![Suzuki GSX-R750 (2004) [10/471] General information](/img/pdf.png)
Suzuki GSX-R750 (2004) [10/471] General information
![Suzuki GSX-R750 (2004) [10/471] General information](/views2/1121294/page10/bga.png)
Содержание
- Foreword 2
- Group index 2
- Component parts and work to be done 3
- How to use this manual 3
- To locate what you are looking for 3
- Symbol 4
- Abbreviations used in this manual 5
- Sae to former suzuki term 7
- Wire color 9
- Contents 10
- General information 10
- General precautions 11
- Warning caution note 11
- Serial number location 13
- Suzuki gsx r750k4 04 model 13
- Brake fluid 14
- Engine oil for other countries 14
- Engine oil for usa 14
- Fuel for other countries 14
- Fuel for usa and canada 14
- Fuel oil and engine coolant recommendation 14
- Anti freeze engine coolant 15
- Engine coolant 15
- Front fork oil 15
- Liquid amount of water engine coolant 15
- Water for mixing 15
- Break in procedures 16
- Cylinder identification 16
- Information labels 17
- Dimensions and dry mass 18
- Drive train 18
- Engine 18
- Specifications 18
- Capacities 19
- Chassis 19
- Electrical 19
- Country and area codes 20
- Contents 22
- Periodic maintenance 22
- Periodic maintenance chart 23
- Periodic maintenance schedule 23
- Lubrication points 25
- Air cleaner 26
- Maintenance and tune up procedures 26
- Spark plug 27
- Valve clearance 29
- Column 32
- Example 32
- Howto use this chart 32
- I measure valve clearance engine is cold 32
- Ii measure present shim size 32
- Ill match clearance in vertical column with present shim size in horizontal 32
- Present shim size 1 0 mm 32
- Shim size to be used 1 0 mm 32
- Tappet shim no 12892 05c00 xxx 32
- Tappet shim selection table intake 32
- Tappet shim set 12800 05830 32
- Valve clearance is 0 3 mm 32
- 12 periodic maintenance 33
- Howto use this chart 33
- I measure valve clearance engine is cold 33
- Ii measure present shim size 33
- Iii match clearance in vertical column with present shim size in horizontal 33
- Present shim size 1 0 mm 33
- Shim size to be used 1 0 mm 33
- Tappet shim no 12892 05c00 xxx 33
- Tappet shim selection table exhaust 33
- Tappet shim set 12800 05830 33
- Valve clearance is 0 3 mm 33
- Engine oil and oil filter 34
- Engine idle speed 36
- Fuel line 36
- Evaporative emission control sys tem e 33 only 37
- Pair air supply system 37
- Throttle valve synchronization 37
- Clutch 38
- Throttle cable play 38
- Cooling system 39
- Cautio 40
- Drive chain 42
- Cautio 44
- Front fork 50
- Rear suspension 50
- Steering 50
- Exhaust pipe bolt and muffler bolt and nut 51
- Chassis bolts and nuts 52
- Compression pressure check 54
- Compression test procedure 54
- Oil pressure check 55
- Contents 56
- Engine 56
- Engine components removable with engine in place 57
- Reinstallation 57
- Engine removal 58
- Engine removal and installation 58
- Engine installation 65
- Engine disassembly 71
- And service 84
- Cylinder head cover 84
- Engine components inspection 84
- Camshaft 85
- Pcv hose 85
- Cam chain tension adjuster 87
- Cam chain guide 88
- Cam chain tensioner 88
- Cylinder head and valve 88
- Clutch 100
- Cautio 101
- Oil pump 101
- Generator 102
- Starter clutch 102
- Gearshift system 103
- Water pump 103
- Oil pressure regulator 104
- Oil strainer 104
- Transmission 105
- Cylinder 108
- Piston and piston ring 109
- Crankcase 111
- Crankshaft and conrod 118
- Crankshaft journal bearing 122
- Crankshaft thrust bearing 125
- Engine reassembly 127
- Cautio 137
- Fl system diagnosis 160
- Electrical parts 162
- Precautions in servicing 162
- Electrical circuit inspection procedure 165
- Using the multi circuit tester 168
- Fl system technical features 169
