Suzuki GSX-R750(W) Repair Service Manual 1993-2008
Complete service repair manual with Electrical Wiring Diagrams for 1993-2008 Suzuki GSX-R750 Motorcycles, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Suzuki GSX-R750 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Suzuki GSX-R750 (GSX-R750K4) Service Manual '04.pdf
Suzuki GSX-R750 (GSX-R750K6) Service Manual '06.pdf
Suzuki GSX-R750 (GSX-R750K6) Service Manual '08.pdf
Suzuki GSX-R750 (GSX-R750T, GSX-R750V, GSX-R750W, GSX-R750X) Service Manual '96-'99.pdf
Suzuki GSX-R750 (GSX-R750Y, GSX-R750K1, GSX-R750K2) Service Manual '00-'02.pdf
Suzuki GSX-R750W (GSX-R750WP, GSX-R750WR, GSX-R750WS) Service Manual '93-'95.pdf
PRODUCT DETAILS:
Total Pages: 3,012 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
Suzuki GSX-R750 (GSX-R750K4) Service Manual '04...2
Suzuki GSX-R750 (GSX-R750K6) Service Manual '06...473
99500-37130-01E GSX-R750 SERVICE MANUAL...473
FOREWORD_GROUP INDEX...474
HOW TO USE THIS MANUAL...475
TO LOCATE WHAT YOU ARE LOOKING FOR:...475
COMPONENT PARTS AND WORK TO BE DONE...475
SYMBOL...476
ABBREVIATIONS USED IN THIS MANUAL...477
01 GENERAL INFORMATION...480
COUNTRY AND AREA CODES...480
WARNING/CAUTION/NOTE...481
GENERAL PRECAUTIONS...481
SUZUKI GSX-R750K6 (’06-MODEL)...483
SERIAL NUMBER LOCATION...483
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION...484
BREAK-IN PROCEDURES...486
CYLINDER IDENTIFICATION...486
INFORMATION LABELS...487
SPECIFICATIONS...488
02 PERIODIC MAINTENANCE...490
PERIODIC MAINTENANCE SCHEDULE...491
MAINTENANCE AND TUNE-UP PROCEDURES...493
COMPRESSION PRESSURE CHECK...521
OIL PRESSURE CHECK...522
SDS CHECK...523
03 ENGINE...526
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE...527
ENGINE REMOVAL AND INSTALLATION...528
ENGINE DISASSEMBLY...539
ENGINE COMPONENTS INSPECTION AND SERVICE...552
ENGINE REASSEMBLY...599
04 FI SYSTEM DIAGNOSIS...629
PRECAUTIONS IN SERVICING...631
FI SYSTEM TECHNICAL FEATURES...638
ECM TERMINAL...643
SELF-DIAGNOSIS FUNCTION...645
FAIL-SAFE FUNCTION...649
FI SYSTEM TROUBLESHOOTING...651
SENSORS...733
05 FUEL SYSTEM AND THROTTLE BODY...736
FUEL DELIVERY SYSTEM...737
FUEL SYSTEM...738
THROTTLE BODY...748
06 EXHAUST SYSTEM...763
EXHAUST SYSTEM...764
EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)...766
07 COOLING AND LUBRICATION SYSTEM...777
ENGINE COOLANT...778
COOLING CIRCUIT...779
RADIATOR AND WATER HOSES...780
COOLING FAN...782
ECT SENSOR...783
THERMOSTAT...785
WATER PUMP...787
LUBRICATION SYSTEM...793
08 CHASSIS...798
EXTERIOR PARTS...800
FRONT WHEEL...806
FRONT FORK...814
STEERING DAMPER...825
STEERING...827
HANDLEBARS...833
REAR WHEEL...837
REAR SHOCK ABSORBER...845
REAR SUSPENSION...851
FRONT BRAKE...861
REAR BRAKE...872
TIRE AND WHEEL...882
DRIVE CHAIN...886
09 ELECTRICAL SYSTEM...890
CAUTIONS IN SERVICING...892
LOCATION OF ELECTRICAL COMPONENTS...895
CHARGING SYSTEM...897
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM...901
IGNITION SYSTEM...909
COMBINATION METER...918
LAMPS...924
RELAYS...926
BATTERY...929
10 SERVICING INFORMATION...932
TROUBLESHOOTING...933
WIRING HARNESS, CABLE AND HOSE ROUTING...948
TIGHTENING TORQUE...968
SERVICE DATA...972
11 EMISSION CONTROL INFORMATION...982
EMISSION CONTROL SYSTEMS...983
PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION...987
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING...989
HO2 SENSOR INSPECTION (For E-02, 19)...990
12 WIRING DIAGRAM...991
Suzuki GSX-R750 (GSX-R750K6) Service Manual '08...995
TABLE OF CONTENTS...999
Precautions...1001
Precautions...1002
Precautions...1002
Warning / Caution / Note...1002
General Precautions...1002
General Information...1009
General Information...1010
General Description...1010
Symbols...1010
Abbreviations...1010
SAE-to-Former SUZUKI Term...1011
Vehicle Side View...1012
Vehicle Identification Number...1013
Fuel and Oil Recommendation...1013
Engine Coolant Recommendation...1014
BREAK-IN Procedures...1014
Cylinder Identification...1014
Country and Area Codes...1015
