Suzuki DR-Z70K8 User guide

K8
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.

1
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.

2
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.

3
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
B
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
G
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
I
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)
TL
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
IF
G

4
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
AA
BB
CC
DD
EE
FF
GGHH
II
JJ
KKLL

5
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.

6
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.

7
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.

8
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.

9
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.