Service manuals for repairing Japanese motorcycles Suzuki DR-Z (Djebel)

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Description and history of Japanese motorcycles Suzuki DR-Z (Djebel)

Content:

DR-Z50 DR-Z70 DR-Z110 DR-Z125 DR-Z250 DR-Z400

Suzuki DR-Z50 (2008-present)

Launched in Japan on April 23, 2008, the Suzuki DR-Z50 is designed for young riders aged 7 and above, with a maximum load capacity of 40 kg.

This model serves as an excellent introduction for children to the basics of motorcycle riding. Its compact 49 cc SOHC single-cylinder engine is engineered to deliver a responsive and manageable power output at low RPMs. The bike features a three-speed transmission equipped with an automatic clutch, simplifying the riding experience, along with a neutral-only starting system that ensures safety by preventing the bike from starting in gear. Additionally, the adjustable throttle limiter allows parents to customize the throttle response based on the rider's skill level.



The DR-Z50 shares similar dimensions and components with the DR-Z70, which has a 67cc engine, including 90 mm drum brakes, bodywork, seat design, and fuel tank. The throttle limiter can be set by parents to help novice riders gradually improve their skills.



Specifications:

• Dimensions: Length: 1320 mm; Width: 580 mm; Height: 790 mm
• Seat Height: 560 mm
• Wheelbase: 935 mm
• Ground Clearance: 135 mm
• Dry Weight: 54 kg
• Engine Type: Air-cooled 49 cc single-cylinder, 2-valve SOHC
• Engine Power: 3.35 hp @ 9500 rpm; Torque: 3.4 Nm @ 7000 rpm
• Bore x Stroke: 39.0 mm x 41.8 mm
• Carburetor: Mikuni VM13
• Transmission: 3-speed constant mesh
• Front Suspension: Telescopic with coil spring
• Rear Suspension: Swingarm type, coil spring, oil-damped
• Brakes: Front and rear drum brakes
• Front Tire: 2.50-10 33J, tube type
• Rear Tire: 2.50-10 33J, tube type
• Fuel Tank Capacity: 3.0 l

Suzuki DR-Z70 (2008-current)

The Suzuki DR-Z70 is a single-cylinder, four-stroke Enduro motorcycle that has been manufactured by Suzuki since 2008.



Its engine is an air-cooled, single-cylinder design with a bore of 48 mm and a stroke of 37 mm, resulting in a displacement of 67 cc. The engine features a single overhead camshaft (SOHC) for efficient fuel delivery. The motorcycle is equipped with a 3-speed transmission, and power delivery is managed through a centrifugal clutch system.



For traction, the DR-Z70 is fitted with 2.50-10 tires on both the front and rear. Stopping power is provided by drum brakes at both ends, utilizing expanding brake mechanisms. The front suspension consists of inverted telescopic forks with coil springs, while the rear suspension features a swingarm design with a coil spring and oil damping for enhanced ride comfort.

The bike is equipped with a fuel tank capacity of 3 liters and has a lightweight design, weighing in at just 53 kg. Its wheelbase measures 935 mm, contributing to its agile handling characteristics.

Suzuki DR-Z110 (2003-2005)

The Suzuki DR-Z 110 is a single-cylinder, four-stroke Supermotard motorcycle that was produced by Suzuki from 2003 to 2005. This model serves as an excellent entry-level option for novice riders looking to explore off-road capabilities.



Powering the DR-Z 110 is an air-cooled, single-cylinder engine with a bore of 53.0 mm and a stroke of 50.6 mm, resulting in a displacement of 111 cc. The engine utilizes a single overhead camshaft (SOHC) for efficient fuel delivery and features a 3-speed transmission with an automatic clutch for smooth operation.



The motorcycle is equipped with a front tire size of 70/90-17 and a rear tire size of 90/90-14, providing a balanced grip on various terrains. Stopping power is delivered through single disc brakes at both the front and rear. The front suspension consists of telescopic forks with oil damping, while the rear suspension features a link-type design, also oil-damped, to enhance ride comfort and stability.

