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Suzuki
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kq750
Suzuki kq750 User Manual
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Wiring System
s:
9A-4
Wiring Harn
ess Routing Diagram
B831G29102002
Clamp
Wiring harness
Wiring harness
Wiring harness
60 – 80 mm (2.36 – 3.15 in)
Clamp
Wiring harness
Clamp
Clamp
Clamp
Wiring harness
Clamp
Clamp
Brake light/taillight
Back up relay (P-17)
Clamp
Wiring harness
Generator
Gear position switch
Clamp
Speed sensor
Clamp
Actuator
Clamp
Clamp
Clamp
Clamp
Actuator
Foot brake switch
Actuator
Foot brake switch
IAP sensor
IAP sensor
IAP sensor
T
o rear fender top
Speed sensor
Clamp
Wiring harness
TP sensor
Injector coupler
ECT sensor coupler
ISC valve
Ignition coil
T
o power source
Clamp
Wiring harness
Wiring harness
Wiring harness
Actuator
Gear position switch
Generator
Hose
Cooling fan thermo switch
Foot brake switch
Parking brake cable
ICES canada
label (P-28)
I831G1910903-07
534
536
Table of Contents
Section 0 General Information
14
Default Chapter
6
Precautions
6
Exhaust System
7
Table of Contents
14
Parking Brake
14
General Information
15
Vehicle Identification Number
17
Fuel System
23
Transfer
23
Front Suspension
24
Rear Suspension
24
General Description
30
Maintenance and Lubrication
30
Precautions
30
Precautions for Maintenance
30
Recommended Fluids and Lubricants
30
Scheduled Maintenance
30
Periodic Maintenance Schedule Chart
30
Lubrication Points
31
Repair Instructions
32
Air Cleaner Element Inspection and Cleaning
32
Exhaust Pipe Bolt and Muffler Bolt Inspection
33
Valve Clearance Inspection and Adjustment
33
Spark Plug Replacement
38
Spark Plug Inspection and Cleaning
38
Spark Arrester Cleaning
39
Fuel Line Inspection
39
Engine Oil and Filter Replacement
39
Front Differential Gear Oil Inspection
41
Front Differential Gear Oil Replacement
42
Final Gear Oil Inspection
43
Final Gear Oil Replacement
43
Throttle Cable Play Inspection and Adjustment
44
Throttle Body Inspection
44
Cooling System Inspection
44
Drive V-Belt Inspection and Replacement
46
Drive Shaft Boots Inspection
46
Front Brake System Inspection
46
Automatic Transmission
46
Rear Brake Pedal / Rear Brake
48
Inspection
48
Tire Inspection
50
Steering System Inspection
50
Toe Adjustment
51
Suspensions Inspection
51
Chassis Bolt and Nut Inspection
52
Compression Pressure Check
55
Oil Pressure Check
55
SDS Check
55
Automatic Clutch Inspection
55
Rear Brakes
55
Tightening Torque Specifications
56
Special Tools and Equipment
56
Recommended Service Material
56
Special Tool
56
Service Data
58
Specifications
58
Tightening Torque List
64
Section 1 Engine
69
Default Chapter
69
Emission Control Devices
69
Engine Electrical Devices
69
Engine General Information and Diagnosis
69
Engine Cooling System
70
Engine Lubrication System
70
Engine Mechanical
70
Ignition System
71
Precautions
73
Precautions for Engine
73
General Description
74
Injection Timing Description
74
Engine General Information and Diagnosis
74
Schematic and Routing Diagram
77
FI System Wiring Diagram
77
Terminal Alignment of ECM Coupler
78
Component Location
79
FI System Parts Location
79
Diagnostic Information and Procedures
81
Engine Symptom Diagnosis
81
Self-Diagnostic Procedures
84
Use of SDS Diagnosis Reset Procedures
86
Show Data When Trouble (Displaying Data at the Time of DTC)
87
SDS Check
88
DTC Table
92
Fail-Safe Function Table
92
FI System Troubleshooting
93
Malfunction Code and Defective Condition Table
95
DTC "C12" (P0335): CKP Sensor Circuit Malfunction
97
DTC "C13" (P0105-H/L): IAP Sensor Circuit Malfunction
100
DTC "C14" (P0120-H/L): TP Sensor Circuit Malfunction