- Injection time injection volume 169
- Compensation of injection time volume 170
- Injection stop control 170
- Injection timing 171
- Fl system parts location 172
- Fl system wiring diagram 174
- Self diagnosis function 175
- User mode 175
- Dealer mode 176
- Tps adjustment 178
- Fail safe function 179
- Customer complaint analysis 181
- Fl system troubleshooting 181
- Self diagnosis reset procedure 183
- Self diagnostic procedures 183
- Malfunction code and defective condition 184
- C11 cmp sensor circuit malfunction 186
- Cl 2 ckp sensor circuit malfunction 188
- C13 iap sensor circuit malfunction 190
- Cl 4 tp sensor circuit malfunction 193
- Cl5 ect sensor circuit malfunction 196
- C21 iat sensor circuit malfunction 198
- C22 ap sensor circuit malfunction 200
- C23 to sensor circuit malfunction 203
- C24 c25 c26 or c27 ignition system malfunction 204
- C28 stv actuator circuit malfunction 205
- C29 stp sensor circuit malfunction 207
- C31 gp switch circuit malfunction 210
- C32 c33 c34 or c35 fuel injector circuit malfunction 211
- C41 fp relay circuit malfunction 213
- C42 ig switch circuit malfunction 213
- C49 pair control solenoid valve circuit malfunction 214
- Ckp sensor inspection 216
- Ckp sensor removal and installation 216
- Cmp sensor inspection 216
- Cmp sensor removal and installation 216
- Iap sensor inspection 216
- Iap sensor removal and installation 216
- Sensors 216
- Tp sensor inspection 216
- Tp sensor removal and installation 216
- Tps adjustment 216
- Ap sensor inspection 217
- Ap sensor removal and installation 217
- Ect sensor inspection 217
- Ect sensor removal and installation 217
- Iat sensor inspection 217
- Iat sensor removal and installation 217
- To sensor inspection to sensor removal and installation 217
- Stp sensor adjustment 218
- Stp sensor inspection stp sensor removal and installation 218
- Contents 219
- Fuel system and throttle body 219
- Fuel delivery system 220
- Cautio 221
- Fuel system 221
- Fuel tank installation 221
- Fuel tank lift up 221
- Fuel tank removal 221
- Fuel pressure inspection 222
- Fuel pump inspection 223
- Fuel pump relay inspection 224
- Fuel pump and fuel filter removal 225
- Fuel mesh filter inspection and cleaning 227
- Fuel pump and fuel mesh filter installation 227
- Construction 231
- Throttle body 231
- Air cleaner box removal 232
- Cautio 233
- Throttle body removal 233
- Throttle body disassembly 234
- Cautio 236
- Inspection 236
- Throttle body cleaning 236
- Throttle body reassembly 237
- Throttle body installation 239
- Air cleaner box installation 240
- Stp sensor adjustment 240
- Fuel injector inspection 241
- Fuel injector installation 241
- Fuel injector removal 241
- Fast idle 242
- Fast idle adjustment 242
- Throttle valve synchronization 244
- Throttle position sensor tps setting 247
- Contents 249
- Exhaust system 249
- Exhaust system components 250
- Precautions for exhaust system 250
- Exhaust pipe and muffler 251
- Removal 251
- Inspection 252
- Installation 252
- Contents 253
- Cooling and lubrication system 253
- Engine coolant 254
- Cooling circuit 255
- Cooling circuit inspection 255
- Radiator and water hoses 256
- Radiator cap inspection 256
- Radiator inspection and cleaning 256
- Radiator removal 256
- Radiator installation 257
- Water hose inspection 257
- Cooling fan 258
- Inspection 258
- Installation 258
- Removal 258
- Cooling fan thermo switch 259
- Inspection 259
- Installation 259
- Removal 259
- Ect sensor 260
- Inspection 260
- Removal 260
- Installation 261
- Removal 261
- Thermostat 261
- Inspection 262
- Installation 262
- Removal and disassembly 263
- Water pump 263
- Inspection 266
- Reassembly and installation 266