Wire Color Symbols...1015
Warning, Caution and Information Labels Location...1016
Component Location...1017
Electrical Components Location...1017
Specifications...1019
Specifications...1019
Special Tools and Equipment...1021
Special Tool...1021
Maintenance and Lubrication...1025
Precautions...1025
Precautions for Maintenance...1025
General Description...1025
Recommended Fluids and Lubricants...1025
Scheduled Maintenance...1025
Periodic Maintenance Schedule Chart...1025
Lubrication Points...1026
Repair Instructions...1027
Air Cleaner Element Replacement...1027
Air Cleaner Element Inspection...1027
Exhaust Pipe Bolt and Muffler Bolt Inspection...1027
Exhaust Control Valve Inspection...1028
Valve Clearance Inspection and Adjustment...1028
Spark Plug Replacement...1033
Spark Plug Inspection and Cleaning...1033
Fuel Line Inspection...1034
Evaporative Emission Control System Inspection (E-33 only)...1034
Engine Oil and Filter Replacement...1034
Throttle Cable Play Inspection and Adjustment...1036
PAIR System Inspection...1036
Throttle Valve Synchronization...1036
Cooling System Inspection...1036
Clutch Cable Play Inspection and Adjustment...1038
Drive Chain Inspection and Adjustment...1039
Drive Chain Cleaning and Lubricating...1040
Brake System Inspection...1041
Tire Inspection...1043
Steering System Inspection...1043
Front Fork Inspection...1044
Rear Suspension Inspection...1044
Chassis Bolt and Nut Inspection...1044
Compression Pressure Check...1046
Oil Pressure Check...1046
SDS Check...1046
Specifications...1046
Tightening Torque Specifications...1046
Special Tools and Equipment...1047
Recommended Service Material...1047
Special Tool...1047
Service Data...1048
Specifications...1048
Service Data...1048
Tightening Torque List...1056
Engine...1061
Precautions...1066
Precautions...1066
Precautions for Engine...1066
Engine General Information and Diagnosis...1067
General Description...1067
Injection Timing Description...1067
Self-Diagnosis Function...1069
Schematic and Routing Diagram...0
Terminal Alignment of ECM Coupler...1072
Component Location...1073
FI System Parts Location...1073
Diagnostic Information and Procedures...1075
Engine Symptom Diagnosis...1075
Self-Diagnostic Procedures...1079
Use of SDS Diagnosis Reset Procedures...1081
Show Data When Trouble (Displaying Data at the Time of DTC)...1082
SDS Check...1083
DTC Table...1087
Fail-Safe Function Table...1089
FI System Troubleshooting...1090
Malfunction Code and Defective Condition Table...1092
DTC “C11” (P0340): CMP Sensor Circuit Malfunction...1096
DTC “C12” (P0335): CKP Sensor Circuit Malfunction...1099
DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction...1102
DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction...1111
DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction...1118
DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction...1123
DTC “C22” (P1450-H/L): AP Sensor Circuit Malfunction...1128
DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction...1137
DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction...1144
DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction...1144
DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction...1148
DTC “C31” (P0705): GP Switch Circuit Malfunction...1155
DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Primary Fuel Injector Circuit Malfunction...1157
DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767): Secondary Fuel Injector Circuit Malfunction...1160
DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction...1163
DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction...1167
DTC “C41” (P2505): ECM Power Input Signal Malfunction...1170
DTC “C42” (P1650): IG Switch Circuit Malfunction...1172
DTC “C44” (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction...1172
DTC “C46” (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction...1178
DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction...1192
DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction...1195
DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only)...1198
DTC “C91” (P0500): Vehicle Speed Sensor Circuit Malfunction...1201
DTC “C93” (P1769): Steering Damper Solenoid Valve Circuit Malfunction...1204
Specifications...1208
Service Data...1208
Special Tools and Equipment...1209
Special Tool...1209
Emission Control Devices...0
General Description...0
Crankcase Emission Control System Description...1212
Exhaust Emission Control System Description...1213
Noise Emission Control System Description...1214
Evaporative Emission Control System Diagram (Only for E-33)...1214
Schematic and Routing Diagram...0
EVAP Canister Hose Routing Diagram (Only for E-33)...1216
Repair Instructions...1217
Heated Oxygen Sensor (HO2S) Removal and Installation...1217
Heated Oxygen Sensor (HO2S) Inspection...1217
PAIR Reed Valve Removal and Installation...1217
PAIR Control Solenoid Valve Removal and Installation...1219
PAIR System Inspection...1219
Crankcase Breather (PCV) Hose Inspection...1220
Crankcase Breather (PCV) Hose / Reed Valve / Cover Removal and Installation...1221
Crankcase Breather (PCV) Cover Inspection...1222
Crankcase Breather (PCV) Reed Valve Inspection...1222
Evaporative Emission Control System Removal and Installation (Only for E-33)...1222
Evaporative Emission Control System Inspection (Only for E-33)...1225
Specifications...1227
Service Data...1227
Tightening Torque Specifications...1227
Special Tools and Equipment...1227
Special Tool...1227
Engine Electrical Devices...1228
Precautions...1228
Precautions for Engine Electrical Device...1228
Component Location...1228
Engine Electrical Components Location...1228
Diagnostic Information and Procedures...1228
Engine Symptom Diagnosis...1228
Repair Instructions...1228
ECM Removal and Installation...1228
CMP Sensor Inspection...1229
CMP Sensor Removal and Installation...1229
CKP Sensor Inspection...1230
CKP Sensor Removal and Installation...1230
IAP Sensor Inspection...1230
IAP Sensor Removal and Installation...1230
TP Sensor Inspection...1230
TP Sensor Removal and Installation...1230
TP Sensor Adjustment...1231
ECT Sensor Removal and Installation...1231
ECT Sensor Inspection...1232
IAT Sensor Removal and Installation...1232
IAT Sensor Inspection...1233
AP Sensor Inspection...1233
AP Sensor Removal and Installation...1233
TO Sensor Inspection...1233
TO Sensor Removal and Installation...1233
STP Sensor Inspection...1234
STP Sensor Adjustment...1234
STP Sensor Removal and Installation...1235
STV Actuator Inspection...1235
STV Actuator Removal and Installation...1235
ISC Valve Inspection...1235
ISC Valve Removal and Installation...1235
ISC Valve Preset and Opening Initialization...1236
HO2 Sensor Inspection...1236
HO2 Sensor Removal and Installation...1236
GP Switch Inspection...1236
GP Switch Removal and Installation...1236
Specifications...1237
Service Data...1237
Tightening Torque Specifications...1237
Special Tools and Equipment...1238
Special Tool...1238
Engine Mechanical...0
Schematic and Routing Diagram...0
Throttle Cable Routing Diagram...1240
Diagnostic Information and Procedures...1241
Engine Mechanical Symptom Diagnosis...1241
Compression Pressure Check...1241
Repair Instructions...1242
Engine Components Removable with the Engine in Place...1242
Air Cleaner Element Removal and Installation...1244
Air Cleaner Box Removal and Installation...1245
Air Cleaner Element Inspection and Cleaning...1245
Throttle Cable Removal and Installation...1245
Throttle Cable Inspection...1245
Throttle Cable Play Inspection and Adjustment...1245
Throttle Body Components...1246
Throttle Body Removal and Installation...1248
Throttle Body Disassembly and Assembly...1249
Throttle Body Inspection and Cleaning...1253
ISC Valve Visual Inspection...1254
Throttle Valve Synchronization...1254
ISC Valve Reset...1256
TP Reset...1256
Engine Assembly Removal...1257
Engine Assembly Installation...1261
Engine Top Side Disassembly...1263