The DR-Z 110 includes a fuel tank capacity of 3.8 liters and has a lightweight construction, tipping the scales at just 64 kg. Its wheelbase measures 1065 mm, contributing to its nimble handling and maneuverability.

Specifications:

• Engine: Air-cooled single-cylinder, 4-stroke, 2 valves
• Cylinder Displacement: 111 cc
• Bore x Stroke: 53.0 mm x 50.6 mm
• Compression Ratio: 9.5:1
• Carburetor: Keihin PB18
• Transmission: 3-speed with automatic clutch
• Final Drive: #428 chain
• Ignition System: CDI
• Front Suspension: Telescopic, oil-damped
• Rear Suspension: Link-type, oil-damped
• Front Brake: Single 90 mm drum
• Rear Brake: Single 90 mm drum
• Front Tire Size: 2.50-14
• Rear Tire Size: 3.00-12
• Fuel Tank Capacity: 3.8 liters (including reserve)
• Color: Champion Yellow

Suzuki DR-Z125/DR-Z125L (2003-current)

The DR-Z125 serves as an excellent entry-level dirt bike for young riders transitioning from machines under 100 cc. Its spirited performance makes it a versatile off-road option that can be enjoyed by the whole family. Developed in collaboration with Kawasaki as part of a strategic alliance, the DR-Z125 was also marketed as the Kawasaki KLX125 from 2003 to 2006. Many of the major components between these early models are interchangeable, as the Kawasaki version is essentially a rebranded DR-Z125.



The Suzuki DR-Z125L, introduced in 2002, is a single-cylinder, four-stroke Supermotard motorcycle. It delivers a maximum torque of 12 Nm at 8600 RPM, with a claimed horsepower of 12 HP (8.9 kW) at 9500 RPM.

This model features an air-cooled, single-cylinder engine with a bore of 57.0 mm and a stroke of 48.8 mm, resulting in a displacement of 124 cc. Fuel is delivered through a single overhead camshaft (SOHC) system.



The DR-Z125L is equipped with a 5-speed transmission, and power is managed via a wet multi-plate clutch. It rolls on a 70/100-19 front tire and a 90/100-16 rear tire, providing good traction on various terrains. Stopping power is provided by a single disc brake at the front and a drum brake at the rear. The front suspension features telescopic forks, while the rear suspension is a link-type design with a coil spring and oil damping for improved ride quality. The bike has a fuel tank capacity of 4.16 liters and weighs in at just 79 kg, with a wheelbase of 1270 mm.



Specifications for DR-Z125:

• Dimensions (L/W/H): 1810 mm / 770 mm / 1060 mm
• Wheelbase: 1245 mm
• Ground Clearance: 260 mm
• Seat Height: 770 mm
• Dry Weight: 80 kg
• Engine Type: Air-cooled, 124.5 cc, single-cylinder, SOHC, 2 valves
• Engine Power: 12 hp (8.83 kW) @ 9500 rpm; Torque: 10 Nm @ 8600 rpm

Specifications for DR-Z125L:

• Dimensions (L/W/H): 1885 mm / 885 mm / 1085 mm
• Wheelbase: 1270 mm
• Ground Clearance: 274 mm
• Seat Height: 800 mm
• Dry Weight: 81 kg
• Engine Type: Air-cooled, 124.5 cc, single-cylinder, SOHC, 2 valves
• Engine Power: 12 hp (8.83 kW) @ 9500 rpm; Torque: 10 Nm @ 8600 rpm

Suzuki DR-Z250 (2001-2019)

The Suzuki DR-Z250, introduced in 2001, is a versatile mid-weight off-road motorcycle designed to cater to a diverse array of riders. It features a compact 249 cc 4-stroke, DOHC single-cylinder engine, equipped with SACS air/oil cooling and a 4-valve TSCC cylinder head, delivering controllable low-end torque and power. The engine is complemented by a balancer shaft, ensuring smooth operation, much like its larger counterpart, the DR-Z400.