- Lubrication system 270
- Oil cooler 270
- Engine lubrication system chart 272
- Engine lubrication system 273
- Main gallery 273
- Sub gallery 2 main gallery 1 to transmission 274
- Chassis 276
- Contents ___________________________ 276
- Exterior parts 278
- Fastener removal and reinstallation 278
- Body cowling cover and lower bracket cover 279
- Right and left under cowlings 279
- Screen 279
- Body cowling 281
- Cowling brace 282
- Front seat 282
- Right and left air intake pipes 282
- Frame cover 283
- Rear seat and seat tail cover 283
- Construction 284
- Front wheel 284
- Inspection and disassembly 285
- Removal 285
- Reassembly and installation 287
- Construction 290
- Front fork 290
- Removal 291
- Disassembly 292
- Cautio 294
- Inspection 294
- Reassembly 295
- Installation 300
- Suspension setting 301
- Construction 302
- Inspection 302
- Removal 302
- Steering damper 302
- Installation 303
- Construction 304
- Steering 304
- Removal 305
- Disassembly 306
- Inspection 306
- Reassembly 306
- Installation 307
- Steering tension adjustment 309
- Construction 310
- Handlebars 310
- Removal 310
- Installation 311
- Construction 314
- Rear wheel 314
- Cautio 315
- Removal 315
- Inspection and disassembly 316
- Reassembly and installation 318
- Construction 322
- Rear shock absorber 322
- Inspection 323
- Removal 323
- Installation 324
- Rear shock absorber scrapping procedure 324
- Suspension setting 325
- Construction 326
- Rear suspension 326
- Removal 327
- Inspection and disassembly 329
- Reassembly 331
- Installation 333
- Final inspection and adjustment 334
- Construction 335
- Front brake 335
- Brake pad replacement 336
- Brake fluid replacement 337
- Caliper disassembly 338
- Caliper removal 338
- Caliper inspection 340
- Caliper reassembly 340
- Caliper installation 341
- Brake disc inspection 342
- Master cylinder removal 343
- Master cylinder disassembly 344
- Master cylinder inspection 344
- Master cylinder installation 345
- Master cylinder reassembly 345
- Construction 347
- Rear brake 347
- Brake pad replacement 348
- Brake fluid replacement 349
- Caliper disassembly 349
- Caliper removal 349
- Caliper inspection 350
- Cautio 350
- Caliper reassembly 351
- Cautio 351
- Caliper installation 352
- Master cylinder disassembly 353
- Master cylinder removal 353
- Master cylinder inspection 354
- Master cylinder reassembly 354
- Master cylinder installation 355
- Tire and wheel 356
- Tire removal 356
- Tire installation 358
- Valve inspection 359
- Balancer weight installation 360
- Cautio 360
- Drive chain 361
- Drive chain cutting 361
- Drive chain connecting 362
- Contents 365
- Electrical system 365
- Cautions in servicing 367
- Connector 367
- Coupler 367
- Battery 368
- Connecting the battery 368
- Semi conductor equipped part 368
- Wiring procedure 368
- Using the multi circuit tester 369
- Location of electrical components 370
- Charging system 372
- Troubleshooting 372
- Inspection 373
- Starter system and side stand ignition interlock system 376
- Troubleshooting 376
- Starter motor removal 377
- Starter motor disassembly 378
- Starter motor inspection 379
- Starter motor reassembly 379
- Cautio 380
- Starter motor installation 380
- Starter relay inspection 380
- Side stand ignition interlock system parts inspection 381
- Ignition system 384
- Troubleshooting 384
- Inspection 386
- Combination meter 390
- Description 390
- Removal and disassembly 391
- Inspection 392
- Headlight brake light taillight license plate light and turn signal light 396
- Fuel pump relay 398
- Relays 398
- Starter relay 398
- Turn signal side stand relay 398
- Ignition switch installation 399
- Ignition switch removal 399
