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GSX-R750 (2000-2002)
Инструкция по эксплуатации Страница: 1

Suzuki GSX-R750 (2000-2002) Инструкция по эксплуатации онлайн

Содержание

Gsx r750 1
Service manual 1
Suzuki 1
Chassis 2
Cooling and lubrication system 2
Electrical system 2
Emission control information 2
Engine 2
Fl system and intake air system 2
Foreword 2
General information 2
Group index 2
Gsx r750k1 01 model 2
Important 2
Periodic maintenance 2
Servicing information 2
Wiring diagram 2
Component parts and work to be done 3
Howto use this manual 3
To locate what you are looking for 3
Abbreviations may be used in this manual 5
Sae to former suzuki term only for u s a 6
General info 8
General information_________ 8
General precautions 9
Warning caution note 9
Serial number location 11
Suzuki gsx r750y 2000 model 11
Brake fluid 12
Engine oil for the other models 12
Engine oil for u s a model 12
Front fork oil 12
Fuel for the other countries 12
Fuel for usa and canada 12
Fuel oil and engine coolant recommendation 12
Anti freeze engine coolant 13
Break in procedures 13
Cylinder identification 13
Engine coolant 13
Liquid amount of water engine coolant 13
Water for mixing 13
Information labels 14
Specifications 15
Country and area codes 17
Periodic maintanance 18
Periodic maintenance 18
Periodic maintenance chart 19
Periodic maintenance schedule 19
Lubrication points 20
Air cleaner____________________________ 21
Maintenance and tune up procedures 21
Spark plug 22
Valve clearance 25
Example 28
Intake side 28
Match clearance in vertical column with present shim size in horizontal 28
Measure valve clearance engine is cold 28
Present shim size 1 0 mm 28
Shim size to be used 1 0 mm 28
Tappet shim no 12892 05c00 xxx 28
Tappet shim selection table intake 28
Tappet shim set 12800 05820 28
Valve clearance is 0 3 mm 28
12 periodic maintenance 29
Example 29
Horizontal 29
Howto i1sfthis chart 29
Iii match clearance in vertical column with present shim size in 29
Present shim size 29
Shim size to be used 29
Tappet shim no 12892 05c00 xxx 29
Tappet shim selection table exhaust 29
Tappet shim set 12800 05820 29
Valve clearance is 29
Engine oil and oil filter 30
Engine idle speed 32
Evaporative emission control sys tem e 33 only 32
Fuel hose 32
Throttle valve synchronization 32
Throttle cable play _______________ 33
Clutch__________________________ 34
Cooling system________________________ 35
Drive chain___ _________________________ 37
Brake _____________ 39
Steering 43
Exhaust pipe bolt and nut 44
Front fork _____________ 44
Rear suspension 44
Chassis bolts and nuts 45
Compression pressure check 47
Compression test procedure 47
Oil pressure check 48
Engine 50
2 engine 51
Engine center 51
Engine components removable with engine in place 51
Engine left side 51
Engine right side 51
The parts listed below can be removed and reinstalled without removing the engine from the frame refer to page listed in each section for removal and reinstallation instructions 51
Engine removal 52
Engine removal and installation 52
Engine installation 60
Engine disassembly 64
Engine disassembly procedure flow chart 64
Engine disassembly 65
Engine components inspection and service 78
Pair valve 78
Camshaft 79
Cylinder head cover 79
Cam chain guide 81
Cam chain tension adjuster 81
Cam chain tensioner 81
Cylinder head and valve 82
Clutch 92
Generator 93
Oil pump 93
Starter clutch 93
Water pump 93
Gearshift system 94
Oil pressure regulator 95
Oil strainer 95
09900 06104 snap ring pliers 96
Disassemble the countershaft and drive shaft 96
Engine 3 47 96
Gears then remove the 2nd drive gear circlip 96
Pay attention to the following point 96
Remove the 6th drive gear circlip from its groove and slide it 96
Slide the 6th and 2nd drive gears toward the 3rd 4th drive 96
Towards the 3rd 4th drive gear 96
Transmission 96
Cylinder 99
Piston and piston ring 100
Crankcase 103
Crankshaft and conrod 109
Crankshaft journal bearing 112
Crankshaft thrust bearing 114
Engine reassembly 116
A cauti 118
Crankshaft 118
Fl system and intake air system 149
Fuel injection air intake 149
Connector coupler 151
Precautions in servicing 151
Ecm various sensors 152
Electrical circuit inspection procedure 153
Using testers 156
Fl system technical features 157
Injection time injection volume 157
Compensation of injection time volume 158
Injection stop control 158
Fuel delivery system 159
Fuel pump 160
Fuel injector 161
Fuel pressure regulator 161
Fuel pump control system 162
Ecm fl control unit 163
Injection timing 164
V v v v u v v 164
V v v v v v v v v 164
V v v v v v v v v v v v v v 164
