening pressure 95 125 kPa 0 95 1 25 kgf cm 13 5 17 8 psi Engine coolant type Use an antifreeze coolant compatible with alumi num radiators mixed with distilled water only at the ratio of 50 50 Engine coolant capacity 1 250 ml 1 3
13. at length 30 9 mm 1 22 in 8 26 SERVICING INFORMATION CAMSHAFT CYLINDER HEAD STANDARD Unit mm in Cam height 36 910 36 960 1 4531 1 4551 36 880 36 930 1 4520 1 4539 Camshaft journal oil clearance 0 019 0 053 0 0007 0 0021 Camshaft journal holder Camshaft journal O D 22 012 22 025 0 8666 0 8671 21 972 21 993 0 8653 0 8659 Camshaft runout Cam chain pin at arrow 3 15th pin Cylinder head distortion Cylinder head cover distortion Decompression cable play DR Z400 CYLINDER PISTON PISTON RING ITEM STANDARD Unit mm in Compression pressure DR Z400E Automatic decompression actuated 1 000 kPa 10 0 kgf cm 142 psi Piston to cylinder clearance 0 030 0 040 0 0012 0 0016 0 120 0 0047 Cylinder bore 90 000 90 015 3 5433 3 5439 Nicks or scratches Piston diameter 89 965 89 980 3 5419 3 5425 Measure 15 0 6 from the skirt end 89 880 3 5386 Cylinder distortion 0 05 0 002 Piston ring free end gap Approximately 6 9 0 27 5 5 0 22 Approximately 11 5 0 45 9 2 0 36 Piston ring end gap Piston ring to piston ring groove clear ance 0 08 0 20 0 003 0 008 0 50 0 020 SERVICING INFORMATION 8 27 STANDARD Piston ring gr
14. emedy Engine is noisy Excessive valve chatter 1 Excessive tappet clearance 2 Weak or broken valve spring 3 Worn camshaft 4 Worn or burnt camshaft journal Noise seems to come from the piston 1 Worn piston 2 Worn cylinder 3 Carbon buildup in combustion chamber 4 Worn piston pin or piston pin bore 5 Worn piston ring or ring groove Noise seems to come from the cam chain 1 Stretched cam chain 2 Worn cam chain sprocket 3 Improperly working cam chain tensioner Noise seems to come from the clutch 1 Worn countershaft spline Worn clutch hub spline Worn clutch plate teeth Distorted clutch plate Weak clutch damper 6 Weak clutch spring oR WP Noise seems to come from the crankshaft 1 Rattling bearing 2 Worn or burnt crank pin bearing 3 Worn or burnt journal bearing 4 Excessive thrust clearance Noise seems to come from the transmission 1 Worn or rubbing gear Adjust Replace Replace Replace Replace Replace Clean Replace Replace Replace cam chain and sprockets Replace cam chain and sprockets Repair or replace Replace countershaft Replace clutch hub Replace clutch plate Replace Replace primary driven gear Replace Replace Replace Replace Replace thrust bearing Replace 2 Worn countershaft spline Replace countershaft 3 Worn driveshaft spline Replace driveshaft 4 Worn or rubbing primary gear Replace
15. ke hose union to the stopper tighten the union bolt to the specified torque Clamp 28 Front brake hose Set brake hose in front of clutch cable VIEW Align the green mark with the bottom end of After touching the brake hose union to the stopper tighten the Front brake caliper union bolt to the specified torque Set brake hose in front of throttle cable REAR BRAKE HOSE ROUTING Hose guide 30 brake hose VIEW After touching the brake hose VIEW union to the stopper tighten the union bolt to the specified torque Rear brake caliper Resevoir tank hose Master cylinder Rear brake hose After touching the brake hose union to the stopper tighten the union bolt to the specified torque SPECIAL TOOLS 09900 00401 Hexagon wrench a 0 9 09900 00410 Hexagon wrench 09900 06104 Snap ring pliers SERVICING INFORMATION 09900 06105 Snap ring pliers 8 19 09900 06108 Snap ring pliers 09900 09004 Impact driver set 09900 20101 Vernier calipers 09900 20103 Vernier calipers 09900 20202 Micrometer 25 50 09900 20204 Micrometer 75 100 09900 20205 Micrometer 09900 20508 Cylinder gauge set 09900 20602 Dial gauge 1 1000 mm 09900 20605 Dial calipers 1 100 mm 10 34 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand A 09900 20803 09900 20805 0990