Engine Top Side Assembly...1265
Camshaft Sprocket...1274
Cam Chain Tension Adjuster Inspection...1274
Cam Chain Guide / Cam Chain Tensioner Removal and Installation...1275
Cam Chain Guide Inspection...1275
Cam Chain Tensioner Inspection...1275
Cylinder Head Disassembly and Assembly...1276
Cylinder Head Related Parts Inspection...1280
Valve Guide Replacement...1283
Valve Seat Repair...1285
Engine Bottom Side Disassembly...1285
Engine Bottom Side Assembly...1293
Balancer Shaft Inspection...1312
Balancer Shaft Journal Bearing Removal and Installation...1312
Balancer Shaft Journal Bearing Inspection and Selection...1313
Crankshaft Journal Bearing Inspection and Selection...1319
Crankshaft Thrust Clearance Inspection and Selection...1321
Specifications...1323
Service Data...1323
Tightening Torque Specifications...1325
Special Tools and Equipment...1326
Recommended Service Material...1326
Special Tool...1326
Engine Lubrication System...1329
Precautions...1329
Precautions for Engine Oil...1329
Schematic and Routing Diagram...1330
Engine Lubrication System Chart Diagram...1330
Engine Lubrication Circuit Diagram...1331
Diagnostic Information and Procedures...1333
Engine Lubrication Symptom Diagnosis...1333
Oil Pressure Check...1333
Repair Instructions...1334
Engine Oil and Filter Replacement...1334
Engine Oil Level Inspection...1334
Oil Pan / Oil Strainer / Oil Pressure Regulator Removal and Installation...1334
Oil Pressure Regulator / Oil Strainer Inspection...1335
Oil Cooler / Oil Cooler Hose Inspection...1336
Oil Cooler Removal and Installation...1336
Oil Pressure Switch Removal and Installation...1337
Oil Pressure Switch Inspection...1337
Oil Jet / Oil Gallery Jet Removal and Installation...1337
Oil Jet / Oil Gallery Jet Inspection...1339
Oil Pump Removal and Installation...1340
Oil Pump Inspection...1341
Oil Pump Drive Gear Removal and Installation...1341
Specifications...1342
Service Data...1342
Tightening Torque Specifications...1343
Special Tools and Equipment...1343
Recommended Service Material...1343
Special Tool...1343
Engine Cooling System...1344
Precautions...1344
Precautions for Engine Cooling System...1344
Precautions for Engine Coolant...1344
General Description...1344
Engine Coolant Description...1344
Schematic and Routing Diagram...1345
Cooling Circuit Diagram...1345
Water Hose Routing Diagram...1346
Diagnostic Information and Procedures...1347
Engine Cooling Symptom Diagnosis...1347
Repair Instructions...1347
Cooling Circuit Inspection...1347
Radiator Cap Inspection...1348
Radiator Inspection and Cleaning...1348
Radiator / Cooling Fan Motor Removal and Installation...1348
Water Hose Inspection...1349
Water Hose Removal and Installation...1350
Radiator Reservoir Tank Inspection...1350
Radiator Reservoir Tank Removal and Installation...1351
Cooling Fan Inspection...1351
Cooling Fan Relay Inspection...1351
ECT Sensor Removal and Installation...1352
ECT Sensor Inspection...1352
Thermostat Removal and Installation...1352
Thermostat Inspection...1353
Water Pump Components...1354
Water Pump Construction...1355
Water Pump Removal and Installation...1355
Water Pump Disassembly and Assembly...1356
Water Pump Related Parts Inspection...1359
Specifications...1361
Service Data...1361
Tightening Torque Specifications...1361
Special Tools and Equipment...1362
Recommended Service Material...1362
Special Tool...1362
Fuel System...1363
Precautions...1363
Precautions for Fuel System...1363
General Description...1364
Fuel Injection System Description...1364
Schematic and Routing Diagram...1365
Fuel Tank Drain Hose and Breather Hose Routing Diagram...1365
Diagnostic Information and Procedures...1366
Fuel System Diagnosis...1366
Repair Instructions...1367
Fuel Pressure Inspection...1367
Fuel Pump Inspection...1367
Fuel Discharge Amount Inspection...1368
Fuel Pump Relay Inspection...1369
Fuel Hose Inspection...1369
Fuel Level Gauge Inspection...1369
Fuel Tank Construction...1370
Fuel Tank Removal and Installation...1371
