DATA SUMMARY MOTORCYCLE, PATROL, OFF ROAD, MC2, SUZUKI DR-Z400E UNCONTROLLED IF PRINTED ELECTRICAL AND MECHANICAL ENGINEERING INSTRUCTIONS
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1 MOTORCYCLE, PATROL, OFF ROAD, MC2, SUZUKI DR-Z400E DATA SUMMARY This instruction is authorised for use by command of the Chief of Army. It provides direction, mandatory controls and procedures for the operation, maintenance and support of equipment. Personnel are to carry out any action required by this instruction in accordance with EMEI General A 001. Figure 1 Motorcycle, Patrol, Off Road, MC2, Suzuki DR-Z400E K4 (E24) General 1. This EMEI lists basic data for the Motorcycle, Patrol, Off Road, MC2, Suzuki DR-Z400E, as shown in Figure Role. The motorcycle is employed to provide mobility and sustainability while undertaking activities in low and medium intensity conflicts. The motorcycle s functionality can also be employed outside the Australian Area of Operations during operations, exercises or training. The primary roles of the motorcycle include: a. route reconnaissance for mobility force elements (carried on the rear of the Long Range Patrol Vehicles (LRPV) and Long Range Logistics Vehicles (LRLV) when not in use); b. area reconnaissance; c. early warning; d. rear warning/protection; e. flank warning/protection; f. communications link during mobility transits; and g. as an administration/liaison vehicle at Forward Observation Base (FOB). 3. Description. The motorcycle is based on an Australian Design Rule (ADR)-compliant Suzuki DR-Z400E off-road trail bike. The base motorcycle has been reconfigured to suit capability requirements specifically for Special Forces. It is powered by a liquid-cooled, 398 cm 3 single-cylinder petrol engine with electric start. Power is delivered through a five-speed manual constant mesh transmission via chain drive to the rear wheel. Use of the equipment is for a single operator only. 1
2 ELECTRICAL AND MECHANICAL Detail 4. Dimensions and Mass a. Height mm b. Length mm c. Width mm d. Wheelbase mm e. Ground Clearance mm f. Seat Height mm g. Dry Mass kg 5. Engine a. Type...four-stroke, liquid-cooled, DOHC b. Number of Cylinders...1 c. Bore mm d. Stroke mm e. Piston Displacement cm³ f. Compression Ratio :1 g. Carburettor...KEIHIN FCR39 h. Air Cleaner...polyurethane foam element i. Starter System... electric and primary kick j. Lubrication System... dry sump k. Idle Speed /-100 rpm 6. Transmission a. Clutch...wet multi-plate type b. Transmission... 5-speed constant mesh c. Gear Shift pattern...1-down, 4-up d. Primary Reduction Ratio (74/25) e. Final Reduction Ratio (47/14) f. Gear Ratio Low (32/14) g. Gear Ratio Second (26/15) h. Gear Ratio Third (22/16) i. Gear Ratio Fourth (24/22) j. Gear Ratio Top (19/22) k. Chain Drive...RK520KZO, 112 links 7. Chassis a. Front Suspension...telescopic, coil spring, oil damped, rebound, damping force 18-way adjustable, compression, damping force 14-way adjustable b. Rear Suspension...link type, coil spring, oil damped, spring pre-load fully adjustable, rebound damping force 21-way adjustable, compression damping force 26-way c. Rear Suspension Coil Spring...Racetech SRSP , heavy-duty, 110 kg d. Front Suspension Stroke mm e. Rear Wheel Travel mm 2