107
DTC "C15" (P0115-H/L): ECT Sensor Circuit Malfunction
114
DTC "C20" (P1752): Diff-Lock Relay Circuit Malfunction
120
DTC "C21" (P0110-H/L): IAT Sensor Circuit Malfunction
122
DTC "C23" (P1651-H/L): to Sensor Circuit Malfunction
126
DTC "C24" (P0351): Ignition Coil Circuit Malfunction
132
DTC "C32" (P0201): Fuel Injector Circuit Malfunction
132
DTC "C40" (P05057): ISC Valve Circuit Malfunction
135
DTC "C41" (P230-H/L): FP Relay Circuit Malfunction
140
Specifications
142
Service Data
142
Special Tools and Equipment
143
Special Tool
143
Precautions
144
Precautions for Emission Control Devices
144
Emission Control Devices
144
Repair Instructions
144
Crankcase Breather (PCV) Hose Inspection
144
Crankcase Breather (PCV) Hose Removal and Installation
144
Repair Instructions
145
ECM Removal and Installation
145
CKP Sensor Inspection
145
IAP Sensor Removal and Installation
146
TP Sensor Inspection
146
TP Sensor Removal and Installation
146
TP Sensor Adjustment
147
IAT Sensor Inspection
147
IAT Sensor Removal and Installation
147
ECT Sensor Removal and Installation
148
ECT Sensor Inspection
148
TO Sensor Inspection
149
TO Sensor Removal and Installation
149
ISC Valve Inspection
149
ISC Valve Removal and Installation
149
GP Switch Inspection
150
GP Switch Removal and Installation
150
Diagnostic Information and Procedures
145
Engine Symptom Diagnosis
145
Component Location
145
Engine Electrical Components Location
145
Precautions
145
Precautions for Engine Electrical Device
145
Engine Electrical Devices
145
Specifications
150
Recommended Service Material
151
Special Tool
151
Schematic and Routing Diagram
152
Throttle Cable Routing Diagram
152
Engine Mechanical
152
Diagnostic Information and Procedures
153
Engine Mechanical Symptom Diagnosis
153
Compression Pressure Check
153
Repair Instructions
154
Engine Components Removable with the Engine in Place
154
Air Cleaner Element Removal and Installation
156
Air Cleaner Element Inspection and Cleaning
156
Air Cleaner Box Removal and Installation
156
Throttle Cable Removal and Installation
157
Throttle Cable Inspection
157
Throttle Cable Play Inspection and Adjustment
157
Throttle Body Components
158
Throttle Body Construction
159
Throttle Body Removal and Installation
159
Throttle Body Disassembly and Assembly
161
Throttle Body Inspection and Cleaning
164
Engine Assembly Removal
164
Engine Assembly Installation
167
Engine Top Side Disassembly
168
Engine Top Side Assembly
172
Valve Clearance Inspection and Adjustment
178
Camshaft Inspection
179
Camshaft Sprocket Inspection
181
Cam Chain Tension Adjuster Inspection
181
Cam Chain Guide Removal and Installation
181
Cam Chain Guide Inspection
181
Cam Chain Tensioner Inspection
182
Cylinder Head Disassembly and Assembly
182
Cylinder Head Related Parts Inspection
186
Valve Guide Replacement
189
Valve Seat Repair
191
Cam Drive Idle Gear / Sprocket Thrust Clearance Inspection and Adjustment
191
Cylinder Disassembly and Assembly
192
Cylinder Inspection
192
Piston Ring Removal and Installation
193
Piston and Piston Ring Inspection
194
Engine Bottom Side Disassembly
196
Engine Bottom Side Assembly
202
Conrod and Crankshaft Inspection
210
Width between Crankshaft Webs
211
Crankshaft Oil Seal Inspection
212
Bearing Inspection
212
Bearing Removal and Installation
212
Specifications
217
Service Data
217
Tightening Torque Specifications
219
Special Tools and Equipment
220
Recommended Service Material
220
Special Tool
220
Engine Lubrication System
224
Precautions
224
Precautions for Engine Oil
224
Schematic and Routing Diagram
224
Engine Lubrication System Chart Diagram
224
Diagnostic Information and Procedures
