Suzuki DR-Z70 User manual

Printed in USA

K8

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

TOP

BOTTOM

9 9 5 0 0 - 4 0 0 3 0 - 0 3 E

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

1 Front axle

2 Spacer (R)

3 Dust seal

4 Bearing (R)

5 Spacer

6 Front wheel rim

7 Bearing (L)

8 Spring

9 Brake shoe

0 Brake camshaft

A Brake panel

B Brake cam lever

A Front axle nut

B Brake cam lever nut

"

ITEM N·m

kgf-m

lb-ft

A 53 5.3 38.5

B 30.32.0

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

1

6

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)

1

is stamped on the right side of the

steering head pipe. The engine serial number

2

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

E

: English

F

: French

No LABEL or PLATE NAME

APPLIED SPECIFICATION

E28 E33

1

Noise label –

c

2

Information label –

c

3

Fuel caution label

c

–

4

Manual notice Label –

c

5

General warning label

E cc

6

General warning label

F c

–

7

Manufacturer label –

c

8

Compliance label

E c

–

9

ICES Canada label

c

–

0

EC mark label

c

–

A

Compliance label

E

/

F c

–

Forward

Left

Front fork E33 E28

Rear fender

Right

Forward

1-7 GENERAL INFORMATION

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length.......................................................................... 1 320 mm (52.0 in)

Overall width ........................................................................... 580 mm (22.8 in)

Overall height.......................................................................... 790 mm (31.1 in)

Wheelbase .............................................................................. 935 mm (36.8 in)

Ground clearance ................................................................... 135 mm (5.3 in)

Seat height.............................................................................. 560 mm (22.0 in)

Dry mass................................................................................. 53 kg (116 lbs)

ENGINE

Type ........................................................................................ 4 stroke, air-cooled, OHC

Number of cylinders ................................................................ 1

Bore ........................................................................................ 48.0 mm (1.890 in)

Stroke...................................................................................... 37.0 mm (1.457 in)

Displacement .......................................................................... 67 cm³ (4.1 cu.in)

Compression ratio................................................................... 9.5:1

Carburetor............................................................................... MIKUNI VM13SH

Air cleaner............................................................................... Polyurethane foam element

Starter system......................................................................... Electric and kick

Lubrication system .................................................................. Wet sump

Idle speed ............................................................................... 1 600 ± 100 r/min

DRIVE TRAIN

Clutch...................................................................................... Wet shoe, auto matic, centrifugal type

Transmission........................................................................... 3-speed constant mesh

Gearshift pattern ..................................................................... 3-up

Primary reduction ratio............................................................ 3.823 (65/17)

Final reduction ratio ................................................................ 2.538 (33/13)

Gear rations, Low ................................................................... 3.400 (34/10)

2nd .................................................................... 1.812 (29/16)

Top .................................................................... 1.200 (24/20)

Drive chain .............................................................................. D.I.D 428, 78 links

GENERAL INFORMATION 1-8

CHASSIS

Front suspension..................................................................... Inverted telescopic, coil spring

Rear suspension ..................................................................... Swingarm type, coil spring, oil damped

Front fork stroke ...................................................................... 96 mm (3.8 in)

Rear wheel travel .................................................................... 76 mm (3.0 in)

Caster...................................................................................... 25 ° 20 ’

Trail ......................................................................................... 35 mm (1.38 in)

Steering angle ......................................................................... 45 ° (right & left)

Turning radius ......................................................................... 1.4 m (4.6 ft)

Front brake.............................................................................. Drum brake

Rear brake .............................................................................. Drum brake

Front tire size .......................................................................... 2.50-10 33J, tube type

Rear tire size ........................................................................... 2.50-10 33J, tube type

ELECTRICAL

Ignition type............................................................................. Electronic ignition (CDI)

Ignition timing .......................................................................... 15 ° B.T.D.C at 1 600 r/min

Spark plug ............................................................................... NGK CR7HSA or DENSO U22FSR-U

Battery..................................................................................... 12 V 8.28 kC (2.3 Ah)/10 HR

Generator ................................................................................ Single-phase A.C. generator

Main fuse................................................................................. 10 A

CAPACITIES

Fuel tank, including reserve .................................................... 3.0 L (0.8/0.7 US/lmp gal)

Reserve.................................................................. 0.8 L (0.2/0.2 US/lmp gal)

Engine oil, oil change.............................................................. 700 ml (0.7/0.6 US/Imp qt)

overhaul ................................................................ 800 ml (0.8/0.7 US/lmp qt)

These specifications are subject to change without notice.

