Suzuki DR-Z70 Manuals

Suzuki DR-Z70 Manuals

Manuals and User Guides for Suzuki DR-Z70. We have 1 Suzuki DR-Z70 manual available for free PDF download: Service Manual

Suzuki DR-Z70 Service Manual

Suzuki DR-Z70 Service Manual (199 pages)

Brand: Suzuki | Category: Motorcycle | Size: 30.5 MB

Table of Contents

General Information

5
- Table of Contents
  5
- Warning/Caution/Note
  6
- General Precautions
  6
- Suzuki Dr-Z70K8 ('08-Model)
  8
- Serial Number Location
  8
- Fuel and Oil Recommendation
  9
- Break-In Procedures
  9
- Information Labels
  10
- Specifications
  11
  - Dimensions and Dry Mass
    11
  - Engine
    11
  - Drive Train
    11
  - Chassis
    12
  - Electrical
    12
  - Capacities
    12
Periodic Maintenance

13
- Periodic Maintenance Schedule
  14
  - Periodic Maintenance Chart
    14
  - Lubrication Points
    15
- Maintenance and Tune-Up Procedures
  16
  - Air Cleaner
    16
  - Exhaust Pipe Bolts and Muffler Mounting Nut
    17
  - Valve Clearance
    18
  - Spark Plug
    20
  - Spark Arrester
    21
  - Fuel Line
    21
  - Engine Oil
    22
  - Throttle Cable Play
    23
  - Idle Speed
    23
  - Clutch
    23
  - Drive Chain
    24
  - Brakes
    26
  - Tires
    26
  - Spoke Nipples
    27
  - Steering
    28
  - Front Fork
    28
  - Rear Suspension
    28
  - Chassis Bolts and Nuts
    29
- Compression Pressure Check
  30
  - Compression Test Procedure
    30
- Oil Pressure Check
  31
  - Oil Pressure Test Procedure
    31
- Automatic Clutch Inspection
  32
  - Initial Engagement Inspection
    32
  - Clutch "Lock-Up" Inspection
    32
Engine

33
- Engine Components Removable with the Engine in Place
  34
- Engine Removal and Installation
  35
  - Engine Removal
    35
  - Engine Installation
    38
- Engine Disassembly
  41
- Engine Components Inspection and Service
  53
  - Cylinder Head
    53
  - Cylinder
    64
  - Piston and Piston Pin
    64
  - Cam Chain Tension Adjuster
    66
  - Cam Chain Guide
    67
  - Conrod and Crankshaft
    68
  - Oil Pump
    70
  - Transmission
    71
  - Gearshift Cam
    73
  - Gearshift Forks
    73
  - Gearshifting Clutch
    74
  - First Clutch
    77
  - Starter Clutch
    77
  - Generator Cover
    79
  - Clutch Cover
    79
  - Crankcase
    81
- Engine Reassembly
  84
  - Crankshaft
    84
  - Kick Starter
    86
  - Transmission
    87
  - Oil Breather Separator
    88
  - Crankcase
    88
  - Starter Idle Gear
    89
  - Cam Chain
    89
  - Starter Clutch and Generator Rotor
    89
  - Gearshift
    90
  - Oil Pump and Drive Gear
    92
  - Gearshifting Clutch
    93
  - First Clutch and Oil Filter Case
    94
  - Clutch Cover
    96
  - Generator Cover
    96
  - Neutral Switch
    97
  - Piston Ring
    97
  - Piston
    98
  - Cylinder
    99
  - Camshaft Sprocket
    100
  - Cam Chain Tension Adjuster
    100
  - Valve Clearance Inspection Cap and Camshaft Sprocket Cover
    101
  - Tdc Plug and Generator Cover Cap
    102
  - Starter Motor
    102
Fuel System

103
- Fuel Tank and Fuel Valve
  104
  - Construction
    104
  - Removal
    105
  - Fuel Filter Inspection and Cleaning
    105
  - Fuel Hose Inspection
    106
  - Remounting
    106
- Carburetor
  107
  - Construction
    107
  - Specifications
    108
  - I.D. No. Location
    108
  - Removal
    108
  - Disassembly
    109
  - Cleaning
    111
  - Inspection and Adjustment
    112
  - Reassembly and Remounting
    113
- Lubrication System
  115
  - Oil Pressure
    115
  - Oil Filter Case
    115
  - Oil Sump Filter
    115
  - Oil Pump
    115
  - Engine Lubrication System Chart
    115
Chassis

116
- Exterior Parts
  117
  - Fastener Removal and Installation
    117
  - Removal
    117
  - Reassembly
    118
- Front Wheel and Front Brake
  119
  - Construction
    119
  - Removal
    119
  - Dust Seal
    119
  - Spacer
    120
  - Inspection and Disassembly
    121
  - Reassembly
    122
  - Remounting
    124
- Front Fork
  125
  - Construction
    125
  - Spring
    125
  - Removal
    126
  - Inspection
    127
  - Reassembly and Remounting
    128
- Steering
  130
  - Construction
    130
  - Removal and Disassembly
    130
  - Inspection
    132
  - Reassembly and Remounting
    133
- Rear Wheel and Rear Brake
  136
  - Construction
    136
  - Brake Shoe
    136
  - Removal
    137
  - Inspection and Disassembly
    138
  - Reassembly and Remounting
    138
- Rear Suspension
  141
  - Construction
    141
  - Removal and Disassembly
    142
  - Inspection
    143
  - Reassembly and Remounting
    145
Electrical System

146
- Cautions in Servicing
  147
  - Connector
    147
  - Coupler
    147
  - Clamp
    147
  - Fuse
    147
  - Semi-Conductor Equipped Part
    148
  - Battery
    148
  - Wiring Procedure
    148
  - Using the Multi-Circuit Tester
    148
- Location of Electrical Components
  149
- Charging System
  150
  - Troubleshooting
    150
  - Inspection
    151
- Starter System
  154
  - Troubleshooting
    154
  - Starter Motor Removal
    155
  - Starter Motor Disassembly
    156
  - Starter Motor Inspection
    157
  - Starter Motor Reassembly and Installation
    158
  - Starter Relay Inspection
    160
- Ignition System
  161
  - Troubleshooting
    161
  - Inspection
    163
- Switches
  165
- Battery
  166
  - Specifications
    166
  - Initial Charging
    166
  - Servicing
    167
  - Recharging Operation
    168
Servicing Information

169
- Troubleshooting
  170
  - Engine
    170
  - Clutch
    173
  - Carburetor
    173
  - Chassis
    174
  - Brakes
    175
  - Electrical
    176
  - Battery
    177
  - Wiring Diagram
    178
- Wiring Harness, Cable and Hose Routing
  179
  - Wiring Harness Routing
    179
  - Cable Routing
    181
  - Carburetor Hose Routing
    182
  - Fuel Hose and Fuel Tank Breather Hose Routing
    183
- Handlebar Installation
  184
- Rear Brake Pedal Installation
  185
- Side-Stand Installation
  185
- Fuel Tank Side Cover Cushion Installation
  186
- Fuel Tank Upper Cover Cushion Installation
  186
- Special Tools
  187
- Tightening Torque
  189
  - Engine
    189
  - Chassis
    190
  - Tightening Torque Chart
    190
- Service Data
  191

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