![Suzuki GSX-R750 (1993-1995) [142/352] Inspection](/img/pdf.png)
Suzuki GSX-R750 (1993-1995) [142/352] Inspection
![Suzuki GSX-R750 (1993-1995) [142/352] Inspection](/views2/1121296/page142/bg8e.png)
Содержание
- Chassis 3
- Foreword 3
- Group index 3
- Important 3
- Suzuki motor corporation 3
- General information 5
- Fuel oil and coolant recommendation 6
- Serial number location 6
- Suzuki gsx r750wp 93 model 6
- Anti freeze engine coolant 7
- Brake fluid 7
- Engine coolant 7
- Engine oil 7
- Front fork oil 7
- Liquid amount of water engine coolant 7
- Water for mixing 7
- Break in procedures 8
- Cylinder identification 8
- Emery cloth and the like how to use them and where to use them are described in the text of this 9
- Kept on hand for ready use they supplement such standard materials as cleaning fluids lubricants 9
- Manual 9
- Special materials 9
- The materials listed below are needed for maintenance work on the gsx r750w and should be 9
- Material part page 10
- Aterial part page 11
- Precautions and general instructions 12
- Replacement parts 12
- Information labels 13
- Dimensions and dry mass 15
- Engine 15
- Specifications 15
- Transmission 15
- Capacities 16
- Chassis 16
- Electrical 16
- Country or area 17
- Periodic maintenance and 19
- Tune up procedures 19
- Periodic maintenance chart 20
- Periodic maintenance schedule 20
- Before lubricating each part dean off any rusty spots and wipe off any grease oil dirt or grime 21
- Lubricate exposed parts which are subject to rust with oil or grease 21
- Lubrication points 21
- Major lubrication points are indicated below 21
- Motorcycle 21
- Proper lubrication is important for smooth operation and long life of each working part of the 21
- Air cleaner 22
- Exhaust pipe bolts 22
- Maintenance and tune up 22
- Procedures 22
- Tappet clearance 23
- Tappet shim selection table intake tappet shim no 1 2892 05c00 x x x tappet shim set no 12800 05820 z 25
- Tappet shim selection table exhaust tappet shim n0 1 2892 05c00 x x x tappet shim set no 12800 05820 26
- Spark plug 27
- Engine oil and oil filter 28
- Carburetor 29
- Fuel cock filter 29
- Fuel line 29
- Clutch 30
- Drive chain 30
- Cooling system 32
- Steering 36
- Front fork 37
- Rear suspension 37
- Chassis bolts and nuts 38
- Compression pressure check 40
- Compression test procedure 40
- Oil pressure check 41
- Oil pressure test procedure 41
- Engine 43
- Engine components removable with engine in place 44
- Engine removal 45
- Engine removal and reinstallation 45
- Engine reinstallation 51
- Engine disassembly 53
- Caution 55
- Cylinder head service 64
- Engine components inspection and service 64
- Cylinder head distortion 65
- Valve face wear 65
- Valve head radial runout 65
- Valve stem deflection 65
- Valve stem runout 65
- Valve guide servicing 66
- Valve stem wear 66
- Valve seat servicing 67
- Valve seat width 67
- Reassembly 69
- Valve spring 69
- Camshaft 70
- Cam wear 71
- Camshaft journal wear 71
- Cam sprocket 72
- Camshaft runout 72
- Reassembly 72
- Cam chain 20 pitch length 73
- Cam chain guide 73
- Cam chain tensioner 73
- Cylinder block distortion 73
- Cylinder bore 74
- Piston cylinder clearance 74
- Piston diameter 74
- Piston ring groove clearance 74
- Piston ring free end gap and piston 75
- Ring end gap 75
- Conrod big end side clearance 76
- Conrod small end i d 76
- Piston pin and pin bore 76
- Conrod crank pin bearing selection 77
- Bearing assembly 78
- Crankcase crankshaft bearing 79
- Selection 79
- Crankshaft thrust clearance 81
- Crankshaft runout 82
- Clutch drive and driven plates 83
- Clutch release bearing 83
- Clutch release pinion and rack 83
- Clutch spring free length 83
- Oil pump 83
- Transmission 84
- Gearshift fork groove clearance 87
- Starter clutch 88
- Engine reassembly 90
- Fuel and lubrication system 111
- Fuel system 112
- Fuel cock removal 113
- Fuel tank and fuel cock 113
- Fuel tank removal 113
- Inspection and cleaning 113
- Carburetor 114
- Construction calif model 114
- Construction except for calif model 115
- I d no location 116
- Specifications 116
- Diaphragm and piston operation 117
- Slow system 118
- Main system 119
- Float system 120
- Starter system 120
- Disassembly 121
- Removal 121
- Float height adjustment 124
- Inspection and adjustment 124
- Needle valve inspection 124
- Reassembly and remounting 124
- Balance of carburetors 125
- Lubrication system 127
- Oil filter 127
- Oil pressure 127
- Oil sump filter 127
- Engine lubrication system 129
- Engine oil cooling system 130
- Cooling system 131
- Cooling system 132
- Description 132
- Construction 133
- Cooling solution 135
- Cooling system removal and 136
- Disassembly 136
- Radiator 136
- Water hoses and thermostat case 136
- And cooling fan thermo switch 137
- Cooling fan 137
- Engine coolant temperature gauge 137
