Suzuki DR-Z70K8 User guide

June ’07 Printed in Japan (TK) 28

99505-01008-01E

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.

PREPARATION

WORKSHOP



A: Packed motorcycle

B: Working space

SELF PROTECTION



UNCRATING THE MOTORCYCLE

Remove the carton.



A: Crate

Remove the strap.

Take out the front wheel assembly and component

parts from the crate base.

A: Strap

B: Front wheel assembly

C: Component parts

The workshop where the machine is assembled

should be clean, spacious, and have a level

floor.

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.

Metal crates may have sharp edges and may

cause injury.

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.





A: Steel frame

B: Crate base

Handling crates requires two operators.

Be careful not to scratch the motorcycle.

LOCATION OF PARTS

Check all the components which have been removed from the base of the crate.

Parts listed above are installed respectively into the positions as follows.

Item Part Name Q’ty Remarks

A Front number plate 1

Handlebars assembly 1

Flange bolt 2 8 × 16 mm

Washer 2 OD:22.0 ID:8.5

Screw 1 5 × 16 mm For

throttle assembly

Brake lever cover 1

Handlebar pad 1

Strap 2 L:140

Strap 1 L:100

Clip 1

CFront fender 1

Flange stepped bolt 3 6 × 18 mm

D Front wheel assembly 1

EFront brake hub panel

assembly 1

F Front wheel spacer 1

Item Part Name Q’ty Remarks

Front fork protector 2 Right and Left

Flange bolt 4 6 × 12 mm

Stepped washer 4 OD:16.0 ID:6.5 T:5.0

HStrap 1 L:100

For starter cable

Reflex reflector 2 Right and Left

Bracket 2 Right and Left

Flange bolt 2 6 × 12 mm

Collared spacer 2 OD:17.0 ID:6.5 T:7.5

Rubber grommet 2 OD:18.0 ID:8.5 T:6.0

Flange nut 2 5 mm

J Fuel label 1 For limited market

KBattery electrolyte

container 1

LOwner’smanualset 1

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

NOTE:

The parts shown as Item I and J in the above table are supplied for limited markets.

Please hand over the parts shown as Item L in the above table to your customer together with motor-

cycle.

GEI

DCA H B

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

GGHH

KKLL

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.



A: Bracket

B: Bolt

C: Washer

D: Paper

Tighten the steering stem head bolt to the specified

torque.

Steering stem head bolt: 45 N·m (4.5 kgf-m)

A: Steering stem head bolt

B: Washer

Be careful not to scratch the fuel tank.

NOTE:

The removed bolt Band washer Care used to

tighten the steering stem.

The bracket and paper are no longer needed

and may be discarded.

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 × 16 mm flange bolt

D: Washer OD:22.0 mm ID:8.5 mm



A: Front brake cable

B: Throttle cable

C: Right switch wiring harness

The line drawings on page 25 and 26 show the

proper routing of the control cables and wir-

ings.

Refer to them in addition to following the

instructions carefully.

THROTTLE

Insert the boss of the throttle housing into the hole on

the handlebars.

Tighten the throttle assembly with two screws.



A: Boss

B: Hole

C: 5 × 16 mm screw

CLAMP

Clamp the right switch wiring harness and handlebar

with the strap.

A: Strap L:100 mm

B: Handlebars

C: Right switch wiring harness

STARTER CABLE

Loosen the cable lock nut.

Insert the starter cable to the starter cable bracket.

A: Starter cable

B: Cable lock nut

C: Starter cable bracket

Fit the flat surface of the starter cable and starter cable

bracket.

Tighten the cable lock nut.

A: Starter cable

B: Starter cable bracket

C: Cable lock nut

D: Flat surface

Check to ensure that the throttle operates freely

and closes automatically.

Place the rubber boot.

A: Rubber boot

B: Cable lock nut

Clamp the rubber boot with the strap.

A: Strap L:100 mm

B: Rubber boot

Remove the crate axle bracket from the crate base.

A: Crate axle bracket

B: Bolt

1. Lift the front of motorcycle by using a hoist.

2. Raise the rear of motorcycle.

3. Pull the crate base forward, then balance the

motorcycle.

NOTE:

Move the rubber boot until it comes to contact

with the cable lock nut.

NOTE:

Cut off the excess strap as shown in the photo-

graph.

NOTE:

The bracket and bolt are no longer needed and

may be discarded.

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

Clean the brake drum with alcohol or other non-petro-

leum based solvent.

Examine the brake shoes, springs, and operating

mechanisms.

Install the brake panel into the front wheel hub.

A: Front brake hub panel assembly

Remove the front axle nut.

Remove the front axle from the fork legs.

A: Front axle nut

B: Front axle

C: Vinyl tube

NOTE:

The vinyl tube is no longer needed and this

may be discarded.

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