Fuel Pump Components...1372
Fuel Pump Disassembly and Assembly...1373
Fuel Mesh Filter Inspection and Cleaning...1375
Fuel Injector / Fuel Delivery Pipe / T-joint Removal and Installation...1375
Fuel Injector Inspection and Cleaning...1375
Specifications...1376
Service Data...1376
Tightening Torque Specifications...1376
Special Tools and Equipment...1377
Recommended Service Material...1377
Special Tool...1377
Ignition System...1378
General Description...1378
Immobilizer Description (For E-02, 19, 24)...1378
Drive Mode Selector Description...1379
Schematic and Routing Diagram...1380
Ignition System Diagram...1380
Ignition System Components Location...1380
Diagnostic Information and Procedures...1381
Ignition System Symptom Diagnosis...1381
No Spark or Poor Spark...1382
Repair Instructions...1383
Ignition Coil / Plug Cap and Spark Plug Removal and Installation...1383
Spark Plug Inspection and Cleaning...1384
Ignition Coil / Plug Cap Inspection...1384
Ignition Switch Removal and Installation...1388
Drive Mode Selector Inspection...1389
Specifications...1390
Service Data...1390
Tightening Torque Specifications...1390
Special Tools and Equipment...1391
Recommended Service Material...1391
Special Tool...1391
Starting System...1392
Schematic and Routing Diagram...1392
Starting System Diagram...1392
Component Location...1392
Starting System Components Location...1392
Diagnostic Information and Procedures...1392
Starting System Symptom Diagnosis...1392
Starter Motor Will Not Run...1393
Starter Motor Runs But Does Not Crank The Engine...1393
Repair Instructions...1394
Starter Motor Components...1394
Starter Motor Removal and Installation...1395
Starter Motor Disassembly and Assembly...1395
Starter Motor Inspection...1396
Starter Relay Removal and Installation...1397
Starter Relay Inspection...1398
Turn Signal / Side-stand Relay Removal and Installation...1398
Starter Clutch Removal and Installation...1401
Starter Clutch Inspection...1403
Starter Button Inspection...1404
Specifications...1405
Service Data...1405
Tightening Torque Specifications...1405
Special Tools and Equipment...1406
Recommended Service Material...1406
Special Tool...1406
Charging System...1407
Schematic and Routing Diagram...1407
Charging System Diagram...1407
Component Location...1407
Charging System Components Location...1407
Diagnostic Information and Procedures...1407
Charging System Symptom Diagnosis...1407
Battery Runs Down Quickly...1408
Repair Instructions...1409
Battery Current Leakage Inspection...1409
Regulated Voltage Inspection...1409
Generator Inspection...1409
Regulator / Rectifier Removal and Installation...1415
Regulator / Rectifier Inspection...1416
Battery Visual Inspection...1420
Specifications...1420
Service Data...1420
Tightening Torque Specifications...1420
Special Tools and Equipment...1421
Recommended Service Material...1421
Special Tool...1421
Exhaust System...0
General Description...0
Exhaust Control System Operation...1423
Repair Instructions...1425
Exhaust Control System Construction...1425
Exhaust System Components...1426
EXCV Cable Removal and Installation...1427
EXCVA Removal and Installation...1428
EXCVA Inspection...1430
EXCVA Pulley Inspection...1430
EXCVA Adjustment...1430
Exhaust Pipe / Muffler Removal and Installation...1432
Exhaust System Inspection...1435
Specifications...1435
Service Data...1435
Tightening Torque Specifications...1436
Special Tools and Equipment...1436
Recommended Service Material...1436
Special Tool...1436
Suspension...1437
Precautions...1438
Precautions...1438
Precautions for Suspension...1438
Suspension General Diagnosis...1439
Diagnostic Information and Procedures...1439
Suspension and Wheel Symptom Diagnosis...1439
Front Suspension...1440
Repair Instructions...1440
Front Fork Components...1440
Front Fork Removal and Installation...1441
Front Suspension Adjustment...1443
Front Fork Disassembly and Assembly...1444
Front Fork Parts Inspection...1450
Specifications...1451