16. nisod youms JOJOW JONES 300 Z Hd M3IA Wa SSB S ST AE esnj euda duer eufBu3 300rZ Hd pee 1UB II eL Sseueu Bu ee yoyms dois ends anels YOUMS uonisod duet WIRE HARNESS CABLE AND HOSE ROUTING WIRE ROUTING SERVICING INFORMATION 8 13 DR Z400 Generator lead wire DR Z400E d B VIEW Starter motor lead een T T T RTI SERVICING INFORMATION 8 14 CABLE ROUTING asoy 1eujeaJq Jo e eui 0 pue ejqeo jo asoy Jeujeauq 10 4 eui pessed eq ejqeo uo UI oi passed eq 1snui ejqeo uoinio e qeo HOU L SSOUIEY 8JIM PAS 3 asoy 10jeipeJ Jepun Ay passed eg snw ejqeo 1 EY esou pue pessed snu e qeo EX s n W SN 00 2 eiqeo e qeo opino 7 epmoJu M3IA YZ ORAS ue E OO yeddois Buas ejqeo Jaye e qeo uoinjo 1004 195 00vZ HQ 9 qeo uoisseJduioooq e qeo yno FSH ut 00 0 0 MIIA 170000 9 MIIA ejqeo Buruunje1 emouu p S U 210 59122179
17. ntake pipe union Fuel valve mounting bolt CHASSIS ITEM SERVICING INFORMATION 8 23 Handlebar clamp bolt Front fork upper clamp bolt Front fork lower clamp bolt Steering stem head nut Front fork cap bolt Front fork damper rod bolt Front fork inner rod locknut Front brake master cylinder mounting bolt Rear brake master cylinder mounting bolt Brake hose union bolt front amp rear Front brake caliper mounting bolt Brake pad mounting pin front amp rear Brake caliper plug front amp rear Brake air bleeder valve front amp rear Rear brake rod locknut Rear brake pedal bolt Brake disc mounting bolt front amp rear Front axle nut Front axle pinch bolt Seat rail mounting nut upper Seat rail mounting bolt lower Rear axle nut E 03 28 The other countries Rear sprocket nut Drive chain roller mounting bolt upper amp lower Spoke nipple front amp rear Swingarm pivot nut Rear shock absorber compression adjuster assembly Rear shock absorber spring adjuster lock ring Rear shock absorber mounting nut upper amp lower Cushion lever mounting nut center Cushion lever mounting nut front Cushion rod mounting nut Side stand bolt Side stand nut
18. oove width 0 78 0 80 0 0307 0 0315 1 30 1 32 0 0512 0 0520 0 81 0 83 0 0319 0 0327 2 01 2 03 0 0791 0 0799 Piston ring thickness 0 71 0 76 0 0280 0 0299 1 08 1 10 0 0425 0 0433 0 77 0 79 0 0303 0 0311 Piston pin bore 20 002 20 008 0 7875 0 7877 Piston pin O D CONROD CRANKSHAFT ITEM 19 995 20 000 0 7872 0 7874 STANDARD Unit mm in Conrod small end I D 20 010 20 018 0 7878 0 7881 Crank web to crank web width 62 0 0 1 2 441 0 004 Conrod deflection Conrod big end side clearance 0 30 0 65 0 012 0 026 Conrod big end width 21 95 22 00 0 864 0 866 Crankshaft runout OIL PUMP ITEM STANDARD Unit mm in Oil pump reduction ratio 2 220 74 25 x 20 16 x 12 20 Oil pressure at 60 C 140 F Above 40 kPa 0 4 5 7 psi Below 140 kPa 1 4 kgf cm 19 9 psi at 3000 r min 8 28 SERVICING INFORMATION CLUTCH Unit mm in ITEM STANDARD Clutch lever play 10 15 0 4 0 6 Clutch drive plate thickness 2 92 3 08 No 1 amp No 2 0 115 0 121 Clutch drive plate claw width 13 7 13 8 No 1 amp No 2 0 539 0 543 Clutch drive plate distortion Clutch spring free length TRANSMISSION DRIVE CHAIN Unit mm in Except ratio ITEM STANDARD
