![Suzuki GSX-R750 (2004) [353/471] Master cylinder disassembly](/img/pdf.png)
Suzuki GSX-R750 (2004) [353/471] Master cylinder disassembly
![Suzuki GSX-R750 (2004) [353/471] Master cylinder disassembly](/views2/1121294/page353/bg161.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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CHASSIS 8 77 MASTER CYLINDER REMOVAL Remove the brake fluid reservoir mounting bolt Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid Remove the union bolt and disconnect the brake hose Loosen the lock nut Remove the mounting bolts CAUTION Immediately and completely wipe off any brake fluid contacting any parts of the motorcycle The fluid reacts chemically with paint plastic and rubber mate rials etc and will damage them severely Disconnect the reservoir hose Remove the master cylinder by turning the master cylinder rod MASTER CYLINDER DISASSEMBLY Remove the reservoir cap and diaphragm Remove the connector by removing the screw Remove the O ring CAUTION Replace the O ring with a new one
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