225
Engine Lubrication Symptom Diagnosis
225
Oil Pressure Check
225
Repair Instructions
226
Engine Oil and Filter Replacement
226
Engine Oil Level Inspection
226
Oil Sump Filter Removal and Installation
226
Oil Sump Filter Inspection and Cleaning
227
Oil Jet Removal and Installation
227
Oil Jet Inspection
228
Oil Pump Removal and Installation
228
Oil Pump Inspection
230
Specifications
230
Service Data
230
Tightening Torque Specifications
230
Special Tools and Equipment
231
Recommended Service Material
231
Special Tool
231
Engine Cooling System
232
Precautions
232
Precautions for Engine Cooling System
232
Precautions for Engine Coolant
232
General Description
232
Engine Coolant Description
233
Schematic and Routing Diagram
233
Cooling Circuit Diagram
233
Water Hose Routing Diagram
234
Diagnostic Information and Procedures
235
Engine Cooling Symptom Diagnosis
235
Repair Instructions
235
Cooling Circuit Inspection
235
Radiator Cap Inspection
236
Radiator Inspection and Cleaning
236
Cooling Fan Assembly / Radiator Removal and Installation
236
Water Hose Removal and Installation
238
Cooling Fan Inspection
238
Radiator Reservoir Tank Removal and Installation
239
Radiator Reservoir Tank Inspection
239
Water Hose Inspection
239
ECT Sensor Removal and Installation
240
ECT Sensor Inspection
240
Cooling Fan Thermo-Switch Removal and Installation
240
Cooling Fan Thermo-Switch Inspection
241
Thermostat Removal and Installation
242
Thermostat Inspection
243
Water Pump Components
244
Water Pump Removal and Installation
244
Water Pump Disassembly and Assembly
245
Water Pump Related Parts Inspection
249
Specifications
250
Service Data
250
Tightening Torque Specifications
250
Special Tools and Equipment
251
Recommended Service Material
251
Special Tool
251
Fuel System
252
Precautions
252
Precautions for Fuel System
252
General Description
253
Fuel System Description
253
Schematic and Routing Diagram
254
Fuel Hose Routing Diagram
254
Fuel Tank Breather Hose Routing Diagram
255
Diagnostic Information and Procedures
256
Fuel System Diagnosis
256
Repair Instructions
257
Fuel Pressure Inspection
257
Fuel Pump Inspection
257
Fuel Discharge Amount Inspection
258
Fuel Pump Relay Inspection
258
Fuel Hose Inspection
259
Fuel Feed Hose Removal and Installation
259
Fuel Level Gauge Inspection
259
Fuel Level Indicator Inspection
259
Fuel Tank Removal and Installation
259
Fuel Pump Components
260
Fuel Pump Assembly Removal and Installation
260
Fuel Pump Disassembly and Assembly
261
Fuel Mesh Filter Inspection and Cleaning
261
Fuel Injector Inspection and Cleaning
261
Fuel Injector / Fuel Delivery Pipe Removal and Installation
261
Fuel Tank Pressure Control (FTPC) Valve Removal and Installation
263
Fuel Tank Pressure Control (FTPC) Valve Inspection
264
Specifications
264
Service Data
264
Tightening Torque Specifications
265
Special Tools and Equipment
265
Special Tool
265
General Description
266
Override Switch Description
266
Ignition System
266
Schematic and Routing Diagram
266
Ignition System Diagram
266
Ignition System Components Location
266
Diagnostic Information and Procedures
267
Ignition System Symptom Diagnosis
267
No Spark or Poor Spark
267
Repair Instructions
268
Spark Plug Cap and Spark Plug Removal and Installation
268
Spark Plug Inspection and Cleaning
268
Ignition Coil and Plug Cap Inspection
268
CKP Sensor Inspection
270
CKP Sensor Removal and Installation
271
Engine Stop Switch Inspection
271
Ignition Switch Inspection
271
Ignition Switch Removal and Installation
272
Override Switch Inspection
272
Specifications
273
Service Data
273
Tightening Torque Specifications
273
Special Tools and Equipment