- Thermostat 137
- Water pump 137
- Inspection 139
- Installation 139
- Radiator 139
- Removal 139
- Engine coolant temperature gauge 140
- Inspection 140
- Removal 140
- Cooling fan 141
- Cooling fan thermo switch 141
- Inspection 141
- Reassembly 141
- Removal 141
- Inspection 142
- Reassembly 142
- Removal 142
- Inspection 143
- Reassembly 143
- Removal 143
- Thermostat 143
- Inspection 144
- Reassembly 144
- Removal and disassembly 144
- Water pump 144
- Electrical system 147
- Changes the stator a c voltages to a d c voltage which appears at the generator output terminal 148
- Charging system 148
- Description generator with ic regulator 148
- Housing a rectifier bridge connected to the stator windings contains six diodes and electrically 148
- Lator voltage setting cannot be adjusted 148
- Ponents are enclosed into a solid mold and this unit is attached to the brush holder frame the regu 148
- The generator features a solid state regulator that is mounted inside the generator all regulator com 148
- The stator windings are assembled on the inside of a laminated core that forms part of the generator 148
- Two brushes carry current through the two slip rings to the rotor coil mounted on the rotor 148
- Charging output check 149
- Removal and disassembly 149
- Inspection 151
- Reassembly and remounting 154
- Reasembly information 156
- Description 157
- Ignition system digital ignitor 157
- Inspection 158
- Monitor 161
- Revolution 161
- Description 162
- Removal and disassembly 162
- Starter system 162
- Inspection 163
- Reassembly 164
- Starter relay inspection 165
- Description 166
- Down this is or warming up the engine 166
- Left down the system is operated by an electric circuit provided between the battery and ignition coil 166
- On the position of the transmission and side stand with the neutral and side stand switches 166
- Side stand ignition interlock system 166
- The circuit consists of relay lamp diode and switches and decides to live the ignition coil depending 166
- The current flow turns on the relay and the ignition coil lives even the side stand is kept 166
- The ignition coil lives only in two situations as follows 166
- This side stand ignition interlock system is to prevent starting the motorcycle with the side stand 166
- Transmission neutral on side stand down off 166
- Working mutually 166
- Inspection 167
- Combination meter 169
- Inspection 169
- Removal and disassembly 169
- Engine coolant temperature meter 171
- Inspection 171
- Oil pressure switch 173
- Switches 173
- Turn signal light 173
- Side stand relay 174
- Starter relay 174
- Turn signal relay 174
- Battery 175
- Initial charging 175
- Specifications 175
- Servicing 176
- Recharging operation 177
- Chassis 179
- Frame cover and cowling 180
- Removal 181
- Front wheel 185
- Removal 185
- Inspection and disassembly 186
- Reassembly and remounting 187
- Cause of this we recommend using a tire changer which is also more efficient than tire levers 190
- For tire removal the following tools are required 190
- Mark the tire with chalk to note the position of the tire 190
- On the rim and rotational direction of the tire 190
- Remove the valve core from the valve stem and deflate 190
- The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead be 190
- The tire completely 190
- Tire and wheel 190
- Tire removal 190
- Inspection 192
- Tire mounting 193
- Brake pad replacement 195
- Front brake 195
- Caliper removal and disassembly 196
- Caliper and disc inspection 197
- Caliper reassembly and remounting 197
- Disassembly 198
- Disc inspection 198
- Disc servicing 198
- Master cylinder removal and 198
- Master cylinder inspection 200
- Master cylinder reassembly and 200
- Remounting 200
- Front fork 201
- Removal and disassembly 201
- Inspection 204
- Reassembly and remounting 204
- Suspension setting 209
- Steering damper 210
- Removal and disassembly 211
- Steering 211
- Disassembly 212
- Inspection 212
- Reassembly and remounting 213
- Steering tension adjustment 214
- Combination meter 215
- Ignition switch 215
- Brake pad replacement 216
- Rear brake 216
- Caliper removal and disassembly 217
- Caliper inspection 218
- Caliper reassembly and remounting 219
- Disassembly 219
- Master cylinder removal and 219
- Master cylinder inspection 220
- Master cylinder reassembly and 221
- Remounting 221
- Rear wheel 222
- Removal and disassembly 222
- Inspection and disassembly 224
- Reassembly and remounting 225
- Rear suspension 228
- Swingarm 228
- Shock absorber and cushion lever 229
- Removal 230
- Inspection 232
- Reassembly and remounting 234
- Reassembly onto frame 234
- Adjustment 235
- Swingarm pivot thrust clearance 235
- Final inspection and adjustment 236
- Suspension setting 237
- Servicing informa tion 239
- Engine 240
- Troubleshooting 240
- Carburetor 243
