Suzuki GSX-R750 (1993-1995) [154/352] Reassembly and remounting

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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6 7 ELECTRICAL SYSTEM REASSEMBLY AND REMOUNTING Reassemble and remount the generator in the reverse ord er of disassembly and removal Pay attention to the follow ing points Apply grease to the lip of the oil seal 99000 25030 SUZUKI SUPER GREASE A CAUTION The removed oil seal should be replaced with a new one Install the bearing by using a hand press as shown Apply a small quantity of THREAD LOCK 1342 to the bearing retainer screws 99000 32050 THREAD LOCK 1342 Install the rotor and bearing by using a hand press as shown