273
Special Tool
273
Starting System
274
Schematic and Routing Diagram
274
Starting System Diagram
274
Component Location
274
Starting System Components Location
274
Diagnostic Information and Procedures
274
Starting System Symptom Diagnosis
274
Starter Motor will Not Run
275
Starter Motor Runs but Does Not Crank the Engine
275
Engine Does Not Turn Though the Starter Motor Runs
275
Repair Instructions
276
Starter Motor Components
276
Starter Motor Removal and Installation
277
Starter Motor Disassembly and Assembly
277
Starter Motor Inspection
278
Starter Relay Removal and Installation
279
Starter Relay Inspection
280
Neutral Relay Removal and Installation
280
Neutral Relay Inspection
281
Neutral Relay Diode Inspection
281
Parking Brake Relay Removal and Installation
281
Parking Brake Relay Inspection
282
Parking Brake Switch Inspection
282
Gear Position Switch Inspection
282
Starter Torque Limiter / Starter Clutch Removal and Installation
283
Starter Driven Gear Bearing Removal and Installation
285
Starter Related Parts Inspection
285
Starter Button Inspection
286
Recoil Starter Components
287
Recoil Starter Assembly Removal and Installation
287
Recoil Starter Disassembly and Assembly
288
Recoil Starter Inspection
290
Specifications
291
Service Data
291
Tightening Torque Specifications
291
Special Tools and Equipment
291
Recommended Service Material
291
Special Tool
292
Diagnostic Information and Procedures
293
Charging System Symptom Diagnosis
293
Battery Runs down Quickly
294
Component Location
293
Charging System Components Location
293
Charging System
293
Schematic and Routing Diagram
293
Charging System Diagram
293
Repair Instructions
295
Battery Current Leakage Inspection
295
Regulated Voltage Inspection
295
Generator Inspection
295
Generator Removal and Installation
296
Regulator / Rectifier Inspection
300
Battery Components
301
Battery Charging
301
Battery Removal and Installation
304
Battery Visual Inspection
304
Specifications
304
Service Data
304
Tightening Torque Specifications
305
Special Tools and Equipment
305
Recommended Service Material
305
Special Tool
305
Exhaust System
306
Precautions
306
Precautions for Exhaust System
306
Repair Instructions
306
Exhaust System Construction
306
Exhaust Pipe / Muffler Removal and Installation
307
Exhaust System Inspection
308
Spark Arrester Inspection
308
Specifications
309
Tightening Torque Specifications
309
Section 2 Suspension
311
Default Chapter
311
Suspension General Diagnosis
311
Wheels and Tires
311
Precautions
312
Precautions for Suspension
312
Suspension General Diagnosis
313
Diagnostic Information and Procedures
313
Suspension and Wheel Symptom Diagnosis
313
Repair Instructions
314
Front Suspension Components
314
Front Suspension Assembly Construction
315
Front Shock Absorber Removal and Installation
316
Front Suspension Inspection
316
Front Shock Absorber Inspection
316
Spring Pre-Load Adjustment
317
Front Wheel Hub / Steering Knuckle Removal and Installation
317
Front Hub Bearing Inspection
320
Front Hub Bearing Removal and Installation
320
Front Suspension Upper / Lower Arm Removal and Installation
322
Steering Knuckle End Inspection
323
Steering Knuckle End Removal and Installation
324
Front Suspension Arm Related Parts Inspection
325
Front Suspension Upper Arm Bushing and Inner Dust Seal Removal and Installation
326
Front Suspension Lower Arm Bushing Removal and Installation
327
Front Suspension
314
Special Tools and Equipment
328
Recommended Service Material
328
Special Tool
329
Specifications
328
Service Data
328
Tightening Torque Specifications
328
Rear Suspension
330
Repair Instructions
330
Rear Suspension Components