19. orn or damaged needle valve Replace level fluctuations Broken needle valve spring Replace Improperly working float Foreign matter on the needle valve Incorrect float chamber fuel level Adjust or replace Clean or replace with needle valve seat Adjust float height bearing 8 6 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Steering is heavy 1 Overtightened steering stem nut Adjust 2 Broken bearing in steering stem Replace 3 Distorted steering stem Replace 4 Low tire pressure Regulate Handlebar wobbles 1 Loss of balance between right and left front forks Adjust or replace 2 Distorted front fork Repair or replace 3 Distorted front axle Replace 4 Twisted tire Replace Front wheel wobbles 1 Distorted wheel rim Replace 2 Worn front wheel bearing Replace 3 Defective or incorrect tire Replace 4 Loose front axle nut Tighten 5 Incorrect fork oil level Adjust Front suspension too 1 Weak spring Replace soft 2 Insufficient fork oil Check level and add 3 Improper suspension setting Adjust Front suspension too 1 Excessively viscous fork oil Replace stiff 2 Excessive fork oil Check level and drain 3 Improper suspension setting Adjust Front suspension too 1 Insufficient fork oil Check level and add noisy 2 Loose front suspension fastener Tighten Rear wheel wobbles
20. r spots on 1 Cracked battery case Replace surfaces of cell 2 Battery has been left in a run down condition for along Replace plates time Battery runs down 1 Incorrect charging method Check generator regulator quickly rectifier circuit connections and make necessary adjust ment to obtain specified charging operation 2 Battery cell plates have lost much of their active mate Replace battery and correct rial as a result of overcharging charging system 3 Internally shorted battery Replace 4 Excessively low battery voltage Charge 5 Battery is too old Replace 6 Dirty container top and sides Clean Battery sulfation 1 Incorrect charging rate Replace When not in use the battery should be checked at least once a month and properly charged if necessary to avoid sulfation 2 The battery was left unused in a cold climate for too Replace the battery if badly long sulfated SERVICING INFORMATION 8 10 WIRING DIAGRAM DR Z400 MOJJ9A 19204 OVUM 30709 SHIM AHOITTIVL 3391934 304 7 934 301933 39 Dee 5 2 lt lt lt lt lt lt 5 2 lt lt lt E L 19 o A 4 lt E
21. rain SERVICING INFORMATION 8 5 Complaint Symptom and possible causes Remedy Engine overheats 1 Carbon buildup on piston crown Clean 2 Insufficient amount of engine oil Check level and add 3 Defective oil pump Replace 4 Clogged oil circuit Clean 5 Float chamber fuel level too low Adjust float height 6 Air leakage from intake pipe Tighten or replace 7 Incorrect engine oil Change CARBURETOR Complaint Symptom and possible causes Remedy Starting difficulty 1 Clogged starter jet Clean 2 Clogged starter jet passage Clean 3 Air leaking from joint between starter body and carbu Tighten adjust or replace retor gasket 4 Air leaking from carburetor joint or vacuum hose joint Tighten or replace defective part 5 Improperly working starter enricher plunger Adjust Idling or low speed trouble Clogged or loose pilot jet Clogged or loose pilot air jet Clean or tighten Clean or tighten 3 Air leaking from carburetor joint vacuum pipe joint or Tighten or replace defective starter part 4 Clogged pilot outlet port Clean 5 Clogged bypass port Clean 6 Starter enricher plunger not fully closed Adjust Medium high 1 Clogged main jet Clean speed trouble 2 Clogged main air jet Clean 3 Clogged needle jet Clean 4 Improperly working throttle valve Adjust 5 Clogged fuel filter Clean or replace Overflow and fuel W
