Suzuki DR-Z400S / DR-Z400SM — Example photo: Eliot Phillips, CC BY-SA 2.0, Wikimedia Commons

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Suzuki · Shim-adjusted overhead-cam four-stroke single, dry sump, gearbox shares engine oil, chain drive

DR-Z400S / DR-Z400SM

Library entry covers 2000-2024

32 factory 35 guideline

Published source

Suzuki DR-Z400S / DR-Z400SM Service Manual, Periodic Maintenance Chart p.2-2

Factory workshop manual. Covers 2000-2009 DR-Z400S/SM service manual.

67 items for a 2003 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Dry sump (separate oil tank)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2003 Suzuki DR-Z400S / DR-Z400SM

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 600 mi

2 items

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain. Factory: Lubricate every 1 000 km (600 miles)

Every 1,000 mi or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 3,000 mi or 12 months

8 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 4,000 mi or 6 months

15 items

Change engine oil

Engine

Factory

Manual: Engine oil. Factory: Initial 1,000 km (600 mi); R in every column
Chassis nuts and bolts

Engine

Factory

Factory: As printed: T at 1 000, 6 000, 12 000, 18 000, 24 000 km (columns: 1 000 km/600 miles/1 month, 6 000/4 000/6, 12 000/7 500/12, 18 000/11 000/18, 24 000/15 000/24)
Engine oil hoses

Engine

Factory

Factory: As printed: I at 1 000, 6 000, 12 000, 18 000, 24 000 km (columns: 1 000 km/600 miles/1 month, 6 000/4 000/6, 12 000/7 500/12, 18 000/11 000/18, 24 000/15 000/24)
Radiator hose

Engine

Factory

Factory: As printed: I at 6 000, 12 000, 18 000, 24 000 km (columns: 1 000 km/600 miles/1 month, 6 000/4 000/6, 12 000/7 500/12, 18 000/11 000/18, 24 000/15 000/24)
Spark arrester (For E-03, 28, 33)

Engine

Factory

Factory: Periodic maintenance chart p.2-2 (archive.org OCR text of the service manual; columns 1000/6000/12000/18000 km, 600/4000/7500/11000 mi, 1/6/12/18 months): C at 6000, 12000 and 18000 km
Clean / inspect air filter

Fuel and air

Factory

Manual: Air cleaner. Factory: Inspect every 6,000 km
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Factory

Manual: Carburetor. Factory: I in every column
Fuel line (I)

Fuel and air

Factory

Factory: Periodic maintenance chart p.2-2 (archive.org OCR text of the service manual; columns 1000/6000/12000/18000 km, 600/4000/7500/11000 mi, 1/6/12/18 months): I in every column from 6000 km; replace every four years
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch. Factory: I from 6,000 km every column
Drive chain (I)

Final drive

Factory

Factory: Periodic maintenance chart p.2-2 (archive.org OCR text of the service manual; columns 1000/6000/12000/18000 km, 600/4000/7500/11000 mi, 1/6/12/18 months): I at 1000 km and in every column; lubricate every 1000 km (600 miles)
Brake hoses (I)

Brakes

Factory

Factory: Periodic maintenance chart p.2-2 (archive.org OCR text of the service manual; columns 1000/6000/12000/18000 km, 600/4000/7500/11000 mi, 1/6/12/18 months): I in every column from 6000 km; replace every four years
Brakes

Brakes

Factory

Factory: As printed: I at 1 000, 6 000, 12 000, 18 000, 24 000 km (columns: 1 000 km/600 miles/1 month, 6 000/4 000/6, 12 000/7 500/12, 18 000/11 000/18, 24 000/15 000/24)
Brakes fluid (I)

Brakes

Factory

Factory: Periodic maintenance chart p.2-2 (archive.org OCR text of the service manual; columns 1000/6000/12000/18000 km, 600/4000/7500/11000 mi, 1/6/12/18 months): I in every column from 6000 km; replace every two years
Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Spoke nipples. Factory: I in every column
Tires

Wheels and tires

Factory

Factory: As printed: I at 6 000, 12 000, 18 000, 24 000 km (columns: 1 000 km/600 miles/1 month, 6 000/4 000/6, 12 000/7 500/12, 18 000/11 000/18, 24 000/15 000/24)

Every 4,000 mi or 12 months

1 item

Inspect, clean and gap spark plugs

Engine

Guideline

Every 6,000 mi or 12 months

6 items

Inspect coolant hoses and clamps

Engine

Guideline
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 7,500 mi or 12 months

7 items

Exhaust pipe nut and bolt and muffler nut and bolts

Engine

Factory

Factory: As printed: T at 1 000, 12 000, 24 000 km (columns: 1 000 km/600 miles/1 month, 6 000/4 000/6, 12 000/7 500/12, 18 000/11 000/18, 24 000/15 000/24)
PAIR (Air supply) system (For E-02, 19, 54)

Engine

Factory

Factory: As printed: I at 12 000, 24 000 km (columns: 1 000 km/600 miles/1 month, 6 000/4 000/6, 12 000/7 500/12, 18 000/11 000/18, 24 000/15 000/24)
Rear suspension

Engine

Factory

Factory: As printed: I at 12 000, 24 000 km (columns: 1 000 km/600 miles/1 month, 6 000/4 000/6, 12 000/7 500/12, 18 000/11 000/18, 24 000/15 000/24)
Replace spark plugs

Engine

Factory

Manual: Spark plug. Factory: R at 12,000 and 24,000 km; I at 6,000/18,000
Spark plug (I)

Engine

Factory

Factory: Printed per the re-read doubt: Spark plug I at 6 000/18 000, R at 12 000/24 000 km; the I marks are 12,000 km apart starting at 6,000 km, taken as inspect every 12,000 km. The existing entry holds the R. (From the re-read doubt notes: Suzuki DR-Z400S / DR-Z400SM, printed line or second operation stated in the DOUBT line.)
Check steering head bearing adjustment

Front end

Factory

Manual: Steering. Factory: I at 1,000, 12,000, 24,000 km
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Front fork. Factory: I at 12,000 and 24,000 km

Every 7,500 mi

1 item

Evaporative emission control system (For E-33)

Controls and cables

Factory

Factory: As printed: Inspect every 12 000 km (7 500 miles)

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 11,000 mi or 18 months

2 items

Replace oil filter

Engine

Factory

Manual: Engine oil filter. Factory: Initial 1,000 km; R at 18,000 km
Replace air filter element

Fuel and air

Factory

Manual: Air cleaner. Factory: R at 18,000 km

Every 12,000 mi or 2 years

2 items

Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 15,000 mi or 2 years

1 item

Check valve clearances (shim adjusted)

Engine

Factory

Manual: Tappet clearance. Factory: I at 24,000 km only

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

4 items

Replace coolant

Engine

Factory

Manual: Engine coolant. Factory: Replace every two years
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Factory

Manual: Brakes fluid. Factory: Replace every two years

Every 4 years

4 items

Replace fuel lines

Fuel and air

Factory

Manual: Fuel line. Factory: Replace every four years
Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hoses. Factory: Replace every four years
Rebuild calipers and master cylinders (seals)

Brakes

Guideline
Evaporative emission control system (For E-33): Replace vapor hoses every four years.

Controls and cables

Factory

Factory: As printed: Replace vapor hoses every four years.

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.