330
Rear Suspension Assembly Construction
331
Rear Shock Absorber Removal and Installation
332
Tightening Torque
332
Rear Suspension Inspection
333
Rear Shock Absorber Inspection
333
Spring Pre-Load Adjustment
333
Rear Wheel Hub / Suspension Knuckle Removal and Installation
333
Rear Hub Bearing Inspection
335
Rear Hub Bearing Removal and Installation
335
Rear Suspension Arm Upper / Lower Removal and Installation
337
Rear Suspension Arm Related Parts Inspection
338
Rear Suspension Upper Arm Bushing Removal and Installation
340
Rear Suspension Lower Arm Bushing Removal and Installation
341
Rear Suspension Knuckle Bushing Removal and Installation
342
Rear Stabilizer Removal and Installation
343
Stabilizer Parts Inspection
344
Specifications
345
Service Data
345
Tightening Torque Specifications
345
Special Tools and Equipment
345
Recommended Service Material
345
Special Tool
346
Repair Instructions
347
Front and Rear Wheel Components
347
Front / Rear Wheel Removal and Installation
348
Tire Removal and Installation
348
Wheels and Tires
347
Precautions
347
Precautions for Wheel and Tire
347
Specifications
350
Service Data
350
Tightening Torque Specifications
350
Section 3 Driveline / Axle
351
Default Chapter
352
Propeller Shafts
352
Precautions
353
Precautions for Driveline / Axle
353
Drive Chain / Drive Train / Drive Shaft
354
Diagnostic Information and Procedures
354
Drive Shaft Symptom Diagnosis
354
Repair Instructions
354
Front Drive Shaft Components
354
Front Drive Shaft Assembly Removal and Installation
355
Front Drive Shaft Disassembly and Assembly
355
Front Drive Shaft Inspection
358
Rear Drive Shaft Components
359
Rear Drive Shaft Assembly Removal and Installation
359
Rear Drive Shaft Disassembly and Assembly
360
Rear Drive Shaft Inspection
360
Special Tools and Equipment
360
Recommended Service Material
360
Special Tool
360
Differential
361
Diagnostic Information and Procedures
361
Drive Train Symptom Diagnosis
361
DTC "C20" (P1752) Diff-Lock Relay Circuit Malfunction
361
Repair Instructions
362
Front Drive (Differential) Components
362
Front Drive (Differential) Construction
363
Front Drive (Differential) Gear Oil Level Inspection
364
Front Drive (Differential) Gear Oil Replacement
364
Front Drive (Differential) Assembly Removal and Installation
364
Front Drive (Differential) Assembly Disassembly and Assembly
365
Front Drive (Differential) Related Parts Inspection
372
Breather Rubber Case Inspection
374
Front Drive (Differential) Gear Shim Inspection and Selection
374
2Wd/4Wd/Diff-Lock System Inspection
377
Rear Drive Breather Hose Routing Diagram
380
Final Gear Components
381
Final Gear Construction
382
Final Gear Oil Level Inspection
383
Final Gear Oil Replacement
383
Final Gear Assembly Removal and Installation
383
Final Gear Assembly Disassembly and Assembly
384
Final Gear Related Parts Inspection
390
Final Gear Shim Inspection and Selection
391
Specifications
394
Service Data
394
Special Tools and Equipment
395
Recommended Service Material
395
Special Tool
395
Transfer
397
Diagnostic Information and Procedures
397
Transfer Symptom Diagnosis
397
Repair Instructions
398
Transfer Components
398
Transfer Removal and Installation
399
Transfer Construction
402
Counter Shaft / Reverse Idle Gear Disassembly and Assembly
402
Gearshift Cam Components
405
Gearshift System Construction
406
Gearshift Cam Disassembly and Assembly
407
Transfer Gear Bearing Removal and Installation
408
Transfer Gear Bearing Inspection
408
Transfer Related Parts Inspection
408
Transfer Related Bearing Inspection
409
Gear Position (GP) Switch Inspection
409
Gear Position (GP) Switch Removal and Installation