22. system Bleed stroke excessive 2 Insufficient brake fluid Check level and add Bleed any air 3 Incorrect brake fluid Change Brake fluid leaks 1 Loose connection joint Tighten 2 Cracked hose Replace 3 Worn piston seal Replace 4 Worn secondary cup Replace Brake drags Rusty part Insufficient brake lever or brake pedal pivot lubrication Clean and lubricate Lubricate 8 8 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1 Defective ignition coil Replace sparking 2 Defective spark plug Replace 3 Defective generator Replace 4 Defective CDI unit Replace Spark plug is wet or 1 Excessively rich air fuel mixture Adjust carburetor quickly becomes 2 Excessively high idling speed Adjust carburetor fouled with carbon 3 Incorrect gasoline Change 4 Dirty air cleaner element Clean or replace 5 Incorrect spark plug cold type Change to hot type spark plug Spark plug quickly be 1 Worn piston ring Replace comes fouled with oil 2 Worn piston Replace or carbon 3 Worn cylinder Replace 4 Excessive valve stem to valve guide clearance Replace 5 Worn valve stem oil seal Replace Spark plug electrodes 1 Incorrect spark plug hot type Change to cold type spark overheat or burn plug 2 Overheated engine Tune up 3 Loose spark plug Tighten 4 Excessively lean air fuel
23. tor no load voltage More than 55 V AC at 5 000 r min Y Y DR Z400 hen engines gold More than 75V AC at 5 000 r min Y Y DR Z400E Regulated voltage 12 5 14 0 V at 5 000 r min DR Z400 13 5 15 0 V at 5 000 r min DR Z400E Generator maximum output 150 W at 5 000 r min DR Z400 200 W at 5 000 r min DR Z400E Starter relay resistance 3 50 DR Z400E Battery Type designation GT7B 4 Capacity 12 V 23 4 6 5 Ah 10 HR DR Z400E WATTAGE Unit W SPECIFICATION Headlight 55 Taillight LED SERVICING INFORMATION 8 33 FUEL OIL SPECIFICATION Fuel type Use only unleaded gasoline of at least 90 pump octane 8 Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corro sion inhibitor is permissible Gasoline used should be graded 95 octane or higher An unleaded gasoline is recommended Fuel tank including reserve 10 0L 2 6 US gal 2 2 Imp gal reserve zr 0 6 US gal 0 5 Imp gal Engine oil type SAE 10 W 40 API SF or SG Engine oil capacity Change T m 1 Dons T 1 800 ml 1 9 US qt 1 6 Imp qt 1 900 ml 2 0 US qt 1 7 Imp qt Filter change Overhaul
24. y in 1 Weak valve spring Replace high speed range 2 Worn camshaft Replace 3 Insufficient spark plug gap Regap or replace 4 Mistimed valves Adjust 5 Ignition not advanced sufficiently due to poorly working Replace CDI unit timing advance circuit 6 Defective ignition coil Replace 7 Defective generator Replace 8 Defective CDI unit Replace 9 Low float chamber fuel level Adjust float height 10 Dirty air cleaner element Clean or replace 11 Clogged fuel hose resulting in inadequate fuel supply Clean and prime to carburetor Exhaust smoke is 1 Excessive amount of engine oil Check level and drain dirty or thick 2 Worn cylinder Rebore or replace 3 Worn piston ring Replace 4 Worn valve guide Replace 5 Scored or scuffed cylinder wall Replace 6 Worn valve stem Replace valve 7 Defective valve stem oil seal Replace 8 Worn oil ring side rail Replace oil ring Engine lacks power 1 Insufficient tappet clearance Adjust 2 Weak valve spring Replace 3 Mistimed valves Adjust 4 Worn cylinder Replace 5 Worn piston ring Replace 6 Improper valve seating Repair or replace 7 Fouled spark plug Clean or replace 8 Incorrect spark plug Replace 9 Clogged carburetor jet Clean 10 Incorrect float chamber fuel level Adjust float height 11 Dirty air cleaner element Clean or replace 12 Air leakage from intake pipe Tighten or replace 13 Excessive amount of engine oil Check level and d

TROUBLESHOOTING

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