Sensors 165
Intake air system 169
Secondary throttle control system 169
Operation 170
22 fl system and intake air system 171
Fl system and intake air system 4 23 172
Fl system diagram 173
Л сл ел 1 m 174
Self diagnosis function 175
User mode 175
Dealer mode 176
Fail safe function 178
Customer complaint analysis 179
Fl system troubleshooting 179
Self diagnosis reset procedure 180
Self diagnostic procedures 180
Malfunction code and defective condition 181
C11 cmp sensor circuit malfunction 183
C12 ckp sensor circuit malfunction 184
C13 iap sensor circuit malfunction 185
C14 tp sensor circuit malfunction 187
C15 ect sensor circuit malfunction 189
C21 iat sensor circuit malfunction 190
C22 ap sensor circuit malfunction 191
C23 to sensor circuit malfunction 193
C24 c25 c26 or c27 ignition system malfunction 194
C28 stv actuator circuit malfunction 194
C31 gear position gp switch circuit malfunction 197
C32 c33 c34 or c35 fuel injection malfunction 198
C41 fp relay circuit malfunction 199
C42 ig switch circuit malfunction 199
Fuel system 200
Fuel tank installation 200
Fuel tank lift up 200
Fuel tank removal 200
Fuel pressure inspection 201
Fuel pump inspection 202
Fuel pump and fuel filter removal 204
Fuel pump relay inspection 204
Fuel filter inspection and cleaning 206
Fuel pump and fuel filter installation 206
Construction 209
Throttle body and stv actuator 209
Throttle body and stv actuator removal 210
Throttle body disassembly 215
Inspection 216
Throttle body cleaning 216
Throttle body reassembly 217
Acaution 218
Throttle body and stv actuator installation 219
Stv actuator adjustment 221
A warning 222
Correctly completed in this case it is unnecessary to proceed to 5th step 222
Don t pinch your fingers in the st valve if the air cleaner is removed 222
Fl system and intake air system 4 73 222
If c28 is indicated repeat the adjustment procedure from 1st 222
Step to 4th step and also perform 5th step 222
Th step turn the mode select switch off turn the ignition switch on to check the stv actuator opera 222
Turn the mode select switch on if c28 is not indicated on the lcd display the adjustment is 222
Fuel injector inspection 224
Fuel injector removal 224
Fast idle adjustment 225
Fuel injector installation 225
Throttle valve synchronization 226
Throttle cable adjustment 229
Throttle position sensor tps setting 229
Ckp sensor inspection 230
Ckp sensor removal installation 230
Cmp sensor inspection 230
Cmp sensor removal installation 230
Iap sensor inspection 230
Iap sensor r e m ova l in stall ati on 230
Iat sensor inspection 230
Iat sensor removal installation 230
Sensors 230
Tp sensor inspection 230
Tp sensor removal installation 230
Ap sensor inspection 231
Ap sensor removal installation 231
Ect sensor inspection 231
Ect sensor removal installation 231
To sensor inspection 231
To sensor removal installation 231
Cooling and lube system 232
Cooling and lubrication system 232
Caution 233
Engine coolant 233
Cooling circuit 234
Cooling circuit inspection 234
Radiator and water hoses 235
Radiator cap inspection 235
Radiator inspection and cleaning 235
Radiator removal 235
Radiator remounting 236
Water hose inspection 236
Cooling fan 237
Cooling fan thermo switch 237
Inspection 237
Installation 237
Removal 237
Inspection 238
Installation 238
Engine coolant temperature sensor 239
Inspection 239
Removal 239
Installation 240
Removal 240
Thermostat 240
Inspection 241
Installation 241
Removal and disassembly 242
Water pump 242
Inspection 245
Reassembly and installation 246
Lubrication system 249
Engine lubrication system chart 250
Engine lubrication system 251
Cooling and lubrication system 5 21 252
View of a 252
Chassis 253
Construction 255
Exterior parts 255
Heat shield 256
Fastener removal and reinstallation 257
Screen 257
Body cowling cover 258
Right and left under cowlings 258
Body cowling 259
Cowling brace 260
Right and left air intake pipes 260
Frame cover 261
Front seat 261
Rear seat and seat tail cover 261
Construction 262
Front wheel 262
Removal 264
Inspection and disassembly 265
Reassembly and remounting 267
Construction 270
Front fork 270
Removal and disassembly 271
Reassembly and remounting 275
Suspension setting 280
Construction 281
Inspection 281
Remounting 281
Removal 281
Steering damper 281
Construction 282
Removal and disassembly 282
Steering 282
Inspection and disassembly 284
Reassembly and remounting 284
Steering tension adjustment 286
Construction 287
Handlebar 287
Removal and disassembly 287
Reassembly and remounting 288
Construction 290
Rear wheel 290
Removal 292
Inspection and disassembly 293
Reassembly and remounting 295
