2003 DRZ400S Service manual?

[Shuswap]

Hi Fellas.....looking for a pdf, if one is available.
Question: Is the stator supposed to be immersed in oil?

Thanks....newbie DRZ owner
Greg

[bigmac]

Here ya go

http://pdftown.com/Suzuki-DR-Z400-Service-Manual.html

[Sparkle]

Hi Greg:

The stator is not supposed to "immersed" in oil. However on most bikes the stator case is vented to the crankcase and is sealed by the gasket and grommets outside of the case for the purpose of crankcase ventilation. Making the case part of the crankcase pressure system reduces pressure on the seals and keeps out water and dust.

This means it's normal to have some small amount of oil behind the cover, but it shouldn't be more than an ounce or two. If you want to minimize the spillage, lean your bike to the other side for a while and most of it will drain back to the crankcase except for a very small amount.


Sparkle


Question: Is the stator supposed to be immersed in oil?

Thanks....newbie DRZ owner
Greg[/QUOTE]

[Shuswap]

Thanks BigMac for the download site. I'm not able to download it and open it, however. It is "Winrar'd"....and asks for a password when I tried to extract the files.

Sparkle,
thanks for the explanation. The previous owner bought it with a faulty stator, had it replaced, sold it to me and I pulled the center-screw plug out and was a little surprised to find oil in there. If I can locate a service manual I'll get this figured out a little better. It's charging, but I do NOT want to risk having to cough up the several-hundred $ that it cost the seller. So, need to investigate. I very much appreciate your help, THANKS!
Greg

[Sparkle]

http://www.scribd.com/doc/7569141/3-...#fullscreen:on

Don't thank me yet Shuswap....I just looked at this page on reassembly (page 3-51)...it says install a new gasket to prevent oil leaks...Also I see the starter drive spins the rotor and it must be lubricated. It looks to me that the rotor-case has oil to the level of the sump normally. I guess a manual is a good idea.

Sparkle

EDIT: the link appears to be the full service manual...not sure you can download it...but you can read it..

[bossche]

Try http://www.sixfivepony.com/drz400/

[Shuswap]

Thanks Fellas. Bossche.......worked well....Great to have a manual.....such as they are.... they sure do beat the heck out of pokin 'n fiddlin around and (often) busting things, like I usually do!
Lots of ideas floating around on the 'wet' stator. I'll just have to get to the bottom of this........funny how many years I've ridden and managed to avoid this particular problem.

Thanks again!

[Sparkle]

Hi again Shuswap:

Yah...I assumed that that the crankshaft would have a seal and the rotor compartment would be dry. On my older bike the cover comes completely off to run the bike while timing etc, and the seal is behind the rotor and the cover is dry. Looking at the exploded diagrams: http://hot-rock.com/drz400/index.html "crankcase cover, crankcase, crankshaft" I see no seals outboard of the crank bearings at all, and the case covers are part of the crankcase oil volume.

I don't have a drz400 manual, but I looked in my dr350 manual, Engine Lower End/ Bearing and Oil Seal Replacement:....I quote:

"The primary bearings in the crankcase halves are NOT equipped with oil seals since each side of the crankcase is covered with a sealed crankcase cover. There is an oil seal for the transmission shaft, the shift lever, the kickstart-lever on models so equipped."

Hmmmm....just when you think you've got them figured out.....

Sparkle

[Shuswap]

Sparkle,
Thanks for the follow-up.
Seems that some oil is quite normal in this area, so I guess that I can stop shopping for another stator and/or seal.

I would think that cooling the stator would extend it's life, but lubricating fluids have the potential of dissolving/weakening protective coatings as well......especially if you have no idea of the compatibility of the two compounds.....winding coating and oil constituents.

Thanks,
Greg

[bigmac]

Thanks BigMac for the download site. I'm not able to download it and open it, however. It is "Winrar'd"....and asks for a password when I tried to extract the files.

Sparkle,
thanks for the explanation. The previous owner bought it with a faulty stator, had it replaced, sold it to me and I pulled the center-screw plug out and was a little surprised to find oil in there. If I can locate a service manual I'll get this figured out a little better. It's charging, but I do NOT want to risk having to cough up the several-hundred $ that it cost the seller. So, need to investigate. I very much appreciate your help, THANKS!
Greg

Go get winrar and extract it. no password necessary. buddy has it

[bigmac]

You're right, there is a password!! It is pdftown.com