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GSX-R750K2 2002
Suzuki GSX-R750K2 2002 User Manual
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SERVICING INFORMATION 8-27
SPECIAL T
OOLS
09900-06104
Snap ring pliers
09900-06107
Snap ring pliers
09900-06108
Snap ring pliers
09900-20101
09900-20102
V
er
nier calipers
09900-20202
Micrometer
(25–50 mm)
09900-20204
Micrometer
(75–100 mm)
09900-20205
Micrometer
(0–25 mm)
09900-20508
Cylinder gauge set
09900-20602
Dial gauge
(1/1000 mm, 1 mm)
09900-20606
Dial gauge
(1/100 mm, 10 mm)
09900-20701
Magnetic stand
09900-20803
09900-20806
Thickness gauge
09900-20805
Tire depth gauge
09900-21304
V
-bloc
k (100 mm)
09900-22401
(10 – 18 mm)
09900-22403
(18 – 35 mm)
Small bore gauge
09900-25008
Multi circuit tester set
09910-20115
Conrod holder
09913-10750
Compression gauge
adapter
09913-13121
Carburetor balancer set
09913-50121
Oil seal remover
09913-70210
Bearing installer set
09915-40610
Oil filter wrench
09915-64510
Compression gauge
09900-22301
09900-22302
Plastigauge
09900-20605
Dial calipers
(1/100 mm, 10–34 mm)
399
401
Table of Contents
Foreword Group Index
2
Table of Contents
2
How to Use this Manual
3
General Information 1
8
General Precautions
9
Warning/Caution/Note
9
Serial Number Location
11
Suzuki Gsx-R750Y (2000-Model)
11
Fuel, Oil and Engine Coolant Recommendation
12
Fuel
12
Engine Oil
12
Brake Fluid
12
Front Fork Oil
12
Engine Coolant
13
Water for Mixing
13
Anti-Freeze/Engine Coolant
13
Liquid Amount of Water/Engine Coolant
13
Break-In Procedures
13
Cylinder Identification
13
Information Labels
14
Specifications
15
Country and Area Codes
17
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
22
Valve Clearance
25
Engine Oil and Oil Filter
30
Fuel Hose
32
Engine Idle Speed
32
Throttle Valve Synchronization
32
Throttle Cable Play
33
Clutch
34
Cooling System
35
ENGINE COOLANT Change
35
Engine Coolant Level Check
35
Drive Chain
37
Brake
39
Tire
42
Tire Tread Depth
42
Steering
43
Front Fork
44
Rear Suspension
44
Exhaust Pipe Bolt and Nut
44
Compression Pressure Check
47
Oil Pressure Check
48
Engine
49
Engine Removal and Installation
51
Engine Removal
51
Engine Installation
59
Engine Disassembly
63
Engine Components Inspection and Service
77
Pair Valve
77
Cylinder Head Cover
78
Camshaft
78
Camshaft Runout
80
Cam Chain Tension Adjuster
80
Cam Chain Tensioner
80
Cam Chain Guide
80
Cylinder Head and Valve
81
Clutch
91
Oil Pump
92
Starter Clutch
92
Generator
92
Water Pump
92
Gearshift System
93
Oil Pressure Regulator
94
Oil Strainer
94
Transmission
95
Cylinder
98
Piston and Piston Ring
99
Piston Diameter
99
Piston Ring Groove Width
100
Piston Ring Thickness
100
Crankcase
102
Crankshaft and Conrod
108
Crankshaft Runout
108
Crankshaft Journal Bearing
111
Crankshaft Thrust Bearing
113
Engine Reassembly
115
Fi System and Intake Air System
147
Fi System and Intake Air
147
Precautions in Servicing
149
Electrical Circuit Inspection Procedure
151
Using Testers
154
Fi System Technical Features
155
Injection Time
155
Compensation of Injection Time
156
Injection Stop Control
156
Fuel Delivery System
157
Fuel Pump
158
Fuel Pressure Regulator
159
Fuel Injector
159
Fuel Pump Control System
160
Ecm (Fi Control Unit)
161
Injection Timing
162
Sensors
163
Intake Air System
167
Secondary Throttle Control System
167
Operation
168
Fi System Parts Location
169
Fi System Diagram
171
Fi System Wiring Diagram
172
Self-Diagnosis Function
173
User Mode
173
Dealer Mode
174
Fail-Safe Function
176
Fi System Troubleshooting
177
Customer Complaint Analysis
177
Self-Diagnostic Procedures
178
Self-Diagnosis Reset Procedure
178
Malfunction Code and Defective Condition
179
C11" Cmp Sensor Circuit Malfunction
181
C12" Ckp Sensor Circuit Malfunction
182