Construction 299
Rear shock absorber 299
Inspection 300
Removal 300
Rear shock absorber scrapping procedure 301
Remounting 301
Suspension setting 302
Rear suspension construction 303
Chassis 6 51 304
Removal 305
Inspection and disassembly 307
Reassembly 309
Remounting 311
Final inspection and adjustment 312
Front brake 313
Brake fluid replacement 314
Brake pad replacement 314
Caliper removal and disassembly 315
Caliper inspection 316
Caliper reassembly and remounting 316
Brake disc inspection 317
Master cylinder removal and disassembly 318
Master cylinder inspection 319
Master cylinder reassembly and remounting 319
A caution 321
Construction 321
Rear brake 321
Brake fluid replacement 322
Brake pad replacement 322
Caliper removal and disassembly 323
Caliper inspection 324
Caliper reassembly and remounting 324
Master cylinder removal and disassembly 325
Master cylinder inspection 326
Master cylinder reassembly and 326
Remounting 326
Inspection 327
Tire and wheel 327
Tire removal 327
Tire installation 328
Valve inspection 328
Valve installation 328
Balancer weight 329
Drive chain 330
Drive chain cutting 330
Drive chain connecting 331
Electrical system 334
Cautions in servicing 335
Connector 335
Coupler 335
Semi conductor equipped part 335
Battery 336
Connecting battery 336
Using multi circuit tester 336
Wiring procedure 336
Location of electrical components 337
Charging system 339
Description 339
Troubleshooting 341
Inspection 342
Electrical system 7 11 344
Side stand ignition interlock system description 344
Starter system and side stand ignition interlock system 344
Starter system description 344
The starter system consists of the following components the starter motor starter relay clutch lever position switch turn signal side stand relay side stand switch gear position switch starter button engine stop switch ignition switch and battery pressing the starter button on the right handlebar switch energizes the starter relay causing the contact points to close thus completing the circuit from the starter motor to the battery the starter motor draws about 80 amperes to start the engine 344
This side stand ignition interlock system prevents the motorcycle from being started with the side stand down the system is operated by an electric circuit provided between the battery and ignition coils 344
I______ _ 346
Trouble shooting 346
Starter motor inspection 347
Starter motor removal and disassembly 347
Starter motor reassembly 348
Starter relay inspection 349
Side stand ignition interlock system part inspection 350
Description 353
Ignition system 353
Troubleshooting 355
Inspection 356
Cautio 359
Combination meter 361
Description 361
Disassembly 364
Removal 364
Inspection 365
Headlight 369
Brake light taillight and turn signal light 370
Switches 371
Turn signal side stand relay 371
Battery 373
Initial charging 373
Specifications 373
Servicing 374
Recharging operation 375
Servicing info 376
Servicing information 376
Fl system malfunction code and defective condition 377
Troubleshooting 377
Engine 379
Chassis 385
Brakes 386
Electrical 387
Battery 388
Wiring harness cable and hose routing 389
Wiring harness routing 389
Servicing information 8 15 390
16 servicing information 391
Servicing information 392
Fuel tank drain hose routing 393
Pair air supply system hose routing 397
24 servicing information 399
Frame cover set up 400
Heat shield set up 400
Servicing information 8 25 400
Servicing information 8 27 402
Special tools 402
28 servicing information 403
Note when order the special tool please confirm whether it is available or not 404
_____________________servicing information 8 29 404
Engine 405
Tightening torque 405
Cooling system 406
Fl system and intake air system 406
Chassis 407
Tightening torque chart 408
Camshaft cylinder head 409
Service data 409
Valve guide 409
Cylinder piston piston ring 410
Clutch 411
Conrod crankshaft 411
Oil pump 411
Thermostat radiator fan coolant 412
Transmission drive chain 412
Fl sensors secondary throttle valve actuator 413
Injector fuel pump fuel pressure regulator 413
Electrical 414
Throttle body 414
Brake wheel 415
Wattage 415
Suspension 416
Fuel oil 417
Emission control info 418
Emission control information 418
Emission control information 9 3 420
Canister 421
Evaporative emission control system inspection only for e 33 421
Tank pressure control valve 421
Emission control information 9 5 422
Pair air supply system diagram 422
Pair air supply system hose routing 423
Pair air supply system inspection 424
Pair control valve 424
Pair reed vavle 424
Gsx r750k1 01 model 426
Updates 426
