Suzuki DR-Z70 User manual

Printed in USA

99500-40030-03E DR-Z70K8_03E SERVICE MANUAL 2007. 5. 15 for PS printing

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99500-40030-03E

GROUP INDEX

GENERAL INFORMATION 1

PERIODIC MAINTENANCE 2

ENGINE 3

FUEL SYSTEM 4

CHASSIS 5

ELECTRICAL SYSTEM 6

SERVICING INFORMATION 7

FOREWORD

This manual contains an introductory description on

the SUZUKI DR-Z70 and procedures for its inspec-

tion/service and overhaul of its main components.

Other information considered as generally known is

not included.

Read the GENERAL INFORMATION section to

familiarize yourself with the motorcycle and its main-

tenance. Use this section as well as other sections

to use as a guide for proper inspection and service.

This manual will help you know the motorcycle bet-

ter so that you can assure your customers of fast

and reliable service.

* This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent of this manual and the actual motorcycle.

* Illustrations in this manual are used to show

the basic principles of operation and work

procedures. They may not represent the

actual motorcycle exactly in detail.

* This manual is written for persons who have

enough knowledge, skills and tools, including

special tools, for servicing SUZUKI motorcy-

cle. If you do not have the proper knowledge

and tools, ask your authorized SUZUKI

motorcycle dealer to help you.

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

services described in this manual.

Improper repair may result in injury to the

mechanic and may render the motorcycle

unsafe for the rider.

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right will allow you to find

the first page of the section easily.

4. The contents are listed on the first page of each section to

help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service information

such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front wheel and front brake



1Front axle



2Spacer (R)



3Dust seal



4Bearing (R)



5Spacer



6Front wheel rim



7Bearing (L)



8Spring



9Brake shoe



0Brake camshaft



ABrake panel



BBrake cam lever



AFront axle nut



BBrake cam lever nut

ITEM N·m

kgf-m

lb-ft



A53 5.3 38.5



B30.32.0

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servic-

ing. The meaning of each symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Measure in voltage range.

Apply oil. Use engine oil unless other-

wise specified. Measure in resistance range.

Apply molybdenum oil solution.

(mixture of engine oil and SUZUKl

MOLY PASTE in a ratio of 1 : 1)

Measure in diode test range.

Apply SUZUKI SUPER GREASE “A” or

equivalent grease.

99000-25010

Measure in continuity test range.

Apply SUZUKI BOND “1215” or equiva-

lent bond.

99000-31110

Use special tool.

Apply THREAD LOCK SUPER “1322”

or equivalent thread lock.

99000-32110

Indicates service data.

1-1 GENERAL INFORMATION

GENERAL INFORMATION

CONTENTS

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE COUNTRY or AREA EFFECTIVE FRAME NO.

E-28 Canada JS1JB41A 82100001-

E-33 U.S.A.

WARNING/CAUTION/NOTE .........................................................................1- 2

GENERAL PRECAUTIONS...........................................................................1- 2

SUZUKI DR-Z70K8 (’08-MODEL) .................................................................1- 4

SERIAL NUMBER LOCATION......................................................................1- 4

FUEL AND OIL RECOMMENDATION ..........................................................1- 5

FUEL (FOR USA AND CANADA)...........................................................1- 5

FUEL (FOR OTHER COUNTRIES).........................................................1- 5

ENGINE OIL (FOR USA).........................................................................1- 5

ENGINE OIL (FOR OTHER COUNTRIES) .............................................1- 5

BREAK-IN PROCEDURES ...........................................................................1- 5

INFORMATION LABELS...............................................................................1- 6

SPECIFICATIONS .........................................................................................1- 7

DIMENSIONS AND DRY MASS .............................................................1- 7

ENGINE ...................................................................................................1- 7

DRIVE TRAIN ..........................................................................................1- 7

CHASSIS .................................................................................................1- 8

ELECTRICAL ..........................................................................................1- 8

CAPACITIES ...........................................................................................1- 8

GENERAL INFORMATION 1-2

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol

and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-

sages highlighted by these signal words.

