Suzuki 1998 GSX-R750 Manuals

Manuals and User Guides for Suzuki 1998 GSX-R750. We have 2 Suzuki 1998 GSX-R750 manuals available for free PDF download: Service Manual

Suzuki 1998 GSX-R750 Service Manual (558 pages)

Brand: Suzuki | Category: Motorcycle | Size: 47.25 MB

Group Index
2
Symbol
4
General Information
6
Warning/Caution/Note
7
General Precautions
7
Serial Number Location
9
Fuel
9
Engine Oil
10
Brake Fluid
10
Engine Coolant
10
Anti-Freeze/Engine Coolant
10
Break-In Procedures
11
Cylinder Identification
11
Information Labels
12
Specifications
14
Country of Area
16
Periodic Maintenance
18
Periodic Maintenance Schedule
19
Periodic Maintenance Chart
19
Lubrication Points
20
Maintenance and Tune-Up Procedures
21
Air Cleaner
21
Spark Plug
21
Carbon Deposit
22
Spark Plug Gap
22
Electrodes Condition
22
Tappet Clearance
23
Tappet Clearance Adjustment
24
Tappet Shim Selection Table
25
Fuel Hose
27
Engine Oil and Oil Filter
27
Engine Oil Replacement
27
Engine Idle Speed
28
Oil Filter Replacement
28
Necessary Amount of Engine Oil
28
Clutch
29
Cooling System
30
Engine Coolant Level Check
30
Engine Coolant Change
30
Drive Chain
31
Radiator Hoses
31
Drive Chain Checking
31
Drive Chain Adjusting
32
Drive Chain Cleaning and Lubricating
32
Brake
33
Brake Fluid Level Check
33
Brake Pads
33
Brake Pedal Height
34
Brake Light Switch
34
Air Bleeding the Brake Fluid Circuit
35
Steering
36
Tire Tread Condition
36
Tire Pressure
36
Tire Type
36
Front Fork
37
Rear Suspension
37
Exhaust Pipe Bolts
37
Chassis Bolts and Nuts
38
Compression Pressure Check
40
Compression Test Procedure
40
Compression Pressure Specification
40
Low Compression Pressure
40
Oil Pressure Check
41
Oil Pressure Test Procedure
41
Low Oil Pressure
41
High Oil Pressure
41
Engine
42
Engine Components Removable with Engine in Place
43
Engine Left Side
43
Engine Right Side
43
Engine Center
43
Engine Removal
44
Engine Installation
49
Front Upper
50
Rear Upper
50
Rear Lower
50
Camshaft/Cylinder Head
54
Camshaft Removal
55
Cylinder Head Removal
56
Camshaft
57
Cam Wear
57
Camshaft Journal Wear
58
Camshaft Runout
59
Cam Sprocket/Bearing
59
Cam Chain Tension Adjuster
59
Cam Chain Guide
60
Cam Chain Tensioner
60
Cylinder Head
61
Cylinder Head Distortion
62
Valve Stem Runout
62
Valve Head Radial Runout
62
Valve Face Wear
62
Valve Stem Deflection
63
Valve Stem Wear
63
Valve Guide Servicing
63
Valve Seat Width
64
Valve Seat Servicing
64
Valve Spring
66
Cylinder Head Reassembly
67
Cylinder Head Installation
68
Camshaft Installation
69
Cylinder/Piston
74
Cylinder/Piston Removal
75
Cylinder/Piston Inspection
76
Cylinder Block Distortion
76
Cylinder Bore
76
Piston Diameter
76
Piston-Cylinder Clearance
77
Piston Ring - Groove Clearance
77
Piston Ring Free End Gap and Piston Ring End Gap
77
Piston/Cylinder Installation
78
Piston Pin and Pin Bore
78
Clutch Removal
83
Clutch Inspection
85
Clutch Diaphragm Spring
85
Clutch Drive and Driven Plates
85
Clutch Installation
86
Clutch Bearing
86
Clutch Release
86
Engine Lubrication System
91
Oil Pump Removal and Disassembly
93
Oil Pump Inspection
94
Oil Pump Reassembly and Installation
94
Oil Filter Removal
96
Oil Filter Installation
96
Oil Cooler Removal
97
Oil Cooler Installation
97
Oil Pan/Oil Sump Filter/Oil Pressure Regulator Removal
98
Oil Pressure Regulator Inspection and Cleaning
98
Oil Pressure Regulator/Oil Sump Filter/Oil Pan Installation
99
Oil Pressure Switch Removal
100
Oil Pressure Switch Inspection
100
Oil Pressure Switch Installation
100
Starter System/Signal Generator
102
Starter Clutch/Signal Generator Removal
103
Starter Clutch/Signal Generator Inspection
104
Starter Clutch/Signal Generator Installation
105
Starter Motor Removal
107
Starter Motor Installation
107
Generator
108
Generator Removal
109