409
Gearshift Shaft No. 2 / Gearshift Cam Plate Removal and Installation
410
Gearshift Linkage Inspection
413
Gearshift Shaft Oil Seal Removal and Installation
413
Specifications
414
Service Data
414
Special Tools and Equipment
414
Recommended Service Material
414
Special Tool
414
Repair Instructions
415
Front Output Shaft Components
415
Front Output Shaft Removal and Installation
415
Front Output Shaft Disassembly and Assembly
416
Front Output Shaft Related Parts Inspection
419
Rear Output Shaft Components
420
Rear Output Shaft Removal and Installation
420
Rear Output Shaft Disassembly and Assembly
422
Rear Output Shaft Related Parts Inspection
424
Rear Output Shaft Drive Bevel Gear Shim Inspection and Adjustment
425
Front Propeller Shaft Components
428
Front Propeller Shaft Removal and Installation
428
Front Propeller Shaft Related Parts Inspection
430
Rear Propeller Shaft Components
431
Rear Propeller Shaft Removal and Installation
431
Rear Propeller Shaft Related Parts Inspection
436
Propeller Shafts
415
Specifications
437
Service Data
437
Tightening Torque Specifications
437
Special Tools and Equipment
437
Recommended Service Material
437
Special Tool
438
Section 4 Brake
439
Default Chapter
439
Front Brakes
439
Precautions
441
Precautions for Brake System
441
Brake Fluid Information
441
Brake Control System and Diagnosis
442
Schematic and Routing Diagram
442
Front Brake Hose Routing Diagram
442
Rear Blake Cable Routing Diagram
443
Diagnostic Information and Procedures
444
Brake Symptom Diagnosis
444
Repair Instructions
445
Brake Pedal Height Inspection and Adjustment
445
Front Brake Light Switch Inspection
445
Rear Brake Light Switch Inspection
445
Rear Brake Switch Inspection and Adjustment
445
Parking / Rear Brake Light Switch Inspection
446
Parking Brake Lever Switch Inspection
446
Brake Fluid Level Check
446
Front Brake Hose Inspection
446
Air Bleeding from Front Brake Fluid Circuit
446
Brake Fluid Replacement
447
Front Brake Hose Removal and Installation
448
Rear Brake Cable Removal and Installation
449
Front Brake Master Cylinder Components
450
Front Brake Master Cylinder Assembly Removal and Installation
450
Front Brake Master Cylinder / Brake Lever Disassembly and Assembly
452
Front Brake Master Cylinder Parts Inspection
453
Rear Brake Pedal Construction
454
Rear Brake Pedal Removal and Installation
455
Specifications
456
Service Data
456
Special Tools and Equipment
457
Recommended Service Material
457
Special Tool
457
Precautions
458
Precautions for Front Brakes
458
Repair Instructions
458
Front Brake Components
458
Front Brake Pad Inspection
459
Front Brake Pad Replacement
459
Front Brake Caliper Removal and Installation
460
Front Brake Caliper Disassembly and Assembly
461
Front Brake Caliper Parts Inspection
463
Front Brake Disc Removal and Installation
464
Front Brake Disc Inspection
465
Front Brakes
458
Specifications
465
Service Data
465
Tightening Torque Specifications
466
Special Tools and Equipment
466
Recommended Service Material
466
Special Tool
466
Precautions
467
Precautions for Rear Brake
467
Rear Brakes
467
Repair Instructions
467
Rear Brake Components
467
Rear Brake Friction Plate Inspection
468
Rear Brake Friction Plate Replacement
468
Rear Brake Assembly Removal and Installation
468
Rear Brake Disassembly and Assembly
469
Rear Brake Parts Inspection
473
Specifications
475
Service Data
475
Tightening Torque Specifications
475
Special Tools and Equipment
476
Recommended Service Material
476
Special Tool
476
Schematic and Routing Diagram
477
Parking / Rear Brake Cable Routing Diagram
477
Parking Brake
477
Repair Instructions
479
Parking / Rear Brake Inspection and Adjustment