Indicates a potential hazard that could result in death or injury.



Indicates a potential hazard that could result in motorcycle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-

INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you

are unsure about how to perform a particular service operation, ask a more experienced mechanic for

advice.

GENERAL PRECAUTIONS

* Proper service and repair procedures are important for the safety of the service mechanic and

the safety and reliability of the motorcycle.

* When 2 or more persons work together, pay attention to the safety of each other.

* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-

doors.

* When working with toxic or flammable materials, make sure that the area you work in is well-

ventilated and that you follow all of the material manufacturer’s instructions.

* Never use gasoline as a cleaning solvent.

* To avoid getting burned, do not touch the engine, engine oil and exhaust system until they

have cooled.

* After servicing the fuel or exhaust systems, check all lines and fittings related to the system

for leaks.

1-3 GENERAL INFORMATION



* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-

lent.

* When removing parts that are to be reused, keep them arranged in an orderly manner so that

they may be reinstalled in the proper order and orientation.

* Be sure to use special tools when instructed.

* Make sure that all parts used in reassembly are clean. Lubricate them when specified.

* Use the specified lubricant, bond, or sealant.

* When performing service to electrical parts, if the service procedures do not require use of

battery power, disconnect the coupler from the battery.

* When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first.

Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci-

fied tightening torque.

* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking

nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with

new ones. Also, before installing these new parts, be sure to remove any left over material

from the mating surfaces.

* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is

completely seated in its groove and securely fitted.

* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a

thread is smeared with them.

* After reassembling, check parts for tightness and proper operation.

* To protect the environment, do not unlawfully dispose of used motor oil: batteries and tires.

* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

GENERAL INFORMATION 1-4

SUZUKI DR-Z70K8 (’08-MODEL)

• Difference between illustration and actual motorcycle may exist depending on the markets.

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number)



is stamped on the right side of the

steering head pipe. The engine serial number



is located on the right side of the right crankcase. These

numbers are required especially for registering the machine and ordering spare parts.

RIGHT SIDE

LEFT SIDE

1-5 GENERAL INFORMATION

FUEL AND OIL RECOMMENDATION

FUEL (FOR USA AND CANADA)

Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the

Research Method.

Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10 % ethanol, or less than 5 % methanol

with appropriate cosolvents and corrosion inhibitor is permissible.

FUEL (FOR OTHER COUNTRIES)

Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recom-

mended.

ENGINE OIL (FOR USA)

Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil.

Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of

SF/SG or SH/SJ in API with MA in JASO.

Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an

alternative according to the following chart.

ENGINE OIL (FOR OTHER COUNTRIES)

Oil quality is a major contributor to your engine’s performance

and life. Always select good quality engine oil. Use of SF/SG or

SH/SJ in API with MA in JASO.

Suzuki recommends the use of SAE 10W-40 engine oil. If SAE

10W-40 engine oil is not available, select an alternative accord-

ing to the right chart.

BREAK-IN PROCEDURES

During manufacture only the best possible materials are used and all machined parts are finished to a very

high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine

to maximum stresses. The future performance and reliability of the engine depends on the care and restraint

exercised during its early life. Refer to the following throttle position recommendations.

• Keep to these break-in throttle position:

Initial 10 hours: Less than 1/2 throttle

Up to 20 hours: Less than 3/4 throttle

10W-30

10W-40. 10W-50

15W-40. 15W-50

20W-50

GENERAL INFORMATION 1-6

INFORMATION LABELS



: English



: French

No LABEL or PLATE NAME APPLIED SPECIFICATION

E28 E33



Noise label –



Information label –



Fuel caution label

–



Manual notice Label –



General warning label



Ecc



General warning label



–



Manufacturer label –



Compliance label



–



ICES Canada label

–



EC mark label

–



Compliance label



–

Forward

Left

Front fork E33 E28

Rear fender

Right

Forward

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