Generator Installation
110
Gearshift Linkage
112
Gearshift Linkage Removal
113
Gearshift Linkage Inspection
113
Gearshift Linkage Installation
114
Crankcase/Transmission/Crankshaft/Conrod
115
Lower Crankcase/Transmission Removal
123
Transmission Inspection and Service
126
Gearshift Fork-Groove Clearance
126
Lower Crankcase/Transmission Installation
132
Location of Gasket Washer
135
Upper and Middle Crankcases/Crankshaft/Conrod Removal
136
Conrod/Crankshaft Inspection
137
Crankcase-Crankshaft Bearing Selection
140
Crankshaft Thrust Clearance
142
Piston Cooling Oil Nozzle Service
143
Thrust Bearing Selection Table
143
Crankshaft Runout
143
Upper and Middle Crankcases/Crankshaft/Conrod Installation
144
Fuel and Lubrication System
148
Fuel System
149
Fuel Tank Lift-Up
150
Fuel Tank Removal
150
Vacuum Fuel Valve
151
Vacuum Fuel Valve Removal
151
Vacuum Fuel Valve Inspection
152
Fuel Pump Inspection
152
Fuel Pump and Fuel Filter Removal
153
Fuel Filter Inspection and Cleaning
154
Fuel Pump Relay Inspection
154
Carburetor Construction
155
Carburetor Specifications
156
Diaphragm and Piston Operation
157
Piston Valve Lift Control System
158
Slow System
159
Main System
160
Starter System
161
Float System
161
Carburetor Cleaning
168
Carburetor Inspection
168
Needle Valve Inspection
168
Fuel Level Inspection
169
Float Height Adjustment
169
Solenoid Valve Inspection
170
Solenoid Valve Voltage Inspection
170
V.T.V. Inspection
170
Throttle Position Sensor Inspection
171
Throttle Valve
171
Starter Plunger
171
Pilot Air Jet
172
Funnel
172
Pilot Screw
172
Float Chamber
172
Piston Valve and Carburetor Top Cap
173
Carburettor Engaging
173
Throttle Position Sensor Positioning
174
Carburetor Clamps
175
Carburetor Synchronization
176
Calibrating each Gauge
176
Lubrication System
178
Oil Sump Filter
178
Engine Lubrication System Chart
179
Engine Oil Cooling System
181
Cooling System Description
183
Cooling System Construction
184
Radiator Inspection
187
Cooling Fan Inspection
188
Cooling Fan Thermo-Switch
189
Cooling Fan Mounting Bolt and Nut
189
Radiator Mounting Bolt
189
Engine Coolant Temperature Gauge
191
Thermostat Removal
193
Thermostat Inspection
193
Thermostat Installation
194
Water Pump Removal and Installation
195
Water Pump Bearing
197
Mechanical Seal
197
Chassis
200
Exterior Parts Constructino
201
Fairing
202
Front Seat
203
Rear Seat and Seat Tail Cover
203
Frame Cover
204
Front Wheel Construction
205
Axle Shaft
207
Wheel
208
Brake Disc
208
Wheel Bearings
208
Spacer Nut
209
Brake Caliper
210
Front Axle
210
Front Fork Construction
211
Inner and Outer Tubes
215
Fork Spring
215
Damper Rod
215
Tube Metals and Seals
215
Compression Damping Force Adjuster
216
Damper Rod Bolt
216
Fork Oil
217
Front Fork Cap Bolt
218
Front Wheel
219
Suspension Setting
220
Spring Pre-Load Adjustment
220
Damping Force Adjustment
220
Standard Front Suspension Setting
220
Steering Construction
221
Steering Removal and Disassembly
221
Steering Inspection and Disassembly
223
Steering Reassembly and Remounting
224
Front Fork and Steering Stem Upper Bracket
225
Steering Tension Adjustment
226
Rear Wheel Construction
227
Rear Wheel Specifications
227
Rear Wheel Removal
229
Rear Wheel Inspection and Disassembly
230
Cushion
230
Sprocket
230
Rear Wheel Reassembly and Remounting
231
Wheel Bearing
231
Sprocket Mounting Drum Bearing and Oil Seal
232
Rear Sprocket
232
Rear Axle Shaft
232
Rear Suspension Construction
233
Rear Suspension Specifications
233
Spacer
237
Swingarm Bearing
237
Cushion Lever Bearing
238
Swingarm Pivot Shaft
238
Chain Buffer
238
Shock Absorber
239
Swingarm Pivot Boss and Height Adjuster
240
Swingarm Pivot Thrust Clearance Adjustment
240
Shock Absorber and Cushion Lever Mounting Nut
241
Brake Pad Replacement
244
Brake Fluid Replacement
