Suzuki DR-Z400 and DR-Z400 SM Maintenance Schedule and Service Intervals

This is the maintenance schedule and associated service intervals for the Suzuki DR-Z400 range of motorcycles.

This maintenance schedule applies to the following models:

  • Suzuki DR-Z400 — the generic name for both
  • Suzuki DR-Z400E/S/SE — specifically the dual sport variant
  • Suzuki DR-Z400SM — the supermoto variant.

The Suzuki DR-Z400 is a dual-sport motorcycle that has been manufactured by Suzuki for over two decades. It’s available in dual sport form and in street bike supermotard form (the SM).

Both the dual-sport and supermotard are powered by a single-cylinder 398 cc carburettor-fed liquid-cooled four-stroke and four-valve engine, with power to the ground through a wet clutch and chain drive.

This page includes the maintenance schedule for both the supermotard and the dual sport together. They share a platform and the same maintenance components, even though there are some differences. The difference between the DR-Z400SM and the DR-Z400E are that the the DRZ400SM gets:

  • An inverted front fork for better suspension in street riding,
  • Wide 17-inch street rims (still spoked, though) with tubeless (rather than tubed) tyres, and
  • A larger 300mm diameter floating front brake rotor (still a single disc)

The DR-Z400 has remained basically the same as when it was launched 20 years ago. You can still buy it new in 2021 with a carburettor-fed engine.

See the pics below for a direct comparison between the dual-sport DR-Z400E and the super motard DR-Z400SM. Note the wheels/tyres, front suspension, and front brake disc.

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What you need to service the Suzuki DR-Z400

If you’re servicing your DR-Z, you are in for a treat — servicing it is both easy and rewarding.

The DR-Z400’s engine is a straightforward one to service. It has a 4-valve single-cylinder engine and everything is very accessible.

PartSuzuki DR-Z400 spec
Engine oilThe service manual recommends SAE 10W-40 oil that meets SF or SG spec. Most motorcycle oils fit this, so use something like Motul 5100 10W-40.
Oil filterUse a Hiflofiltro HF139 oil filter.
Spark plugThe spark plug is an NGK CR8E.
Air filterYou can usually clean the air filter. But if you need to replace it, the Twin-Air 153156 air filters are popular on the DR-Z.
CoolantThe service manual specifies Suzuki coolant, or another coolant/antifreeze suitable for aluminium radiators. Most ethylene glycol coolants with rust inhibitors are fine, e.g. Pro Honda Coolant.
Brake padsThe brake pads are the same on the SM and E versions despite different size discs. Use an EBC FA185R pad for the front, and FA131R for the rear.
Brake fluidThe manual specifies DOT 4, e.g. Castrol DOT 4.
Fork oilThe service manual specifies Suzuki fork oil SS-05, which is a similar weight to Bel-Ray 5W Fork Oil.
Chain lubricantYou can use engine oil, or Motul chain paste, which is low-mess and easy to carry.
Cable lubricantYou can use engine oil to lubricate cables or use Protect all cable life, a well-known lube.
General lubeUse lithium soap-based grease for general lubrication.
Suzuki DR-Z400 maintenance parts

Suzuki DR-Z400 Maintenance Schedule

Below is the maintenance schedule for the Suzuki DR-Z400 motorcycles. It’s the same between the DR-Z400E and the DR-Z400SM (same engine).

The maintenance schedule is the same as that which you see in the manual — it’s just formatted differently here so it’s easier to parse.

NOTES

  • There are time-based and distance-based intervals — follow the shorter of the two.
  • I= Inspect and clean, adjust, replace or lubricate as necessary.
  • R= Replace
  • T= Tighten
Months212243648
km x 100016121824
miles x 10000.647.51114.5Every
Air cleaner element (Twin-Air 153156)IIRI
Exhaust pipe bolts and muffler boltsTTT
Valve clearanceI
Spark plug (NGK CR8E)IRIR
Spark arresterCCCC
Fuel hoseIIII
Engine oil (Motul 5100 10W-40)RRRRR
Engine oil filter (HF139)RR
Engine oil hosesIIIII
Engine coolant (Suzuki Super Long Life Coolant kind — Blue, or Honda Coolant)Replace every 4 years or 48000 km (29000 miles)
Radiator hoseIIII
Idle speedIIIII
Throttle cable playIIIII
ClutchIIII
Drive chain (use Motul chain paste)IIIIILubricate every 1000 km (600 miles)
Brakes (same pads on both bikes, even though different disc)
* Front: FA185R
* Rear: FA131R
IIIII
Brake hoseIIIIReplace every 4 years
Brake fluid (Use DOT 4 fluid only)IIIIReplace every 2 years
TiresIIII
Spoke nipplesIIIII
SteeringIII
Front forkII
Rear suspensionII
Chassis nuts and boltsTTTTT
Evaporative emission control system (California model only)Inspect every 12000 km (7500 miles) and replace vapor hose every 4 years
PAIR (air supply) systemII
General lubrication (Use a lithium soap-based grease on external pivot points)Lubricate every 1,000 km (600 miles)
DR-Z400 Maintenance Schedule

Tyre size and tyre pressure for the Suzuki DR-Z400

The manual gives the following tyre specs for the DR-Z400, as well as the following recommended tyre pressure ranges when cold.

