Service Procedures: Suzuki DR-Z400S 2000-2024

Technical Reference

Member-uploaded diagrams & documents for this generation. AI-classified; community-verified where badged.

Service Procedures

• Suzuki DR-Z400S Front Fork Inspection - Spring Free Length & Seal Removal
  This is one page of a motorcycle service manual covering front fork disassembly and inspection procedures. The top section instructs the mechanic to remove the oil seal (1), oil seal retainer (2), outer tube…
• Front fork reassembly with Suzuki Fork Oil SS-05 (99000-99001-SS5) and fork oil seal installer set 09940-52861, ending with the oil seal stopper ring.
• Front fork disassembly: remove dust seal and stopper ring, clamp in a soft-jaw vise, remove the damper rod bolt with special tool 09940-54821.
• Service manual front fork removal: brake hose clamp, upper and lower clamp bolts, boot, cap bolt and fork spring, then draining the fork oil.
• Front fork remount: lower clamp 32 N·m, upper clamp 30 N·m, cap bolt 23 N·m; standard setting is preload 3rd groove from top, compression 7 clicks out.
• Front fork damper rod bolt 80 N·m, Suzuki Fork Oil SS-05 at 709 ml (24.0 US oz) per leg, 165 mm (6.5 in) oil level, spring and cap bolt install.