Service Data...1451
Tightening Torque Specifications...1451
Special Tools and Equipment...1452
Recommended Service Material...1452
Special Tool...1452
Rear Suspension...0
Repair Instructions...0
Rear Suspension Assembly Construction...1454
Rear Shock Absorber Removal and Installation...1455
Rear Suspension Inspection...1456
Rear Shock Absorber Inspection...1456
Rear Suspension Adjustment...1456
Rear Shock Absorber Disposal...1457
Cushion Lever Removal and Installation...1458
Cushion Lever Inspection...1458
Cushion Lever Bearing Removal and Installation...1459
Cushion Rod Removal and Installation...1460
Cushion Rod Inspection...1460
Cushion Rod Bearing Removal and Installation...1461
Swingarm Removal and Installation...1462
Swingarm Related Parts Inspection...1464
Swingarm Bearing Removal and Installation...1465
Specifications...1467
Service Data...1467
Tightening Torque Specifications...1467
Special Tools and Equipment...1468
Recommended Service Material...1468
Special Tool...1468
Wheels and Tires...1469
Precautions...1469
Precautions for Wheel and Tire...1469
Repair Instructions...1470
Front Wheel Components...1470
Front Wheel Assembly Construction...1471
Front Wheel Assembly Removal and Installation...1472
Front Wheel Related Parts Inspection...1474
Front Wheel Dust Seal / Bearing Removal and Installation...1475
Rear Wheel Components...1477
Rear Wheel Assembly Construction...1478
Rear Wheel Assembly Removal and Installation...1479
Rear Wheel Related Parts Inspection...1479
Rear Wheel Dust Seal / Bearing Removal and Installation...1481
Tire Removal and Installation...1483
Wheel / Tire / Air Valve Inspection and Cleaning...1484
Air Valve Removal and Installation...1485
Wheel Balance Check and Adjustment...1486
Specifications...1487
Service Data...1487
Tightening Torque Specifications...1487
Special Tools and Equipment...1488
Recommended Service Material...1488
Special Tool...1488
Driveline / Axle...1489
Precautions...1490
Precautions...1490
Precautions for Driveline / Axle...1490
Drive Chain / Drive Train / Drive Shaft...1491
Diagnostic Information and Procedures...1491
Drive Chain and Sprocket Symptom Diagnosis...1491
Repair Instructions...1491
Drive Chain Related Components...1491
Engine Sprocket Removal and Installation...1492
Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation...1493
Drive Chain Related Parts Inspection...1494
Sprocket Mounting Drum Dust Seal / Bearing Removal and Installation...1495
Drive Chain Replacement...1497
Specifications...1500
Service Data...1500
Tightening Torque Specifications...1500
Special Tools and Equipment...1501
Recommended Service Material...1501
Special Tool...1501
Brake...1503
Precautions...1504
Precautions...1504
Precautions for Brake System...1504
Brake Fluid Information...1504
Brake Control System and Diagnosis...1505
Schematic and Routing Diagram...1505
Front Brake Hose Routing Diagram...1505
Diagnostic Information and Procedures...1507
Brake Symptom Diagnosis...1507
Repair Instructions...0
Brake Fluid Level Check...1509
Brake Hose Inspection...1509
Air Bleeding from Brake Fluid Circuit...1509
Brake Fluid Replacement...1511
Front Brake Hose Removal and Installation...1513
Rear Brake Hose Removal and Installation...1513
Front Brake Master Cylinder Components...1514
Front Brake Master Cylinder Assembly Removal and Installation...1515
Front Brake Master Cylinder / Brake Lever Disassembly and Assembly...1516
Front Brake Master Cylinder Parts Inspection...1518
Rear Brake Master Cylinder Components...1519
Rear Brake Master Cylinder Assembly Removal and Installation...1520
Rear Brake Master Cylinder Disassembly and Assembly...1520
Rear Brake Pedal Removal and Installation...1523
Specifications...1523
Service Data...1523
Tightening Torque Specifications...1523
Special Tools and Equipment...1524
Recommended Service Material...1524
Special Tool...1524
Front Brakes...1525
Repair Instructions...1525
Front Brake Components...1525
Front Brake Pad Inspection...1526
