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FOREWORD
This motorcycle has been designed and produced utilizing Suzuki's most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this motorcycle.
Please review this set-up manual carefully before performing any work. Take spe-
cial care to properly perform the required assembly and servicing marked by either
a Warning or a Caution. Failure to follow the directions in either of these two (2) cat-
egories could lead to serious problems. and areas are
denoted to emphasize certain areas and carry the following meanings:
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motorcycle damage.
This set-up manual is based on a motorcycle of standard specification. Some minor
differences from this manual may be found in other specifications.
K8
99505-01008-01E
June '07 Printed in Japan (TK) 28
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Summary of Contents for Suzuki DR-Z70K8
- Page 1 FOREWORD This motorcycle has been designed and produced utilizing Suzuki’s most modern technology. The finest product, however, cannot perform properly unless it is cor- rectly assembled and serviced. This set-up manual has been produced to aid you in properly assembling and servicing this motorcycle.
- Page 2 PREPARATION WORKSHOP The workshop where the machine is assembled should be clean, spacious, and have a level floor. A: Packed motorcycle B: Working space SELF PROTECTION The technician should wear protective clothing such as leather gloves, a long sleeve shirt, eye protection and safety shoes as shown in the illustration when handling metal crates.
- Page 3 Remove the bolts of the bracket. Remove the bolts to take off the rear wheel holding bracket. A: Bolt Remove the bolts from the crate. A: Bolt Lift the steel frame to separate it from the base of the crate. ...
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Page 4: Location Of Parts
LOCATION OF PARTS Check all the components which have been removed from the base of the crate. Item Part Name Q’ty Remarks Item Part Name Q’ty Remarks Front number plate Front fork protector Right and Left Handlebars assembly Flange bolt 6 ×... - Page 5 The photograph shown indicates the parts dis- mounted from the motorcycle in addition to the items shown in the preceding page. A: Throttle assembly B: Starter cable...
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Page 6: Removing The Bracket
Before assembling the motorcycle, thoroughly understand the “Safety Check Out” described on page 27. After completion of assembly, carefully check the motorcycle referring to the “Safety Check Out”, then deliver the motorcycle to the customer. ASSEMBLY REMOVING THE BRACKET Remove the bracket from the handlebar mounting position. - Page 7 HANDLEBARS Loosen the throttle housing retaining screws. Insert the throttle assembly onto the handlebars. A: Throttle assembly B: Handlebars Install the handlebars to the front fork upper bracket. Tighten the handlebar mounting bolts to the specified torque. Handlebar mounting bolt: 23 N·m (2.3 kgf-m) A: Handlebar assembly B: Front fork upper bracket C: 8 ×...
- Page 8 THROTTLE Insert the boss of the throttle housing into the hole on the handlebars. Tighten the throttle assembly with two screws. Check to ensure that the throttle operates freely and closes automatically. A: Boss B: Hole C: 5 × 16 mm screw CLAMP Clamp the right switch wiring harness and handlebar with the strap.
- Page 9 Place the rubber boot. NOTE: Move the rubber boot until it comes to contact with the cable lock nut. A: Rubber boot B: Cable lock nut Clamp the rubber boot with the strap. NOTE: Cut off the excess strap as shown in the photo- graph.
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Page 10: Front Fender
FRONT FENDER Install the front fender to the front fork lower bracket. A: Front fender B: 6 × 18 mm flange stepped bolt FRONT WHEEL Remove the adjuster nut. Remove the front brake cable assembly from the front brake hub panel assembly. A: Adjuster nut B: Front brake hub panel assembly C: Front brake cable assembly... - Page 11 Mount the front wheel assembly properly. A: Right fork leg B: Left fork leg C: Axle nut D: Front wheel spacer E: Front axle Attach the front wheel spacer to the front wheel hub. When attaching the front wheel spacer, be care- ful not to scratch the oil seal lip.
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Page 12: Front Brake Cable
FRONT BRAKE CABLE Pass the front brake cable through the guide. Pass the front brake cable through the lever cover. A: Front brake cable B: Guide C: Lever cover Insert the inner cable end into the recess in the brake lever. -
Page 13: Front Number Plate
Set the pin into the brake cam lever. Insert the end of the brake cable into the pin hole. Attach the adjuster nut on the end of the brake cable. Do not adjust at this time. Adjustment will be covered in the SERVICING section. A: Brake cam lever B: Pin C: Front brake cable... -
Page 14: Fuel Tank Vent Hose
HANDLEBAR PAD Install the handlebar pad to the handlebar reinforcing bar. A: Handlebar pad B: Strap L:140 mm FRONT FUEL TANK VENT HOSE Insert the free end of fuel tank vent hose to the hole of starter cable bracket. Be sure not to bend or twist the hose when installing. -
Page 15: Warning Tag
Install the reflex reflector assembly to the front fork lower bracket. A: Reflex reflector assembly B: 6 × 12 mm flange bolt REMOVING THE WRAP FILM Remove the wrap film from the fuel tank cover. A: Fuel tank cover B: Wrap film FUEL LABEL (FOR LIMITED MARKET) Stick the label on the fuel tank cover. - Page 16 SERVICING BATTERY The battery is located under the seat. Remove the bolts to take off the seat. A: Seat assembly B: Flange stepped bolt Remove the bolts to take off the battery holder. Remove the battery from the motorcycle. A: Battery holder B: Flange bolt, Stepped washer Filling electrolyte Remove the aluminium tape sealing the battery elec-...