C13" Iap Sensor Circuit Malfunction
183
C14" Tp Sensor Circuit Malfunction
185
C15" Ect Sensor Circuit Malfunction
187
C21" Iat Sensor Circuit Malfunction
188
C22" Ap Sensor Circuit Malfunction
189
C23" to Sensor Circuit Malfunction
191
C24", "C25", "C26" or "C27" IGNITION SYSTEM MALFUNCTION
192
C28" Stv Actuator Circuit Malfunction
192
C31" Gear Position Switch Circuit Malfunction
195
C32", "C33", "C34" or "C35" FUEL INJECTION MALFUNCTION
196
C41" Fp Relay Circuit Malfunction
197
C42" Ig Switch Circuit Malfunction
197
Fuel System
198
Fuel Tank Lift-Up
198
Fuel Tank Removal
198
Fuel Tank Installation
198
Fuel Pressure Inspection
199
Fuel Pump Inspection
200
Fuel Pump Relay Inspection
202
Fuel Pump and Fuel Filter Removal
202
Fuel Filter Inspection and Cleaning
204
Fuel Pump and Fuel Filter Installation
204
Throttle Body and Stv Actuator
207
Construction
207
Throttle Body and Stv Actuator Removal
208
Throttle Body Disassembly
213
Throttle Body Cleaning
214
Inspection
214
Throttle Body Reassembly
215
Throttle Body and Stv Actuator Installation
217
Stv Actuator Adjustment
219
Fuel Injector Inspection
222
Fuel Injector Removal
222
Fuel Injector Installation
223
Fast Idle Adjustment
223
Throttle Valve Synchronization
224
Throttle Position Sensor (Tps) Setting
227
Throttle Cable Adjustment
227
Sensors
228
Iap Sensor Inspection
228
Iap Sensor Removal/Installation
228
Tp Sensor Inspection
228
Tp Sensor Removal/Installation
228
Ckp Sensor Inspection
228
Ckp Sensor Removal/Installation
228
Cmp Sensor Inspection
228
Cmp Sensor Removal/Installation
228
Iat Sensor Inspection
228
Ect Sensor Inspection
229
Ect Sensor Removal/Installation
229
Ap Sensor Inspection
229
Ap Sensor Removal/Installation
229
To Sensor Inspection
229
To Sensor Removal/Installation
229
Cooling and Lubrication System
230
Cooling and Lubrication
230
Engine Coolant
231
Cooling Circuit
232
Cooling Circuit Inspection
232
Radiator and Water Hoses
233
Radiator Removal
233
Radiator Cap Inspection
233
Radiator Inspection and Cleaning
233
Radiator Remounting
234
Water Hose Inspection
234
Cooling Fan
235
Removal
235
Inspection
235
Installation
235
Cooling Fan Thermo-Switch
235
Inspection
236
Installation
236
Engine Coolant Temperature Sensor
237
Removal
237
Inspection
237
Installation
238
Thermostat
238
Removal
238
Inspection
239
Installation
239
Water Pump
240
Removal and Disassembly
240
Inspection
243
Reassembly and Installation
244
Lubrication System
247
Oil Pressure
247
Oil Filter
247
Oil Pressure Regulator
247
Oil Strainer
247
Oil Jet
247
Oil Pump
247
Oil Pressure Switch
247
Engine Lubrication System Chart
248
Oil Pan
248
Engine Lubrication System
249
System
250
Chassis
251
Exterior Parts
253
Construction
253
Heat Shield
254
Fastener Removal and Reinstallation
255
Screen
255
Body Cowling Cover
256
Right and Left under Cowlings
256
Body Cowling
257
Right and Left Air Intake Pipes
258
Cowling Brace
258
Front Seat
259
Rear Seat and Seat Tail Cover
259
Frame Cover
259
Front Wheel
260
Construction
260
Removal
262
Inspection and Disassembly
263
Reassembly and Remounting
265
Front Fork
268
Construction
268
Removal and Disassembly
269
Inspection
272
Reassembly and Remounting
273
Suspension Setting
278
Steering Damper
279
Construction
279
Removal
279
Inspection
279
Remounting
279
Steering
280
Construction
280
Removal and Disassembly
280
Inspection and Disassembly
282
Reassembly and Remounting
282
Steering Tension Adjustment
284
Handlebar
285
Construction
285
Removal and Disassembly
285
Reassembly and Remounting
286
Rear Wheel
288
Construction
288
Removal
290
Inspection and Disassembly
291
Reassembly and Remounting
293
Rear Shock Absorber
297
Construction
297
Removal
298
Inspection
298
Rear Shock Absorber Scrapping Procedure
299