Note: The DR-Z400E (dual sport) runs tubed tyres. the DR-Z400SM runs tubeless tyres.

DR-Z400 tyres

TyreSizeBrand(s)Tyre pressure (cold)
Front100/90-19M/C 57HBRIDGESTONE TRAIL WING-41Solo: 125 kPa (1.25 kgf/cm2) 18 psi
Dual: 125 kPa (1.25 kgf/cm2) 18 psi
Rear140/80-15M/C 67HBRIDGESTONE TRAIL WING-42Solo: 150 kPa (1.50 kgf/cm2) 22 psi
Dual: 175 kPa (1.75 kgf/cm2) 25 psi
Tyres and tyre pressures for the DR-Z400

DR-Z400SM tyres

TyreSizeBrand(s)Tyre pressure (cold)
Front120/70-17Dunlop Sportmax D208Solo: 125 kPa (1.25 kgf/cm2) 18 psi
Dual: 125 kPa (1.25 kgf/cm2) 18 psi
Rear140/70-17Dunlop Sportmax D208Solo: 150 kPa (1.50 kgf/cm2) 22 psi
Dual: 175 kPa (1.75 kgf/cm2) 25 psi
Tyres and tyre pressures for the DR-Z400

About the Suzuki DR-Z400

Black Suzuki DR-Z400SM

The Subaru DR-Z400 is an enduro / dual sport / supermotard platform that has been around for a long time and has been essentially unchanged for decades.

You could consider it to be the little sibling of the Suzuki DR650, but it has some important differences and isn’t just the smaller version of the bigger dual sport.

The core of the Suzuki DR-Z400 is a 398cc liquid-cooled single-cylinder engine. It’s fed by a single 36mm Mikuni carburettor and makes what seems like a modest 29 kW (40 hp) at 8500 rpm, or 39 Nm (29 ft-lb) of torque at 6600 rpm.

But to quote power and torque specs would be a disservice to the DR-Z400.

The engine is actually an extremely versatile one, good for both on-road speeds from urban to highway (though you probably won’t stay on the highway for long), as well as for doing wheelies or climbing over rocks when going offroad.

The DR-Z400S (a.k.a. the DR-Z400SE) is the dual sport, and the DR-Z400SM is the road/supermotard version of the same bike.

The most obvious ways in which the dual sport version and the super motard versions differ are in the suspension, braking, and wheels.

SpecDR-Z400SDR-Z400SM
PurposeDual sport (Street legal)Street/Supermotard (Street legal)
Years2001+2005+
Compression ratio11.3:111.3:1
Front suspensionConventional 49mm fork, adjustable preload, compression damping, and rebound damping, 11.3-inch travelShowa inverted fork, adjustable damping
Rear suspensionAdjustable rear shock with preload compression damping adjustment, 11.6 inch travelFully adjustable rear shock with high/low speed compression damping
Front brake250mm disc, 2-piston caliper300mm floating disc, 2-piston caliper
Front tyre80/100-21, tube typed120/70 R17, tubed
Rear tyre120/90-18, tubed140/70 R17, tubed
Main differences between DR-Z400S and DR-Z400SM

There are some other differences, like in the length of the swing-arm.

Also, in prior years there was an off-road-only version of the DR-Z400 sold, with a different carburettor and camshafts, and a different compression ratio. Some of those came with a kick starter only.

The main way to understand the differences is that the DR-Z400E / DR-Z400S / DR-Z400SE is the dual-sport version with a big 21-inch front wheel, long-travel suspension, and slightly less braking power, whereas the SM has street 17-inch wheels, better braking, and less suspension travel.

Those who have ridden both versions of the bike say they’re completely different bikes, but nonetheless the maintenance of each is quite similar.

Both the DR-Z400E and DR-Z400SM are easy to maintain. You have easy access to the air filter and clutch, making minor and major jobs a cinch. It has old-fashioned technology — a carburetor, LCD screen (heck, I’ve seen worse), and halogen lighting, but in many parts of country or world, this makes it much easier to find parts.

Reference — Manual for the Suzuki DR-Z400

The above maintenance schedule comes directly from the user’s manual for the Suzuki DR-Z400. It’s identical between the two models (the E and SM).

Suzuki DR-Z400 Maintenance Schedule Screenshot From Manual

You can download it from here.

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