3 f. Caster...27º20 g. Trail mm h. Steering Angle...45º (right and left) i. Turning Radius m j. Front Brake...Disc k. Rear Brake...Disc l. Hydraulic Brake Fluid Type...DOT 4, Glycol-based m. Front Tyre Size...80/ M/C51P, tube type n. Rear Tyre Size...120/90-18 M/C65P, tube type 8. Electrical a. Ignition Type...electronic ignition (CDI) b. Ignition Timing... 7º BTDC at 1800 rpm c. Spark Plug...NGK: CR8E or DENSO: U24ESR-N d. Generator... three-phase AC generator e. Battery...12V, 21.6 kc (6Ah)/10 HR f. Cooling Fans...2 x 12V, thermostatic controlled g. Thermostatic Switch ºC h. Fuse Cooling Fans... 5 Amp i. Fuse Main Amp j. Headlights... 12V, 20W (two) k. Tail-light...12V, 21/5W l. Turn Signal Light... 12V, 21W (four) m. Speedometer Light... LED n. Neutral Indicator Light...12V, 2W o. High Beam Indicator Light...12V, 2W p. Turn Signal Indicator Light...12V, 2W 9. Capacities a. Main Fuel Tank (including reserve) L b. Reserve ml each side c. Engine Oil Oil Change (refer to Paragraph 10 for oil specification) ml (1) Oil and Filter Change ml (2) Engine Overhaul ml d. Front Fork Oil (each leg) ml e. Rear Suspension Unit Oil (high-pressure nitrogen charged) ml f. Engine Coolant ml 3
4 ELECTRICAL AND MECHANICAL 10. Engine Oil. Two types of engine oils are certified for use. Both types of engine oils are synthetic and have been specifically developed for use in motorcycle engines only. These oils do not have friction modifiers that compromise correct operation of wet clutch systems as used in motorcycle transmissions. Depending on the geographical location for operation of the motorcycle(s), the type of oil to be used is described below: a. In-country... Shell Advance SX4, 15W-50, synthetic (1) NSN (4.0 litre) (2) NSN (1.0 litre) b. When Deployed... Castrol R4 Superbike, 5W-40, synthetic (1) NSN (3 x 4.0 litre) (2) NSN (6 x 1.0 litre) 11. Manufacturer and Suppliers Details a. Manufacturer: Suzuki Motor Corporation 300 Takatsuka Hamamatsu, Shizuoka Japan b. Australian Importer/Supplier: Suzuki Australia P/L Cherry Lane Laverton North, VIC, 3028 Tel: (03) Fax: (03) http: // c. Australian Supplier: Bale Defence Industries P/L Jindalee Road Port Macquarie, NSW, 2444 Tel: (02) Fax: (02) sales@baledefence.com http: // 12. Point of Contact National Fleet Manager (NFM) Lt B Vehicles, CGSVSPO DPM 7, Defence Plaza Melbourne 661 Bourke Street MELBOURNE VIC 3000 Tel: (03) Associated Information a. SIGC b. NSN c. Model Identification... DR-Z400E K4 (E24) d. RPS not issued, use Commercial Parts Catalogue and Addendum: (1) Suzuki DR-Z400/E Parts Catalogue, 9 th Edition (Suzuki Part No: 9900B ); and (2) Suzuki DR-Z400E Addendum to Parts Catalogue (Bale Defence Part No: BDI-3879). e. SCES f. ILSI...MM
5 g. Grade of Configuration Management (CM)...Grade D h. User Handbooks (as initially supplied with each motorcycle): (1) Suzuki DR-Z400E Owner s Manual (Suzuki Part No: F55-01M); (2) Suzuki DR-Z400E Supplementary Owner s Manual (Suzuki Part No: F55-24A); and (3) Suzuki DR-Z400E Addendum to Owner s Manual (Bale Defence Part No: BDI-2424). i. Other EMEI: (1) Vehicle B Authority for Use (2) Vehicle B Manual (Service Manual Suzuki Part No: E) (3) Vehicle B Manual (Addendum to Service Manual Bale Defence Part No: BDI-3379) (4) Vehicle B Manual (Addendum to Parts Catalogue Bale Defence Part No: BDI-9936) (5) Vehicle B Manual (Addendum to Owner s Manual Bale Defence Part No: BDI-9935) END Distribution List: VEH B 02.0 Code 1 (Maint Level) (Sponsor: CGSVSPO, Light B Vehicle Section) (Authority: ECO CGSVSPO 120/10) 5
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