- Page 17 With just enough force to break the nozzle seal of elec- trolyte container, push each nozzle of the electrolyte container into the battery’s electrolyte filler ports and hold the container firmly so that it does not fall. Take precaution not to allow any of the fluid to spill. A: Electrolyte containers Make sure air bubbles are coming up in each electro- lyte container, and leave in this position for about 20...
- Page 18 Charge the battery with a battery charger. For charging the battery, make sure to use the charger specially designed for MF battery. Otherwise, the battery may be overcharged resulting in shortened service life. Do not remove the cap during charging. Position the battery with the cap facing upward during charging.
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Page 19: Throttle Cable
Reinstall the battery holder. A: Battery holder B: Flange bolt, Stepped washer To install the seat, insert the seat hook into the seat hook retainer. Tighten the bolts. A: Seat assembly B: Seat hook C: Seat hook retainer D: Boss THROTTLE CABLE Check the throttle cable play at the throttle grip. -
Page 20: Front Brake
FRONT BRAKE Check the front brake lever play at the brake lever end when squeezing the lever until pressure is felt. Brake lever play: 15–25 mm If adjustment is necessary, carry out the procedure below. 1. Turn the front brake cable adjuster A clockwise or counterclockwise to obtain the specified play. -
Page 21: Rear Brake Pedal
Verify that the chain joint clip is installed properly. The opening of the chain joint clip faces away from the direction of travel. A: Direction of travel B: Chain joint clip REAR BRAKE PEDAL After the drive chain slack has been checked or adjusted, check the brake pedal free travel. -
Page 22: Engine Oil
ENGINE OIL This motorcycle is shipped from factory with the engine filled with engine oil. Be sure to check oil level. Check the engine oil level with the engine oil dipstick. The motorcycle held vertically on level ground. 1. Start the engine and allow it to run for a few minutes at idling speed. - Page 23 SAE Engine Oil Viscosity ENGINE OIL VISCOSITY RATING SELECTION CHART Suzuki recommends the use of SAE 10W-40 engine oil. 20W - 50 If SAE 10W-40 engine oil is not available, select an 15W - 40 15W - 50 alternative according to the left chart.
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Page 24: Idle Speed Adjustment
IDLE SPEED ADJUSTMENT After completing all of the servicing procedures, adjust the engine idle speed by turning the throttle stop screw. NOTE: The engine idle should be adjusted with engine warmed up. Engine idle speed: 1 500–1 700 r/min A: Throttle stop screw Test ride the motorcycle checking all mechanical func- tions. -
Page 25: Tightening Torque
TIGHTENING TORQUE Item Part Name N·m kgf-m Item Part Name N·m kgf-m FRONT FORK AXLE Handlebar mounting bolt Front axle nut Steering stem head bolt Rear axle nut Front fork upper bracket bolt ABSORBER BRAKE Rear shock absorber nut (Upper) Front brake cam lever nut Rear shock absorber nut (Lower) Rear brake cam lever nut... -
Page 26: Harness Routing
HARNESS ROUTING To battery Clamp Wiring harness Wiring harness Wiring harness Clamp Neutral switch lead wire Clamp Generator lead wire Clamp Clamp Wiring harness Wiring harness Clamp Ignition switch Clamp Starter motor Ignition coil Clamp To handlebar switch Wiring harness Neutral switch lead wire Generator lead wire Ignition switch lead wire... -
Page 27: Cable Routing
CABLE ROUTING Cable guide Starter cable Clamp Handlebar switch lead wire Front brake cable Throttle cable Starter cable White tape Throttle cable Front brake cable Clip Front number plate Front brake cable Cable guide Clip Starter cable Cable guide Handlebar switch lead wire Starter cable Throttle cable Pass the throttle cable and starter cable... -
Page 28: Safety Check-Out
SAFETY CHECK OUT COLD TIRE INFLATION PRESSURE FRONT REAR After completion of the setting-up the motorcy- 100 kPa 125 kPa cle all the following items should be double- 1.0 kgf/cm 1.25 kgf/cm checked to confirm that the operation and func- 14 psi 18 psi tion of the motorcycle are satisfactory.
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