2-1 PERIODIC MAINTENANCE

CONTENTS

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE .....................................................2- 2

PERIODIC MAINTENANCE CHART .....................................................2- 2

LUBRICATION POINTS .........................................................................2- 3

MAINTENANCE AND TUNE-UP PROCEDURES ........................................2- 4

AIR CLEANER .......................................................................................2- 4

EXHAUST PIPE BOLTS AND MUFFLER MOUNTING NUT ................2- 5

VALVE CLEARANCE ............................................................................2- 6

SPARK PLUG ........................................................................................2- 8

SPARK ARRESTER ...............................................................................2- 9

FUEL LINE .............................................................................................2- 9

ENGINE OIL ...........................................................................................2-10

THROTTLE CABLE PLAY .....................................................................2-11

IDLE SPEED ...........................................................................................2-11

CLUTCH .................................................................................................2-11

DRIVE CHAIN .........................................................................................2-12

BRAKES .................................................................................................2-14

TIRES .....................................................................................................2-14

SPOKE NIPPLES ...................................................................................2-15

STEERING ..............................................................................................2-16

FRONT FORK ........................................................................................2-16

REAR SUSPENSION .............................................................................2-16

CHASSIS BOLTS AND NUTS ...............................................................2-17

COMPRESSION PRESSURE CHECK .........................................................2-18

COMPRESSION TEST PROCEDURE ...................................................2-18

OIL PRESSURE CHECK ..............................................................................2-19

OIL PRESSURE TEST PROCEDURE ...................................................2-19

AUTOMATIC CLUTCH INSPECTION ..........................................................2-20

1. INITIAL ENGAGEMENT INSPECTION ..............................................2-20

2. CLUTCH “LOCK-UP” INSPECTION .................................................2-20

2

6

PERIODIC MAINTENANCE 2-2

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep

the motorcycle operating at peak performance and economy.

NOTE:

More frequent servicing may be performed on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART

NOTE:

I = Inspect and clean, adjust, replace or lubricate as necessary

C= Clean

R = Replace

T = Tighten

Interval

Item

Initially

1 month

Every

6 months

Every

12 months

Air cleaner element

Inspect each time the motorcycle is

ridden and clean as necessary.

Exhaust pipe bolts and muffler mounting nut T T T

Valve clearance I I I

Spark plug — I R

Spark arrester — C C

Fuel line I I I

Engine oil R R R

Throttle cable I I I

Idle speed I I I

Clutch I I I

Drive chain

Clean, oil and inspect each time

the motorcycle is ridden.

Brakes I I I

Tires — I I

Spoke nipples Inspect each time the motorcycle is ridden.

Steering I I I

Front fork I I I

Rear suspension I — I

Chassis nuts and bolts T T T

2-3 PERIODIC MAINTENANCE

LUBRICATION POINTS

Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.

Major lubrication points are indicated below.

NOTE:

* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

* Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle

has been operated under wet or rainy conditions.

Side-stand pivot

and spring hook

Kick starter leverBrake pedal pivot

Throttle cable

Drive chain

Front brake

lever holder

PERIODIC MAINTENANCE 2-4

MAINTENANCE AND TUNE-UP

PROCEDURES

This section describes the servicing procedures for each item of

the Periodic Maintenance requirements.

AIR CLEANER

If the air cleaner element is clogged with dust, intake resistance

will be increased, with a resultant decrease in power output and

increase in fuel consumption. Check and clean the air cleaner

element in the following manner.

• Remove the air cleaner box cover

1

.

• Remove the air cleaner element

2

.

• Fill a container with a non-flammable cleaning solvent.

• Immerse the air cleaner element in the cleaning solvent and

wash it.

• Squeeze the cleaning solvent out of the washed element by

pressing it between the palms of both hands: do not twist or

wring the element or it will develop tears.

• Immerse the element in air filter oil and squeeze the oil out of

the element leaving it slightly wet with oil.



A

Non-flammable cleaning solvent

B

Air filter oil

Inspect each time the motorcycle is ridden and clean

as necessary.