479
Parking / Rear Brake Cable Removal and Installation
479
Parking / Rear Brake Lever Components
480
Section 5 Transmission / Transaxle
483
Precautions
484
Precautions for Transmission / Transaxle
484
Automatic Transmission
485
Schematic and Routing Diagram
485
Drive Train System
485
Diagnostic Information and Procedures
486
Automatic Transmission Symptom Diagnosis
486
Repair Instructions
487
Automatic Transmission Components
487
V-Belt Cooling Duct Removal and Installation
489
Clutch Engagement and Lock-Up Speed Inspection
489
V-Belt Type Continuously Variable Automatic Transmission Removal and Installation
489
Movable Drive Face Disassembly and Assembly
493
Movable Driven Face Disassembly and Assembly
495
Drive V-Belt Inspection
498
Movable / Fixed Drive Face Parts Inspection
499
Movable / Fixed Driven Face Parts Inspection
499
Clutch Shoe Removal and Installation
500
Clutch Housing Case Disassembly and Assembly
503
Clutch Parts Inspection
504
Movable Drive Face Cover Disassembly and Assembly
506
Clutch Housing Cover Parts Inspection
507
Shift Lever Assembly Components
507
Gear Shift Knob Removal and Installation
508
Shift Lever Assembly Removal and Installation
508
Shift Lever Disassembly and Assembly
509
Shift Rod Adjustment
509
Specifications
510
Service Data
510
Special Tools and Equipment
512
Special Tool
512
Section 6 Steering
513
Precautions
514
Precautions for Steering
514
Steering General Diagnosis
515
Diagnostic Information and Procedures
515
Steering Symptom Diagnosis
515
Steering / Handlebar
516
Repair Instructions
516
Steering / Handlebars Components
516
Steering / Handlebars Assembly Construction
517
Handlebars Removal and Installation
518
Handlebars Inspection
520
Steering Shaft Removal and Installation
521
Tie-Rod / Tie-Rod End Removal and Installation
524
Steering Parts Inspection
525
Specifications
526
Service Data
526
Tightening Torque Specifications
527
Special Tools and Equipment
527
Recommended Service Material
527
Special Tool
527
Section 9 Body and Accessories
529
Precautions
531
Precautions for Electrical System
531
Component Location
531
Electrical Components Location
531
Wiring Systems
532
Schematic and Routing Diagram
532
Wiring Diagram
532
Wiring Harness Routing Diagram
535
Specifications
537
Service Data
537
Repair Instructions
538
Headlight Components
538
Headlight Bulb Replacement
539
Headlight Beam Adjustment
539
Auxiliary Headlight Components
540
Auxiliary Headlight Bulb Replacement
541
Auxiliary Headlight Beam Adjustment
542
Rear Combination Light Components
542
Rear Combination Light Removal and Installation
543
Rear Combination Light Bulb Replacement
543
Reversing Light Bulb Replacement (for
544
Reversing Light Relay Inspection (for
544
Dimmer Switch Inspection
544
Lighting Systems
538
Specifications
545
Service Data
545
Special Tools and Equipment
545
Special Tool
545
Combination Meter / Fuel Meter / Horn
546
General Description
546
Combination Meter System Description
546
Repair Instructions
547
Combination Meter Components
547
Combination Meter Removal and Installation
548
Combination Meter Disassembly and Assembly
548
Combination Meter Inspection
549
Engine Coolant Temperature Indicator Light Inspection
549
Engine Coolant Temperature Removal and Installation
549
Fuel Level Indicator Inspection
550
Fuel Level Gauge Inspection
551
Speedometer Inspection
551
Speed Sensor Removal and Installation
551
Speed Sensor Inspection
552
Ignition Switch Inspection
552
Ignition Switch Removal and Installation
552
Horn Inspection (for
553
Horn Removal and Installation (for
553
Service Data
553
Tightening Torque Specifications
553
Special Tools and Equipment