245
Caliper Removal and Disassembly
245
Caliper Inspection
247
Caliper Reassembly and Remounting
247
Piston Seal
247
Caliper Bolts
247
Disc Servicing
248
Master Cylinder Removal and Disassembly
248
Disc Inspection
248
Master Cylinder Inspection
250
Master Cylinder Reassembly and Remounting
250
Rear Brake Construction
251
Rear Brake Specifications
252
Tire and Wheel
257
Tire Removal
257
Wheel Inspection
259
Tire Inspection
259
Valve Inspection
259
Valve Installation
260
Tire Installation
260
Electrical System
266
Cautions in Servicing
267
Connector
267
Coupler
267
Clamp
267
Battery
268
Connecting Battery
268
Wiring Procedure
268
Using Pocket Tester
268
Location of Electrical Components
269
Charging System Description
271
Function of Regulator
271
Electrical System Troubleshooting
273
Battery Runs down Quickly
273
Battery Leak Current Inspection
274
Charging Output Inspection
274
Generator Coil Continuity Inspection
275
Generator No-Load Performance Inspection
275
Regulator/Rectifier
276
Starter System Description
277
Side-Stand/Ignition Interlock System Description
277
Starter Motor will Not Run
279
Starter Motor Removal and Disassembly
280
Starter Motor Inspection
280
Carbon Brush
280
Commutator
281
Armature Coil Inspection
281
Oil Seal Inspection
281
Starter Motor Reassembly
281
Starter Relay Inspection
283
Side-Stand/Ignition Interlock System Part Inspection
284
Neutral Switch
284
Side-Stand Switch
285
Side-Stand/Ignition Interlock Relay
285
Ignition System (Digital Ignitor)
286
No Spark or Poor Spark
287
Ignition Coil Primary Peak Voltage
288
Ignition Coil
289
Signal Generator
290
Ignitor Unit
292
Combination Meter Removal
294
Combination Meter Disassembly
294
Combination Meter Inspection
295
Engine Coolant Temperature Meter and Indicator Inspection
296
Fuel Level Indicator Inspection
297
Fuel Level Indicator Light Inspection
297
Fuel Level Indicator Switch Inspection
298
Speedometer Inspection
299
Speed Sensor Inspection
299
Oil Pressure Indicator Inspection
299
Lamps
300
Headlight
300
Bulb Replacement
300
Tail/Brake and Turn Signal Unit
301
Switches
302
Starter Relay
303
Side-Stand Relay
303
Fuel Pump Relay
303
Turn Signal Relay
303
Recharging Operation
305
Servicing Information
306
Troubleshooting
307
Wiring Diagram
315
Wire Harness Routing
319
Cable Routing
322
Fuel System Hose Routing
323
Cooling System Hose Routing
325
Front Brake Hose Routing
326
Rear Brake Hose Routing
327
Pair (Air Supply) System Hose Routing
328
Fairing Set up
329
Frame Cover Set up
330
Under Fairing Heat Shield
330
Lower Fairing Cushion and Heat Shield
331
Special Tools
332
Tightening Torque
335
Tightening Torque Chart
337
Service Data
338
Emission Control Information
348
Emission Control Carburetor Components
349
Evaporative Emission Control System
350
Canister Hose Routing
351
Pair System Diagram
352
Pair System Hose Routing
353
Gsx-R750V
354
Gsx-R750W
370
C11 CMP Sensor Circuit Malfunction
443
C12 CKP Sensor Circuit Malfunction
444
C13 IAP Sensor Circuit Malfunction
445
C14 TP Sensor Circuit Malfunction
447
C15 ECT Sensor Circuit Malfunction
449
C21 IAT Sensor Circuit Malfunction
450
C22 AP Sensor Circuit Malfunction
451
C23 to Sensor Circuit Malfunction
453
C24 or C25 Ignition System Malfunction
454
C31 Gear Position Switch Circuit Malfunction
454
C32, C33, C34 and C35 Fuel Injection Malfunction
455
C41 FP Relay Circuit Malfunction
456
Gsx-R750X
538

Suzuki 1998 GSX-R750 Service Manual (557 pages)

Brand: Suzuki | Category: Motorcycle | Size: 47.25 MB

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Suzuki 1998 GSX-R750 Service Manual (558 pages)

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Suzuki 1998 GSX-R750 Service Manual (557 pages)

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