20 Most Recent 2003 Suzuki DR-Z 400 Questions & Answers


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2003 Suzuki DR-Z... | Answered on May 07, 2019


Hi, Bobby_silos and the usual suspects are:
1. Fuel tank empty.
2. The fuel tank has old dead gas.
3. Fuel tank bottom contaminated with ethanol sludge, dirt, water, rust, etc.
4. Fuel supply valve/petcock turned off.
5. Fouled spark plugs.
6. Engine flooded as a result of overuse of the choke.
7. Vacuum hose to the fuel supply valve/petcock disconnected, broken, cracked, or pinched.
8. Fuel valve/petcock or filter clogged.
9. Fuel line to carburetor or throttle body pinched, kinked or blocked.
10. Carburetor float stuck.
11. Fuel injectors clogged.
12. Fuel injectors stuck open.
13. Quick disconnect check ball stuck.
14. Compression below 75 PSI.
15. A stuck-bent-burnt valve.
16. Improper valve clearance (too tight)
17. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a cursory reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
18. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
19. Loose or corroded wire connection at the coil or plug between ignition sensor and ECM module.
20. Spark plug cables in bad condition and shorting check for spark leakage in the dark, cable connections are loose or connected to the wrong cylinders.
21. Ignition timing incorrect due to a faulty ignition coil, ignition module or MAP, CMP, CKP, O2, TPS, ETP, IAC sensors.
22. Faulty neutral, clutch, kickstand safety switch.
23. Faulty fuel pump or fuse or relay.
24. Faulty or corroded run/stop switch.
25. Tilt sensor needs a reset.
26. Security system not disarming alarm needs a reset.
27. Check for engine trouble codes.
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2003 Suzuki DR-Z... | Answered on May 06, 2019


Hi, Nicholaspoug and the usual suspects are:
1. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
2. Failed alternator/generator and or voltage regulator.
3. Loose or corroded battery terminals and or cables especially the "NEGATIVE" cable, look for loose, corroded, or broken connectors inside the cable harness at "BOTH" ends.
4. Failed main circuit breaker or ignition switch, check for loose connections and continuity.
5. Failed system and or ignition relay, check for continuity.
6. Failed ignition coil, stator, magneto, ignition/electronic module.
7. Failed CKP, CPS, CMP, MAP, TPS, or BAS sensor, corroded, loose or broken wire connector pins/sockets.
8. Throttle cables and or idle speed improperly adjusted hot idle speed should be 950 RPM to 1000 RPM.
9. Faulty neutral, side stand or clutch lever safety switch.
10. Faulty or corroded kill switch.
11. Accelerator pump damaged or not working.
12. Water or dirt in the fuel system, carburetor or filter.
13. Restricted, blocked or kinked fuel line.
14. Fuel tank empty.
15. The gas cap is not venting properly or fuel tank venting system blocked, loosen gas cap and go for a test ride.
16. A failed fuel pump, pressure regulator and or fuel injectors.
17. Vacuum line from intake manifold to petcock broken, cracked, or not attached, carburetor vent line plugged.
18. Needle and seat stuck closed in the float bowl.
19. Petcock clogged or damaged.
20. Lean angle switch is faulty or needs adjustment.
21. Catastrophic engine failure, perform a compression test.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
DRZ Only starting with jump dying while riding
DRZ 400S Died While Riding Stator Readings
Suzuki DR Z400E 2000 Service Repair Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
Suzuki DRZ400SM Owner Manual

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2003 Suzuki DR-Z... | Answered on Dec 12, 2017


Is there. Power in bike?

2003 Suzuki DR-Z... | Answered on Dec 10, 2016


K4 usually denotes 2004. This may be late 2003 onwards.

2003 Suzuki DR-Z... | Answered on Jun 23, 2014


I guess in theory no it doesn't but I would be concerned that if stuff can get out then the opposite is stuff can get in. grit or grime getting in potentially could affect everything.