This engine boasts a displacement of 249 cc, with bore and stroke measurements of 73.0 mm and 62.6 mm, respectively. The mid-sized engine also has a compression ratio of 10.4:1 and is paired with a six-speed transmission. The DR-Z250 features an electric starter, alongside a backup kickstarter and an automatic decompression system for added convenience.

The bike is built on a durable steel frame, complemented by an aluminum swingarm and a protective skid plate. Its front suspension consists of a conventional long-travel fork, offering 12-way compression and 17-way rebound damping adjustments. The rear suspension features a remote-reservoir shock absorber, fully adjustable for compression damping, rebound damping, and spring preload.



For braking, the DR-Z250 is equipped with a single hydraulic disc brake at the front, featuring a twin-piston caliper, and a rear single disc brake with a caliper and disc guard for added safety.

Despite being primarily an off-road motorcycle, the DR-Z250 is street-legal, thanks in part to its lightweight lighting system.



Developed in collaboration with Kawasaki as part of the Kawasaki-Suzuki alliance, the DR-Z250 was also marketed as the Kawasaki KLX250 from 2003 to 2006. Many major components between the two brands are interchangeable, as the Kawasaki model is essentially a rebranded DR-Z250.

The Suzuki DR-Z250 enjoyed a long production run with minimal changes over the years, remaining available in the USA until 2019.

Specifications:

• Dimensions (L/W/H): 2150 mm / 880 mm / 1205 mm
• Seat Height: 900 mm
• Ground Clearance: 300 mm
• Wheelbase: 1455 mm
• Dry Weight: 115 kg
• Engine Type: Liquid-cooled, 249 cc DOHC single-cylinder, 4 valves
• Engine Power: 32 hp (23.5 kW) @ 7000 rpm; Torque: 19.1 Nm @ 5500 rpm

Suzuki DR-Z400 (2000-current)

The DRZ 400 is a motorcycle produced by the Japanese manufacturer Suzuki since 2000.

The Suzuki DRZ 400 was introduced in 1999 as a replacement for the previous DR 350. It has been regularly available for sale since 2000, initially offering three models: the DRZ 400 S, which is more suited for dual-sport use, and the DRZ 400 (without electric start) and DRZ 400 E, which are more focused on exclusive off-road use.



In Europe, the DRZ 400 S has always been marketed by the Suzuki network, while the DRZ 400 E by Valenti, which approved for road circulation a model otherwise intended for use exclusively on the track. Some DRZ models without electric starter, conceptually very close to the E model, have arrived in Italy, imported by Valenti. The latter, having seized on the nascent interest in the Supermotard phenomenon, since 2002 has approved the DRZ 400 E also with the 17" wheels typical for this use: in this way, with a not excessive expense, you can have a motorbike with dual use, Enduro and Supermotard.



Given the success of this initiative, in 2005 the parent company also introduced the SM model alongside the S enduro model with 21 and 18-inch wheels, starting from 2005. However, these two models, S and SM, do not have the dual homologation like the E model.

There have been few modifications over the years for both the DRZ 400 S and the DRZ 400 E. The former underwent a suspension update in 2003, with forks very similar to those of the DRZ 400 E, as well as the shock absorber, although with a less stiff spring. Side cover protections and a rear disc brake guard, which were missing in the first version, were also added.



The DRZ 400 E also received a stronger shock absorber spring and larger cooling tubes in 2004. Other changes for both models have been limited to graphics and plastic colors, as well as Euro 2 homologation from 2005.



Since 2008, the DRZ 400 S and SM models are no longer present in the official Suzuki Europe catalog and remain available in the USA and some European countries.

The DR-Z400 has been produced in four variants:

• DR-Z400 - Kick-start only, not street legal in the US, but possibly street legal in Australia.
• DR-Z400E - Electric start, not street legal in the US, but street legal in Australia; features a kick-start.
• DR-Z400S - Street legal (equipped with a headlight, taillight, turn signals, mirrors, and electric start).
• DR-Z400SM - Supermoto variant, introduced in 2005, street legal, and comes standard with 17-inch (430 mm) sportbike-inspired wheels, oversized front and rear brakes, an RMZ rear swingarm, and inverted forks.