Remounting
299
Suspension Setting
300
Reassembly
307
Remounting
309
Final Inspection and Adjustment
310
Front Brake
311
Construction
311
Brake Pad Replacement
312
Brake Fluid Replacement
312
Caliper Removal and Disassembly
313
Caliper Inspection
314
Caliper Reassembly and Remounting
314
Brake Disc Inspection
315
Master Cylinder Removal and Disassembly
316
Master Cylinder Inspection
317
Master Cylinder Reassembly and Remounting
317
Rear Brake
319
Construction
319
Brake Pad Replacement
320
Brake Fluid Replacement
320
Caliper Removal and Disassembly
321
Caliper Inspection
322
Caliper Reassembly and Remounting
322
Service Limit
322
Master Cylinder Removal and Disassembly
323
Master Cylinder Inspection
324
Master Cylinder Reassembly and Remounting
324
Tire and Wheel
325
Tire Removal
325
Inspection
325
Valve Inspection
326
Valve Installation
326
Tire Installation
326
Drive Chain
328
Drive Chain Cutting
328
Drive Chain Connecting
329
Electrical System
332
Cautions in Servicing
333
Location of Electrical Components
335
Charging System
337
Description
337
Troubleshooting
339
Inspection
340
Starter System and Side-Stand/Ignition Interlock System
342
Starter System Description
342
Side-Stand/Ignition Interlock System Description
342
Troubleshooting
344
Starter Motor Removal and Disassembly
345
Starter Motor Inspection
345
Starter Motor Reassembly
346
Starter Relay Inspection
347
Side-Stand/Ignition Interlock System Part Inspection
348
Ignition System
351
Description
351
Troubleshooting
353
Inspection
354
Combination Meter
359
Description
359
Removal
362
Inspection
363
Lamps
367
Headlight
367
Switches
369
Battery
371
Specifications
371
Initial Charging
371
Servicing
372
Recharging Operation
373
Servicing Information
374
Troubleshooting
375
Fi System Malfunction Code and Defective Condition
375
Engine
377
Radiator (Cooling System)
382
Chassis
383
Brakes
384
Electrical
385
Battery
386
Wiring Harness Routing
387
Cable Routing
390
Fuel Tank Drain Hose Routing
391
Cooling System Hose Routing
392
Front Brake Hose Routing
393
Rear Brake Hose Routing
394
Pair (Air Supply) System Hose Routing
395
Fuel Tank Set-Up
396
Cowling Set-Up
397
Frame Cover Set-Up
398
Heat Shield Set-Up
398
Gearshift Pedal Set-Up
399
Side-Stand Set-Up
399
Special Tools
400
Tightening Torque
403
Service Data
407
Emission Control Information
416
Emission
416
Fuel Injection System
417
Evaporative Emission Control System
417
Canister Hose Routing
418
Evaporative Emission Control System Inspection
419
Pair (Air Supply) System Diagram
420
Pair (Air Supply) System Hose Routing
421
Pair (Air Supply) System Inspection
422
Gsx-R750K1 ('01-Model)
423
Specifications
424
Service Data
425
Clutch
427
Clutch Reassembly
434
Clutch Drive Plates Inspection
435
Fuel Pressure Inspection
436
Ap Sensor
437
Throttle Stop Screw
437
Engine Mounting Bolt and Nut
438
Canister Hose Routing (for E-33)
439
Gsx-R750K2 ('02-Model)
440
Specifications
441
Engine
443
Clutch
443
Tightening Torque for Cam Chain Tension Adjuster
443
Fi System and Intake Air System
444
Malfunction Code and Defective Condition
444
C28" Stv Actuator Circuit Malfunction
446
C29" Stp Sensor Circuit Malfunction
447
Fuel Pump
449
Throttle Body
451
Throttle Valve Synchronization
462
Chassis
465
Front Axle
465
Swingarm Pivot Boss
465
Torque Link
467
Servicing Information
468
Wire Harness Routing
468
Cooling System Hose Routing
471
Front Brake Hose Routing
472
Rear Brake Hose Routing
473
CANISTER HOSE ROUTING (Only for E-33)
474
Service Data
475
Wiring Diagram
484
4
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Suzuki GSX-R750K2 2002 Specifications
General
Brand
Suzuki
Model
GSX-R750K2 2002
Category
Motorcycle
Language
English
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