2 gsx r750k1 01 model 427
Specifications 427
Camshaft cylinder head 428
Service data 428
Valve guide 428
Cylinder piston piston ring 429
Clutch 430
Conrod crankshaft 430
Oil pump 430
Thermostat radiator fan coolant 431
Transmission drive chain 431
Fl sensors secondary throttle valve actuator 432
Injector fuel pump fuel pressure regulator 432
Electrical 433
Throttle body 433
Brake wheel 434
Wattage 434
Suspension 435
Fuel oil 436
Clutch 437
Clutch reassembly 437
Clutch drive plates inspection 438
Fuel pressure 439
Fuel pressure inspection 439
Ap sensor 440
Throttle stop screw 440
Engine mounting bolt 441
Engine mounting bolt and nut 441
Canister hose routing 442
Canister hose routing for e 33 442
Purge hose 442
Foreword 444
Gsx r750k2 02 model 444
Suzuki motor corporation 444
Updates 444
Specifications 445
Clutch 447
Engine 447
Tightening torque for cam chain tension adjuster cap 447
Fi and air intake 448
Fl system and intake air system 448
Malfunction code and defective condition 448
C28 stv actuator circuit malfunction 450
C29 stp sensor circuit malfunction 451
Fuel pump 453
Construction 455
Throttle body 455
Throttle valve synchronization 466
Chassis 469
Front axle 469
Swingarm pivot boss 469
Torque link 471
Servicing info 472
Servicing information 472
View a 472
Wire harness routing 472
Gsx r750k2 02 model 473
Cooling system hose routing 475
Front brake hose routing 476
Rear brak ehose routing 477
Canister hose routing only for e 33 478
Camshaft cylinder head 479
Service data 479
Valve guide 479
Cylinder piston piston ring 480
Clutch 481
Conrod crankshaft 481
Oil pump 481
Thermostat radiator fan coolant 482
Transmission drive chain 482
Fl sensors secondary throttle valve actuator 483
Injector fuel pump fuel pressure regulator 483
Electrical__________ 484
Throttle body 484
Brake wheel 485
Wattage 485
Suspension 486
Fuel oil 487
Wiring diagrams 488
For e 24 490
For e 03 28 33 491
Iâsâ 491
Ltáilli 491
S ââs 491
B bi black with blue tracer b br black with brown tracer b g black with green tracer b lg black with light green tracer b o black with orange tracer b r black with red tracer b w black with white tracer b y black with yellow tracer bl b blue with black tracer bl g blue with green tracer bl r blue with red tracer bl w blue with white tracer bl y blue with yellow tracer g b green with black tracer g bi green with blue tracer g r green with red tracer g w green with white tracer g y green with yellow tracer o b orange with black tracer o bi orange with blue tracer o g orange with green tracer o r orange with red tracer o w orange with white tracer o y orange with yellow tracer p b pink with black tracer r b red with black tracer r bi red with blue tracer r w red with white tracer w b white with black tracer w bi white with blue tracer w r white with red tracer y b yellow with black tracer y bi yellow with blue tracer y g yellow with green tracer y r yellow with red tracer y w yellow with 492
B black bl blue br brown dbr dark brown dg dark green g green gr gray lbl light blue lg light green o orange 492
Fl system wiring diagram 492
P pink 492
V violet 492
W white 492
Wiring diagram 492
Y yellow 492
For e 03 28 33 493
Wiring diagram y model 493
B bi black with blue tracer b br black with brown tracer b g black with green tracer b lg black with light green tracer в ó black with orange tracer b r black with red tracer b w black with white tracer b y black with yellow tracer 494
Bl g blue with green tracer bi r blue with red tracer bl w blue with white tracer 494
Black blue brown dark brown dark green green gray light blue light green 494
Blue with black tracer bl b 494
Blue with yellow tracer green with black tracer green with blue tracer green with red tracer 494
For e 03 28 33 494
G b g bi 494
G w green with white tracer g y green with yellow tracer 494
Lbi lg 494
O b orange with black tracer o bi orange with blue tracer o g orange with green tracer o r orange with red tracer o w orange with white tracer o y orange with yellow tracer p b pink with black tracer r b red with black tracer r bi red with blue tracer r w red with white tracer w b white with black tracer w bi white with blue tracer w r white with red tracer y b yellow with black tracer y bi yellow with blue tracer y g yellow with green tracer y r yellow with red tracer y w yellow with white tracer 494
Pink red violet white yellow 494
Wire color 494
Wiring diagram k1 model 494
В bl br dbr dg g 494
For e 24 495
For e 24 496
For e 02 19 497
The others 498

Suzuki GSX-R750 (2000-2002) Инструкция по эксплуатации онлайн

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