2006 suzuki drz400s service manual free download

All pages are printable. Engine will not start or starting difficult 2. Engine has a rough idle 3. Yamaha Outboard engine stalls 4. Outboard has poor deceleration 5. Outboard engine will not stop 6. Engine has poor performance, bogging, hesitation, backfires etc. Torquing Bolts Torque it down. Automatic Clutches Clutch lever? Sand Blasting Blowing Chunks, so to speak!

Soldering The Joining of the Wires. Changing Tires Fix a Flat Tire. Engine Compression Testing Finding the Pressure. Carburetors Servicing your Caburetor. Twist Grip Throttles Turning the power on and off.

Steering Bearings keep your Handlebars Turning. Batteries Servicing Your Battery. Unsticking a Stuck Engine Getting it unstuck. Helmets Skidlids, and why you need one. Troubleshooting Plan… Planning how to fix the problem. Quick Troubleshooting Do These Things first! Mysterious Two Stroke Seizure Getting stuck without trying!

Advanced Tools The next step up, or what do I want for next Christmas. Be Patient, it takes awhile to load. Wheel Bearings keeping your rims rolling. Four Stroke Exhaust Pipes Keeping the sound down. Fastener Theory Trying to Hold it together. 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. NOTE: The end of the fork spring with the smaller inside diameter should be at the bottom of the front fork.

Install a washer 1. Remove the odometer assembly. Remove the clamps 1 and engine stop switch 2. DR-Z Remove the front fender. Remove the handlebar 1 and ignition switch 2 DR-ZE. Remove the steering stem head nut. Remove the steering stem nut using the special tools. NOTE: Hold the steering stem lower bracket to prevent it from falling. Remove the steering stem upper bearing. Page Forward specified torque.

E, 28 Remove the rear axle nut. Replace the removed cotter pin with a new one. Support the motorcycle with a jack or wooden block and re- move the rear axle 1 and rear wheel. Do not operate the brake pedal during or after rear wheel removal. Page Inspection Reassemble and remount the rear wheel in the reverse order of removal and disassembly. DR-ZE Remove the clamps. Disconnect the air cleaner breather hose and loosen the car- buretor clamp.

If any damages are found, replace the spring or rear shock ab- sorber with a new one. Low gas pres- sure can result in oil leakage.

Abnormal gas pressure cannot provide normal performance of the rear shock absorber. Be sure to fill the rear shock absorber unit to the speci- fied pressure. Disconnect the brake hose from the brake hose guide. Remove the cushion lever mounting bolt and nut. Inspect the spacers for any flaws or other damage. If any dam- ages are found, replace the spacers with new ones. If any damages are found, replace the swingarm with a new one.

If there is excessive play, re- place the bearings with new ones. Page Reassembly And Remounting Reassemble and remount the rear suspension in the reverse order of removal and disassembly. Remove the brake pads. Do not operate the brake lever during or after brake pad removal.

Replace the brake pads as a set, otherwise braking performance will be adversely affected. Install the new brake pads. Remove the master cylinder reservoir cap and diaphragm. Remove as much old brake fluid as possible.

Fill the reservoir with new brake fluid. Specification and classification: DOT 4 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle. Remove the spring. Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using com- pressed air.

Do not use extremely high pressure air to remove the brake caliper pistons, otherwise damage to the pistons will result. Page Brake Caliper Reassembly And Remounting Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly. Remove the brake hose union bolt and disconnect the brake hose.

Immediately wipe off any brake fluid contacting any part of the motorcycle. If any damages are found, replace the master cylinder with a new one. Do not operate the brake pedal during or after brake pad removal.

Remove the reservoir cap and diaphragm. Replace the brake fluid. Remove the brake caliper. Do not use extremely high pressure air to remove the brake caliper piston, otherwise damage to the piston will result.

Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid. Pay special attention to the fol- lowing points: Wash the master cylinder components with new brake fluid before reassembly. When connecting a connector, push it in so it is firmly attached. Inspect the connector for corrosion, contamination and any breakage in the cover. Everything from re-wiring to rebuilding the engine is covered — as well as electrical diagrams, service procedures, fluid capacities, Etc.

Covers everything you will ever need to know to repair, maintain or repair your vehicle. Print out the pages you need or print the entire manual as a whole or just view from your screen. All Manuals supplied are make, model and year specific, not vague generic manuals like many others are selling.