Front Brake Pad Replacement...1526
Front Brake Caliper Removal and Installation...1527
Front Brake Caliper Disassembly and Assembly...1528
Front Brake Caliper Parts Inspection...1530
Specifications...1532
Service Data...1532
Tightening Torque Specifications...1532
Special Tools and Equipment...1533
Recommended Service Material...1533
Special Tool...1533
Rear Brakes...1534
Repair Instructions...1534
Rear Brake Components...1534
Rear Brake Pad Inspection...1535
Rear Brake Pad Replacement...1535
Rear Brake Caliper Removal and Installation...1536
Rear Brake Caliper Disassembly and Assembly...1537
Rear Brake Disc Removal and Installation...1539
Special Tools and Equipment...1541
Recommended Service Material...1541
Special Tool...1541
Transmission / Transaxle...1543
Precautions...1544
Precautions...1544
Precautions for Transmission / Transaxle...1544
Manual Transmission...1545
Diagnostic Information and Procedures...1545
Manual Transmission Symptom Diagnosis...1545
Repair Instructions...1546
Transmission Components...1546
Transmission Removal...1547
Transmission Installation...1549
Transmission Construction...1553
Countershaft Gear / Driveshaft Gear Disassembly and Assembly...1553
Gear Position (GP) Switch Inspection...1557
Gear Position (GP) Switch Removal and Installation...1557
Gearshift Shaft / Gearshift Cam Plate Components...1559
Gearshift Shaft Construction...1559
Gearshift Shaft / Gearshift Cam Plate Removal and Installation...1560
Gearshift Linkage Inspection...1562
Gearshift Shaft Oil Seal / Bearing Removal and Installation...1563
Specifications...1564
Service Data...1564
Tightening Torque Specifications...1564
Special Tools and Equipment...1565
Recommended Service Material...1565
Special Tool...1565
Clutch...1567
Precautions...1567
Precautions for Clutch System...1567
Schematic and Routing Diagram...1567
Clutch Cable Routing Diagram...1567
Diagnostic Information and Procedures...1567
Clutch System Symptom Diagnosis...1567
Repair Instructions...1568
Clutch Lever Position Switch Inspection...1568
Clutch Cable Inspection...1568
Clutch Cable Removal and Installation...1568
Clutch Control System Components...1569
Clutch Components...1570
Clutch Removal...1571
Clutch Installation...1573
Clutch Lifter Pin Inspection and Adjustment...1579
Specifications...1580
Service Data...1580
Tightening Torque Specifications...1580
Special Tools and Equipment...1581
Recommended Service Material...1581
Special Tool...1581
Steering...1583
Precautions...1584
Precautions...1584
Precautions for Steering...1584
Steering General Diagnosis...1585
Diagnostic Information and Procedures...1585
Steering Symptom Diagnosis...1585
Steering / Handlebar...1586
Repair Instructions...1586
Handlebar Components...1586
Handlebar Removal and Installation...1587
Handlebars Inspection...1589
Steering Components...1590
Steering Damper Construction...1591
Steering / Steering Damper Removal and Installation...1591
Steering Tension Adjustment...1596
Specifications...1597
Tightening Torque Specifications...1597
Special Tools and Equipment...1598
Recommended Service Material...1598
Special Tool...1598
Body and Accessories...1599
Precautions...1601
Precautions...1601
Precautions for Electrical System...1601
Component Location...1601
Electrical Components Location...1601
Wiring Systems...1602
Schematic and Routing Diagram...1602
Wiring Diagram...1602
Wiring Harness Routing Diagram...1604
Specifications...1608
Service Data...1608
Tightening Torque Specifications...1608
Special Tools and Equipment...1608
Recommended Service Material...1608
Lighting Systems...1609
Repair Instructions...1609
Headlight Components...1609
Headlight Removal and Installation...1610
Headlight Bulb and Position Light Bulb Replacement...1610
Headlight Beam Adjustment...1612
Front Turn Signal Light Components...1612
Front Turn Signal Light Removal and Installation...1613
Front Turn Signal Light Bulb Replacement...1613
Rear Lighting System Construction...1614