- Switches inspection 400
- О о о 400
- Battery 401
- Initial charging 401
- Specifications 401
- Recharging operation 403
- Servicing 403
- Contents 404
- Servicing information 404
- Fl system malfunction code and defective condition 405
- Troubleshooting 405
- Engine 407
- Radiator cooling system 413
- Chassis 414
- Brakes 415
- Electrical 416
- Battery 418
- Wiring harness cable and hose routing 419
- Wiring harness routing 419
- 1 after throttle cable adjustment install the throttle 422
- 3 tighten the bolt together with the bracket and 422
- And left under cowling 422
- Cable clip as shown 4 pass through the throttle cable no over the 422
- Cable guide 6 pass through the clutch cable between the frame 422
- Cable routing 422
- Harness 422
- Locate the throttle cable guide under the reser voir hose __________ 5 pass through the clutch cable under the wiring 422
- Throttle cable no 422
- Throttle body hose routing 423
- Fuel tank drain hose routing 424
- Cooling system hose routing 425
- Front brake hose routing 426
- Rear brake hose routing 427
- Pair air supply system hose routing 428
- Fuel tank installation 429
- Fuel tank lower side cover 430
- Center under cowling 431
- Cowling installation 431
- Frame cover installation 432
- Under cowling heat shield installation 433
- Footrest 434
- Gearshift pedal installation 434
- Seat lock cable routing 435
- Combination meter installation 436
- Handlebar balancer 436
- Rear combination light installation 437
- Special tools 438
- Engine 442
- Tightening torque 442
- Cooling system 443
- Fl system and intake air system 443
- Chassis 444
- Tightening torque chart 445
- Service data 446
- Valve valve guide 446
- Camshaft cylinder head 447
- Cylinder piston piston ring 447
- Conrod crankshaft______________ 448
- Clutch 449
- Oil pump 449
- Transmission drive chain 449
- Injector fuel pump fuel pressure regulator 450
- Thermostat radiator fan coolant 450
- Fl sensors secondary throttle valve actuator 451
- Throttle body 452
- Brake wheel 453
- Wattage 453
- Suspension 455
- Fuel oil 456
- Emission control information 458
- Emission control systems 459
- Fuel injection system 459
- Crankcase emission control system 460
- Exhaust emission control system pair system 461
- Evaporative emission control system only for e 33 462
- Noise emission control system 462
- Pair air supply system and emission control system inspection 463
- Pair hoses 463
- Pair reed valve 463
- Pcv hose 463
- Pair control solenoid valve 464
- Pair air supply system diagram 465
- Pair air supply system hose routing 466
- Evap canister 467
- Evaporative emission control system inspection only for e 33 467
- Tank pressure control tpc valve 467
- Fuel shut off valve 468
- Evap canister hose routing only for e 33 469
- E 03 24 28 33 470
- Wiring diagram 470
- Wiring diagrams wire color refer to section wire color 470
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F GENERAL INFORMATION 1 1 GENERAL INFORMATION CONTENTS WARNING CAUTION NOTE GENERAL PRECAUTIONS SUZUKI GSX R750K4 SERIAL NUMBER 1 2 1 2 04 MODEL 1 4 LOCATION 1 4 FUEL OIL AND ENGINE COOLANT RECOMMENDATION 5 FUEL FOR USA AND CANADA 5 FUEL FOR OTHER COUNTRIES 1 5 ENGINE OIL FOR USA 1 5 ENGINE OIL FOR OTHER COUNTRIES 1 5 BRAKE FLUID 1 5 FRONT FORK OIL 1 6 ENGINE COOLANT 1 6 WATER FOR MIXING 1 6 ANTI FREEZE ENGINE COOLANT 1 6 LIQUID AMOUNT OF WATER ENGINE COOLANT 1 6 BREAK IN PROCEDURES 1 7 CYLINDER IDENTIFICATION 1 7 INFORMATION LABELS 1 8 SPECIFIC A TIONS 1 9 DIMENSIONS AND DRY MASS ENGINE DRIVE TRAIN CHASSIS ELECTRICAL CAPACITIES COUNTRY AND AREA CODES 1 9 1 9 1 9 1 10 1 10 1 10 1 11
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