Suzuki GSX-R750 Sports Motorcycle Bike Service Manual

Suzuki GSX-R750 Sports Motorcycle Bike Service

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
4. The contents are listed on the first page of each section to help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

• Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel

SUZUKI GSX-R750K6 (’06-MODEL)

FRONT FORK OIL

• Use fork oil SS-05 or an equivalent fork oil.
• ENGINE COOLANT
• Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only.
• WATER FOR MIXING
• Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator.
• ANTI-FREEZE/ENGINE COOLANT
• The engine coolant performs as a corrosion and rust inhibitor as well as an anti-freeze. Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point.
•  Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent that is compatible with an aluminum radiator.

CYLINDER IDENTIFICATION

• The four cylinders of this engine are identified as No. 1, No. 2, No. 3 and No. 4 cylinder, as counted from left to right (as viewed by the rider on the seat.)

INFORMATION LABELS

PERIODIC MAINTENANCE SCHEDULE

• The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometers, miles and time for your convenience. IMPORTANT (For E-28): The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not exceed emission standards and it will also ensure the reliability and performance of the motorcycle.https://manualslibraryy.com/dell-xps-13-9350-high-performance-laptop-service-manual/
• PERIODIC MAINTENANCE CHART
  

  Interval   Item	miles	600	4 000	7 500	11 000	14 500
  	km	1 000	6 000	12 000	18 000	24 000
  	months	2	12	24	36	48
  Air cleaner element		—-	I	I	R	I
  Spark plugs		—-	I	R	I	R
  Valve clearance		—-	—-	—-	—-	I
  Exhaust control valve		I	—-	I	—-	I
  Engine oil		R	R	R	R	R
  Engine oil filter		R	—-	—-	R	—-
  Fuel line		—-	I	I	I	I
  Idle speed		I	I	I	I	I
  Throttle valve synchronization		I (E-33 only)	—-	I	—-	I
  Evaporative emission control system (E-33 only)		—-	—-	I	—-	I
  PAIR (air supply) system		—-	—-	I	—-	I
  Throttle cable play		I	I	I	I	I
  Clutch cable play		—-	I	I	I	I
  Radiator hoses		—-	I	I	I	I
  Engine coolant		Replace every 2 years.
  Drive chain		I	I	I	I	I
  		Clean and lubricate every 1000 km (600 miles).
  Brakes		I	I	I	I	I
  Brake hoses		—-	I	I	I	I
  		Replace every 4 years.
  Brake fluid		—-	I	I	I	I
  		Replace every 2 years.
  Tires		—-	I	I	I	I
  Steering		I	—-	I	—-	I
  Front forks		—-	—-	I	—-	I
  Rear Suspension		—-	—-	I	—-	I
  Exhaust pipe bolts and muffler bolts and nut		T	—-	T	—-	T
  Chassis bolts and nuts		T	T	T	T	T

LUBRICATION POINTS

• Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below

VALVE CLEARANCE

• Remove the right under the cowling. (8-5)
• Lift and support the fuel tank. (5-3)
• Remove the air cleaner box. (5-14)
• Disconnect the CMP sensor coupler 1.
• Remove the PAIR control solenoid valve 2.
• Remove the spark plugs. (2-5)
• Loosen the throttle body clamp screws at the intake pipe side.
• Move the throttle body assembly.
• Move the radiator forward. (6-10)
• Remove the regulator/rectifier and horn. (3-6)
• Remove the cylinder head cover. (3-14)

VALVE CLEARANCE ADJUSTMENT

The clearance is adjusted by replacing the existing tappet shim with a thicker or thinner shim.

• Remove the intake or exhaust camshafts. (3-14)
• Remove the tappet and shim by fingers or magnetic hand.
• Check the figures printed on the shim. These figures indicate the thickness of the shim, as illustrated.
• Select a replacement shim that will provide a clearance within the specified range. For the purpose of this adjustment, a total of 21 sizes of tappet shim are available ranging from 1.20 to 2.20 mm in steps of 0.05 mm. Fit the selected shim to the valve stem end, with numbers toward the tappet. Be sure to check shim size with a micrometer to ensure its size. Refer to the tappet shim selection table (2-10 and -11) for details

OIL FILTER REPLACEMENT

• Drain the engine oil as described in the engine oil replacement procedure.
• Remove the oil filter 1 with the special tool.
• 09915-40610: Oil filter wrench
• Apply engine oil lightly to the gasket of the new oil filter before installation.
• Install the new oil filter. Turn it by hand until you feel that the oil filter gasket contacts the oil filter mounting surface. Then, tighten the oil filter two full turns (or to specified torque) with the special tool.

BRAKE

BRAKE FLUID LEVEL CHECK

• Keep the motorcycle upright and place the handlebars straight.
• Check the brake fluid level relative to the lower limit lines on the front and rear brake fluid reservoirs.
• When the level is below the lower limit line, replenish with brake fluid that meets the following specifications.
• Specification and classification: DOT

EXHAUST PIPE BOLT AND NUT

• Tighten the exhaust pipe bolts, muffler mounting bolt and nut to the specified torque

CHASSIS BOLTS AND NUTS

COMPRESSION PRESSURE CHECK

• The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.

COMPRESSION PRESSURE SPECIFICATION

Low compression pressure can indicate any of the following conditions:

• Excessively worn cylinder walls
  * Worn piston or piston rings
  * Piston rings stuck in grooves
  * Poor valve seating
  * Ruptured or otherwise defective cylinder head gasket
  

Overhaul the engine in the following cases:

• Compression pressure in one of the cylinders is 1 000 kPa (10 kg/cm2, 148 psi) and less.
• The difference in compression pressure between any two cylinders is 200 kPa (2 kg/cm2, 28 psi) and more.
• All compression pressure readings are below 1 300 kPa (13 kg/cm2, 185 psi) even when they measure 1000 kPa (10 kg/cm2, 148 psi) and more.

CYLINDER HEAD AND VALVE

VALVE AND VALVE SPRING DISASSEMBLY

• Remove the tappet 1 and shim 2 by fingers or magnetic hand.
• Install the special tool 3 between the valve spring and cylinder head.
• Using the special tools, compress the valve spring and remove the two cotter halves from the valve stem

TRANSMISSION

DRIVESHAFT REMOVAL

DISASSEMBLY

Disassemble the countershaft and driveshaft. Pay attention to the following points:

• Remove the 6th drive gear snap ring 1 from its groove and slide it towards the 3rd/4th drive gear 2.
• Slide the 6th 3 and 2nd 4 drive gears toward the 3rd/4th drive gears 2, then remove the 2nd drive gear circlip 5.

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Suzuki GSX-R750 Sports Motorcycle Bike Service-FAQs