- Radiator 243
- Electrical 244
- Battery 245
- Chassis 246
- Brakes 247
- X 3wlz x a 250
- Wire routing 251
- Ignition coil 252
- Wire routing 252
- Cable routing 253
- C x vh f 254
- The air cleaner drain hose by removing the drain plug 255
- When you dean the air deaner element drain water from 255
- Cooling system hose routing 256
- Front brake hose routing 258
- Rear brake hose routing 259
- Handlebars 260
- Reservoir tank hose routing 260
- Frame cover set up 262
- Under cowl cushion 262
- Prop stand 263
- Canister hose routing only for california model 264
- Xi i o 265
- Special tools 267
- When ordering the special tool please confirm whether it is available or not 269
- Engine 270
- Tightening torque 270
- Chassis 271
- Tightening torque chart 272
- Service data 273
- Valve guide 273
- Camshaft cylinder head 274
- Cylinder piston piston ring 274
- Conrod crankshaft 275
- Oil pump 275
- Clutch 276
- Thermostat radiator fan 276
- Transmission drive chain 276
- Carburetor 277
- Electrical 279
- Wattage 279
- Brake wheel 280
- Fuel oil engine coolant 281
- Suspension 281
- Tire pressure 281
- Emission control informa tion 283
- 115 n b 284
- Emission control carburetor components 284
- M 30 i o cd m 30 o c 286
- Pair control valve 287
- Pair reed valve 287
- Pair system diagram only for california model 287
- 30 i o v m 33 o c 288
- Foreword 291
- Gsx r750wr 94 model 291
- Dimensions and dry mass 292
- Engine 292
- Specifications 292
- Transmission 292
- Capacities 293
- Chassis 293
- Electrical 293
- Service data 294
- Valve guide 294
- Camshaft cylinder head 295
- Cylinder piston piston ring 295
- Conrod crankshaft 296
- Oil pump 296
- Clutch 297
- Thermostat radiator fan 297
- Transmission drive chain 297
- Carburetor 298
- Electrical 300
- Specification 300
- Wattage 300
- Brake wheel 301
- Fuel oil engine coolant 302
- Suspension 302
- Tire pressure 302
- Clutch 303
- Note measuring point of the clutch lever play has been changed as follows 303
- Service information 304
- Special tools 304
- Starter clutch 305
- Engine mounting 307
- Test jv 308
- Xo j s 308
- Front brake 309
- Steering damper 312
- Front fork 313
- Swingarm pivot thrust clearance adjustment 314
- Front suspension setting 316
- Rear suspension setting 317
- Drive chain 318
- Drive chain adjustment 321
- Drive chain cover set up 322
- Bl blue p pink b r black with red tracer o r orange with red tracer 323
- Br brown r red b w black with white tracer o w orange with white tracer 323
- G green w white b y black with yellow tracer o y orange with yellow tracer 323
- Gr gray y yellow bl b blue with black tracer w b white with black tracer 323
- Gsxr750wr c94 m0del 10 32 323
- Lbl light blue b bi black with blue tracer g y green with yellow tracer y g yellow with green tracer 323
- Lg light green b br black with brown tracer o b orange with black tracer y w yellow with white tracer 323
- W h hw 323
- Wire color 323
- В black 0 orange b g black with green tracer o bi orange with blue tracer 323
- Wire harness cable and hose routing 324
- Wire harness routing 324
- High tension cord routing 327
- Speedometer cable routing 328
- Cable routing 329
- Seat lock cable routing 330
- Front brake hose routing 331
- Rear brake hose routing 332
- Cooling system hose routing 333
- Foreword 335
- Gsx r750ws 95 model 335
- Dimensions and dry mass 336
- Engine 336
- Specifications 336
- Transmission 336
- Capacities 337
- Chassis 337
- Electrical 337
- Service data 338
- Valve guide 338
- Camshaft cylinder head 339
- Cylinder piston piston ring 339
- Conrod crankshaft 340
- Oil pump 340
- Clutch 341
- Thermostat radiator fan 341
- Transmission drive chain 341
- Carburetor 342
- Electrical 344
- Wattage 344
- Brake wheel 345
- Item standard limit 345
- Fuel oil engine coolant 346
- Suspension 346
- Tire pressure 346
- Service information 348
- The windscreen fitting method has been changed from pin type to bolt type 348
- Windscreen 348
- Carburetor 349
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5 11 COOLING SYSTEM REMOVAL Refer to page 5 6 INSPECTION The thermo switch must be checked for its temperatureinitiated closing action at the specification value of 105 C 221 F by testing it at the bench as shown in the figure Connect the thermo switch to a circuit tester and place it in the oil contained in a pan which is placed on a stove heat the oil to raise its temperature slowly and read the column thermometer when the switch closes 09900 25002 Pocket tester Thermo switch specification OFF ON Approx 105 C 221 F ON OFF Approx 100 C 21 2 F REASSEMBLY NOTE Do not forget the new O ring Tightening torque Thermo switch 9 0 14 Nm 0 9 1 4 kg m 6 5 10 0 Ib ft CAUTION Take special care when handling the thermo switch It may cause damage if it gets a sharp impact Replace the O ring with a new one