Suzuki GSX-R750 (1993-1995) [156/352] Reasembly information

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 9 ELECTRICAL SYSTEM REASEMBLY INFORMATION O ring Oil seal Generator end housing Bearing seat Bearing Bearing retainer Rotor Bearing cover No 2 Bearing Bearing cover No 1 Generator housing Rectifier Rectifier cover IC regulator Generator lead wire Brush holder Brush cover Generator end cover Tightening torque ITEM Nm kg m Ib ft 3 7 5 5 0 37 0 55 2 6 4 0 2 2 3 3 0 22 0 33 1 5 2 5 3 7 5 5 0 37 0 55 2 6 4 0 21 29 2 1 2 9 15 0 21 0