Inspect the air cleaner element for tears. A torn ele-

ment must be replaced.

2-5 PERIODIC MAINTENANCE

• Reinstall the cleaned or new air cleaner element in the

reverse order of removal.



• Remove the drain plug

4

to allow any water to drain out.

EXHAUST PIPE BOLTS AND MUFFLER

MOUNTING NUT

• Tighten the exhaust pipe bolts

1

and muffler mounting nut

2

to the specified torque.

" Exhaust pipe bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

Muffler mounting nut: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

The open mesh

A of the air cleaner element must be

faced outside.

The surest way to accelerate engine wear is to operate

the engine without the element or to use a torn ele-

ment. Make sure that the air cleaner is in good condi-

tion at all times. The life of the engine depends largely

on this component.

Tighten initially at 1 month and every 6 months

thereafter.

PERIODIC MAINTENANCE 2-6

VALVE CLEARANCE

REMOVAL

• Remove the spark plug. (



2-8)

• Remove the camshaft sprocket cover

1

.

• Remove the valve inspection caps

2

.

• Remove the TDC plug

3

and generator cover plug

4

.

INSPECTION

The valve clearance specification is different for intake and

exhaust valves. Valve clearance adjustment must be checked

and adjusted, 1) at the time of periodic inspection, 2) when the

valve mechanism is serviced, and 3) when the camshaft is dis-

turbed by removing it for servicing.

NOTE:

* The piston must be at “TDC” on the compression stroke in

order to check the valve clearance or to adjust valve clear-

ance.

* The clearance specification is for COLD state.

* To turn the crankshaft for clearance checking, and rotate in the

normal running direction.

 Valve clearance (when cold):

IN.: 0.04 – 0.07 mm (0.0016 – 0.0028 in)

EX.: 0.05 – 0.10 mm (0.0020 – 0.0039 in)

Inspect initially at 1 month and every 6 months there-

after.

2-7 PERIODIC MAINTENANCE

• Turn the crankshaft to bring the “Top” line

A

on the generator

rotor to the center of hole on the generator cover and also to

bring the mark

B

on the camshaft sprocket with the concave

line

C

of the cylinder head as shown.

• Insert a thickness gauge between the valve stem end and the

adjusting screw on the rocker arm.

If the clearance is out of specification, bring it into the speci-

fied range.

\ 09900-20803: Thickness gauge

09917-14910: Valve clearance adjusting driver

" Valve adjuster lock-nut: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

• After finishing the valve clearance adjustment, reinstall the fol-

lowing items.

* TDC plug (



3-70)

* Generator cover plug (



3-70)

* Camshaft sprocket cover (



3-69)

* Spark plug (



2-8)

Adjusting screw

Lock-nut

PERIODIC MAINTENANCE 2-8

SPARK PLUG

REMOVAL

• Disconnect the spark plug cap

1

and remove the spark plug

2

.

HEAT RANGE

• Check spark plug heat range by observing electrode color. If

the electrode of the spark plug is wet appearing or dark color,

replace the spark plug with hotter type one. If it is white or

glazed appearing, replace the spark plug with colder type

one.

\ 09930-10121: Spark plug wrench set

CARBON DEPOSIT

Inspect the carbon deposit on the spark plug.

If carbon is deposited, remove it with a spark plug cleaner

machine or carefully using a tool with a pointed end.

SPARK PLUG GAP

Measure the spark plug gap with a thickness gauge. Adjust the

spark plug gap if necessary.

 Spark plug gap:

Standard: 0.6 – 0.7 mm (0.024 – 0.028 in)

\ 09900-20803: Thickness gauge

ELECTRODE’S CONDITION

Inspect the worn or burnt condition of the electrodes. If it is

extremely worn or burnt, replace the new spark plug. And also

replace the plug if it has a broken insulator, damaged thread,

etc.



Inspect every 6 months.

Replace every 12 months.

Hot type Standard Cold type

NGK CR6HSA CR7HSA CR8HSA

DENSO U20FSR-U U22FSR-U U24FSR-U

Confirm the thread size and reach when replacing the

plug. If the reach is too short, carbon will be deposited

on the screw portion of the plug hole and engine dam-

age may result.

0.6 – 0.7 mm

(0.024 – 0.028 in)

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Suzuki DR-Z70 User manual

Suzuki DR-Z70 User manual

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