554
Recommended Service Material
554
Special Tool
554
Exterior Parts
555
Repair Instructions
555
Exterior Parts Construction
555
Rear Fender Heat Shield Construction
558
Fuel Tank Lower Cover Heat Shield Installation
559
Fastener Removal and Installation
560
Front Side Exterior Parts Removal and Installation
560
Rear Side Exterior Parts Removal and Installation
563
Seat Removal and Installation
565
Under Cover Components
566
Under Cover Removal and Installation
566
Body Structure
568
Repair Instructions
568
Body Frame Construction
568
Footrest Construction
568
Footrest Removal and Installation
569
Carrier Construction
570
Front Carrier Removal and Installation
571
Rear Carrier Removal and Installation
572
Front Grip Bar Construction
573
Front Grip Bar Removal and Installation
573
Trailer Towing Construction
574
Trailer Towing Removal and Instruction
574
Specifications
575
Recommended Service Material
575
Brake ........................................................................... 4-I Precautions
580
Driveline / Axle ........................................................... 3-I Precautions
580
Engine ......................................................................... 1-I Precautions
580
General Information ................................................... 0-I General Information
580
Steering....................................................................... 6-I Precautions
580
Special Tools and Equipment
575
Section 6 Steering
632
Steering / Handlebar
642
Installation
644
Service Data (LT-A750XP/ZK9)
645
6C-1 Power Assisted Steering System
647
Precautions for EPS (LT-A750XP/ZK9)
647
P/S System Note (LT-A750XP/ZK9)
647
Precautions in Diagnosing Troubles
647
General Description
648
P/S System Description (LT-A750XP/ZK9)
648
EPS Diagnosis General Description (LT-A750XP/ZK9)
651
Fail-Safe Function Description (LT-A750XP/ZK9)
651
Self Diagnostic System Description (LT-A750XP/ZK9)
651
Schematic and Routing Diagram
652
EPS Wiring Diagram (LT-A750XP/ZK9)
652
EPS Control Unit Diagram (LT-A750XP/ZK9)
653
Component Location
654
EPS Components Location
654
EPS System Wiring Harness Routing
654
Diagnostic Information and Procedures
655
EPS Troubleshooting (LT-A750XP/ZK9)
655
Pre-Diagnosis Inspection (LT-A750XP/ZK9)
656
EPS System Check (LT-A750XP/ZK9)
658
DTC (Diagnostic Trouble Code) Output (LT- A750XP/ZK9)
665
DTC (Diagnostic Trouble Code) Deleting (LT- A750XP/ZK9)
667
SDS Check (LT-A750XP/ZK9)
670
DTC Table (LT-A750XP/ZK9)
671
DTC "C1111": Torque Sensor (Main) Circuit Malfunction (LT-A750XP/ZK9)
672
DTC "C1113": Torque Sensor (Main / Sub) Circuit Correlation Malfunction (LT-A750XP/ZK9)
675
DTC "C1114": Torque Sensor Power Supply Circuit Malfunction (LT-A750XP/ZK9)
679
DTC "C1115": Torque Sensor (Sub) Circuit Malfunction (LT-A750XP/ZK9)
681
DTC "C1121": Vehicle Speed Signal Circuit Malfunction (LT-A750XP/ZK9)
684
DTC "C1122": Engine Speed Signal Circuit Malfunction (LT-A750XP/ZK9)
687
DTC "C1141", "C1142", "C1143", "C1145" EPS Motor Circuit Malfunction (LT-A750XP/ZK9)
690
DTC "C1153" EPS Control Unit Supply Voltage Circuit Malfunction (LT-A750XP/ZK9)
692
DTC "C1152", "C1154", "C1155" EPS Control Unit Malfunction (LT-A750XP/ZK9)
693
EPS Control Unit Construction
694
EPS Control Unit Removal and Installation
694
EPS Body Assembly Components (LT- A750XP/ZK9)
696
EPS Body Assembly Removal and Installation (LT-A750XP/ZK9)
696
EPS Motor Inspection (LT-A750XP/ZK9)
699
5
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Suzuki kq750 Specifications
General
Brand
Suzuki
Model
kq750
Category
Offroad Vehicle
Language
English
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