Rear Combination Light Removal and Installation...1615
Rear Combination Light Replacement...1616
License Plate Light Components...1616
License Plate Light Removal and Installation...1616
License Plate Light Bulb Replacement...1617
Rear Turn Signal Light Components...1618
Rear Turn Signal Light Removal and Installation...1618
Rear Turn Signal Light Bulb Replacement...1619
Reflex Reflector Construction...1619
Headlight Relay Inspection...1620
Turn Signal / Side-Stand Relay Inspection...1620
Turn Signal / Side-Stand Relay Removal and Installation...1620
Hazard Switch Inspection...1620
Turn Signal Switch Inspection...1621
Passing Light Switch Inspection...1621
Dimmer Switch Inspection...1622
Specifications...1622
Service Data...1622
Tightening Torque Specifications...1622
Special Tools and Equipment...1623
Recommended Service Material...1623
Special Tool...1623
Combination Meter / Fuel Meter / Horn...1624
General Description...1624
Combination Meter System Description...1624
Repair Instructions...1625
Combination Meter Components...1625
Combination Meter Removal and Installation...1625
Combination Meter Disassembly and Assembly...1625
Combination Meter Inspection...1626
Engine Coolant Temperature Indicator Light Inspection...1626
Fuel Level Indicator Inspection...1628
Fuel Level Gauge Inspection...1628
Speedometer Inspection...1628
Speed Sensor Removal and Installation...1628
Speed Sensor Inspection...1629
Oil Pressure Indicator Inspection...1629
Ignition Switch Removal and Installation...1631
Horn Inspection...1631
Horn Removal and Installation...1631
Specifications...1632
Service Data...1632
Tightening Torque Specifications...1632
Special Tools and Equipment...1632
Special Tool...1632
Exterior Parts...0
Repair Instructions...0
Under Cowling Heat Shield / Cushion Attachment...1635
Rear Fender Construction...1636
Frame Cover Construction...1637
Frame Side Cover Cushion Attachment...1638
Fuel Tank Cover Cushion Attachment...1639
Rear View Mirror Construction...1640
Rear View Mirror Cushion Attachment...1641
Fastener Removal and Installation...1642
Exterior Parts Removal and Installation...1643
Specifications...1647
Tightening Torque Specifications...1647
Body Structure...1648
Repair Instructions...1648
Body Frame Construction...1648
Front Footrest Bracket Construction...1649
Side-stand Construction...1650
Pillion Footrest Construction...1650
Side-stand Removal and Installation...1651
Specifications...1651
Tightening Torque Specifications...1651
Special Tools and Equipment...1651
Recommended Service Material...1651
Suzuki GSX-R750 (GSX-R750T, GSX-R750V, GSX-R750W, GSX-R750X) Service Manual '96-'99...1654
Index...1654
Section 1 - General Information...1658
Section 2 - Periodic Maintenance...1670
Section 3 - Engine...1694
Section 4 - Fuel & Lubrication System...1800
Section 5 - Cooling System...1834
Section 6 - Chassis...1852
Section 7 - Electrical System...1918
Section 8 - Servicing Information...1958
Section 9 - Emission Control Information...2000
Section 10 - GSX-R750V ('97 Model)...2006
Section 11 - GSX-R750W ('98 Model)...2022
Section 12 - GSX-R750X ('99 Model)...2190
Suzuki GSX-R750 (GSX-R750Y, GSX-R750K1, GSX-R750K2) Service Manual '00-'02...2210
Cover...2210
Index...2211
1- General Info...2217
2- Periodic Maintanance...2227
3- Engine...2259
4- Fuel Injection/ Air Intake...2358
5- Cooling and Lube System...2441
6- Chassis...2462
7- Electrical System...2543
8- Servicing Info...2585
9- Emission Control Info...2627
2001 Updates...2635
Specs...2636
Clutch...2646
Fuel Pressure...2648
Engine Mounting Bolt...2650
Canister Hose Routing...2651
2002 Updates...2653
Specs...2654
Engine...2656
FI and Air Intake...2657
Chassis...2678
Servicing Info...2681
Cooling System Hose Routing...2684
Front Brake Hose Routing...2685
Rear Brak eHose Routing...2686
Service Data...2688
Wiring Diagrams...2697
Suzuki GSX-R750W (GSX-R750WP, GSX-R750WR, GSX-R750WS) Service Manual '93-'95...2708
Suzuki GSX-R750(W) Repair Service Manual 1993-2008