I assuming it leaking from the counter shaft seal ? if it is recommend fixing as its only about $30 and 20 minute job why would you leave it?? Just my opinion, you could also just keep topping up with oil now and again I guess.

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2003 Suzuki DR-Z... | Answered on Oct 28, 2012


Saddlebags? Hein Gerike do nice ones at £49 works for me.

2003 Suzuki DR-Z... | Answered on May 09, 2012


I have same problem have to add oil after every ride

2003 Suzuki DR-Z... | Answered on Dec 27, 2011


The screw setting depends on the engine and carb condition,but you can usually start off with the screw turned out about 1 1/2 (one and one half) turns out and adjust it to obtain the best running setting from there.

2003 Suzuki DR-Z... | Answered on Mar 21, 2011


If you are cleaning the carburetor, the place you need to concentrate your effort is not just the slow jet but the passageway through the carburetor body. That is usually wear the blockage is located. If you have an unusually long slow jet be sure ALL the tiny holes are clear.
You should also carefully check that the intake manifold and any gaskets between the carburetor body and the cylinder head are not cracked, separated, leaking, etc.. The extra air from a leaking connection can keep the bike from idling. Also be sure there are no cracked or leaking tubes on the outside plumbing of the carburetor.
Ethanol/alcohol style fuels lower your fuel economy and have to be taken into the carburetor through larger jets for the motorcycle to idle and run properly. you can adjust for this with bigger jets or like most people by turning up the idle. Suzuki recommends not more than 5 percent alcohol content in the fuel. If you are in an area where they are selling fuel with 10-20 percent or more, drain your fuel from the motorcycle tank and burn it in your truck. Locate a station with NO ALCOHOL fuel and see if that helps.
Poor idle can also be caused by week spark usually caused by a burnt out resister in the spark plug cap. NGK makes various styles of spark plug caps for about $5 each. Unscrew the old plug cap off the end of the wire and replace it with a new one.
Long term use of Sea Foam can eat away the interior of a motorcycle carburetor. I recommend Chevron Techron. Usually 5-10 minutes of running idle time with a shock treatment will bring many carburetors back to life with out disassembly.

2003 Suzuki DR-Z... | Answered on Jan 09, 2011


PUSH AND HOLD THE TRIP SET FOR 5 SECS

2003 Suzuki DR-Z... | Answered on Jan 07, 2011


there is only 1 drain plug, the oil is mostly stored in the front part of the bike and the drain is as normal at the lowers part if the engine.
the drain plug tap is found close to the front forks on the frame and is just like s normal drain opening screw top.

2003 Suzuki DR-Z... | Answered on Jul 11, 2010


maybe--just go buy a clymer repair book and become a pro like us at the fix

2003 Suzuki DR-Z... | Answered on May 17, 2010


replace it

2003 Suzuki DR-Z... | Answered on Mar 27, 2010


check plug for cracked insulator. Coils? Bad fuel /fuel filter

2003 Suzuki DR-Z... | Answered on Mar 07, 2010


Sounds like carby is flooding, If so remove carby dismantle / clean / reassemble. All good.

2003 Suzuki DR-Z... | Answered on Dec 20, 2009


Recheck the float level, adjust if necessary.
Reblow the jets with compressed air.
If you have tampered with the air-mixture screw you will have to reset it too.
Standard setting is all the way in ...slowly as not to damage the tip, thn outwards 2 & a half turns to 3.
Hope this helps!

2003 Suzuki DR-Z... | Answered on Nov 20, 2009


not 100% sure but around 20 to 40 ft.lbs

2003 Suzuki DR-Z... | Answered on Sep 21, 2009


I'd check to see if it has a clutch safety switch

2003 Suzuki DR-Z... | Answered on Sep 20, 2009


about 2L to 2.5L of oil and do it slowly it overfills very fast

2003 Suzuki DR-Z... | Answered on Aug 12, 2009

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