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Manuals
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Suzuki Manuals
Motorcycle
GT750
Service manual
Suzuki GT750 Service Manual
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Service manual
(38 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Section Index
General Description
Product View
General Specification
Performance Curves
Dimensions
Special Tools
Gauge and Service Materials
Engine Tune-Up
Inspection and Adjustment
Battery
Engine Oil (CCI Oil) and Oil Pump
Cooling System
Air Cleaner
Fuel Cock
Spark Plug
Ignition Timing
Carburetor
Checking Contact Point Gap
Adjusting Cable Play
Transmission Oil
Coordinating Three Carburetor
Adjusting Pilot Air Adjusting Screw
Adjusting Throttle Valve Stop/Oil Level Screw
Clutch
Adjusting Clutch Cable Adjuster
Engine/Contents
Front/Side View of GT750 Engine
Engine Troubleshooting
On Frame Service
Cylinder Head Removal
Cylinder Removal
Water Drain Plug
Piston/Starter Clutch/Alternator/Clutch Removal
Removing Clutch Cover
Taking off Starter Clutch
Removing Alternator Brush/Rotor
Major Service/Removal
Starting Motor Removal
Removing Primary Driven Gear Spacer and Bushing
Taking off By-Pass Hose Union
Major Service/Disassembly
Removing Cooling Fan/Engine Sprocket
Exhaust Pipes and Coupler Tubes
Electric Parts Holder
Contact Breaker Assembly
Removing Water Pump Driving Parts
Removing Gear Shifting Switch and Oil Seal Retainer
Removing Piston Pin Circlip/Starting Motor
Cylinder Head Inspection and Repair
Cylinder and Piston Inspection and Repair
Transmission Oil Reservoir
Checking Cylinder Head Flatness
Checking Cylinder Block Flatness
Measuring Cylinder Bore for Wear
Directions/Positions to be Measured
Measuring Piston Diameter
Measuring Point
Piston's Out-Of-Round and Tapering
Measuring Cylinder Clearance
Piston Ring Inspection and Repair
Polishing Piston Surface
Checking Piston Ring End Gap
Measuring Piston Ring Side Clearance
Crankshaft, Conecting Rod and Bearing
Function/Dimension of Piston Ring
Checking Con-Rod Big End Wear
Crankshaft Assembly
Checking Crankshaft Bending
Aligning Mark on Crankshaft Bearing
Upper/Lower Crankcase
Clutch/Contents
Cross-Sectional View of Clutch
Clutch Specifications
Clutch Troubleshooting
Clutch Removal and Disassembly
Clutch Inspection and Repair
Checking Clutch Drive Plate for Wear
Measuring Free Length of Clutch Spring
Clutch Assembly and Adjustment
Cross Sectional View of Clutch
Tightening Release Shaft Nuts
Adjusting Clutch/Cable Play
Transmission/Contents
GT750 Transmission Gears
Transmission Specifications
Transmission Troubleshooting
Transmission Removal and Disassembly
Gear Shifting Mechanism
Transmission Operation
Gear Positions
Transmission Inspection
Measuring Gear Backlash
Checking Shifting Fork Shaft for Wear and Bend
Transmission Assembly
Measuring Shifting Cam Diameter
Distance between both End Gears
Kick Starter Mechanism
Aligning Punch Marks
Lubricating System/Contents
GT750 Engine Lubricating System
Oil Pump Specification
Oil Pump Construction and Operation
Oil Delivering Curve
Oil Pump Body
Oil Pump Valve and Plunger
Control Cam and Shaft
Sucking/Discharging Oil
Feed-Back Passage
Oil Circulating Passage
Overal Construction and Arrangement under Operating Conditions
SRIS Construction/Operation
Oil Pump Troubleshooting
Oil Pump and Oil Pipe Removal
Oil Pump and Oil Pipe Disassembly/Inspection/Repair
Loosening Oil Pipe Union Bolts
Expelling Air in Oil Pipes/Pump
Oil Pump and Oil Pipe Assembly/Adjustment
SRIS Removal/Inspection/Repair
Expelling Air in Oil Passage
Adjusting Oil Pump
SRIS Assembly
Checking SRIS Check Valve
SRIS Piping
Cooling System/Contents
GT750 Engine Cooling System
Cooling System Specification/Troubleshooting
Radiator Removal/Inspection/Repair
Checking Radiator Cap
Pressure-Boiling Point Curve
Radiator Installation
Thermostat
Radiator Mounting Shims
Thermostat Removal/Inspection/Repair/Installation
Water Pump
Testing Thermostat
Water Pump Removal/Disassembly
Removing Impeller/Pump Holder Circlip
Extracting Pump Holder
Water Pump Inspection/Assembly
Cooling Water
Pump Holder Notch
Anti-Freeze and Summer Coolant
Coolant Density-Boiling/Freezing Point Curve
Anti-Leakage Material
Cooling System Flushing
Required Amount of Anti-Freeze Coolant at each Temperature
Fuel System/Contents
Fuel System Description/Specification/Troubleshooting
Carburetor Description
Carburetor Specification (Setting Table)
Carburetor Construction and Operation
Starter System
Slow/Main System
Principle of Carburetor
Float System
Carburetor Removal/Disassembly/Reassembly
Starter/Slow System Inspection and Adjustment
Carburetor Construction
Main System Inspection and Adjustment
Synchronizing Carburetors
Float System Inspection and Adjustment
Adjusting Throttle Cable
Foreign Material on Needle Valve
Checking/Adjusting Float Level
Fuel Cock Inspection and Repair
Fuel Cock Construction
Exhaust System/Contents
GT750 Exhaust System
Exhaust System Removal/Inspection/Assembly
Exhaust Coupler Tube
Fixing Exhaust Pipe Clamp
Engine Electrical System/Contents
GT750 Engine Electrical System
Starting/Charging/Ignition System
Engine Electrical System Troubleshooting
Starting System Description
Equipments for Starting System
Wiring of Cumulative Compound Motor
Performance Curves of Cumulative Compound Motor
Starter Clutch Construction
Starting System Specification
Starting System Removal/Disassembly
Armature Inspection and Repair
Exploded View of Starting Motor
Field Coil Inspection and Repair
Commutator
Checking Commutator for Ground
Checking Armature for Short/Open Circuit
Checking Field Coil for Open Circuit/For Ground
Checking Field Coil by Exiting It
Battery Connection for Field Coil Test
Brush/Brush Holder Inspection and Repair
Starter Clutch/Relay Inspection and Repair
Starting Motor Assembly
Checking Brush Holder Insulation/Spring Tension
Starter Clutch Assembly
Punch Mark and Pin
Assembling Breaker Cam Shaft
Charging System Operation/Wiring
Charging System Specification
Alternator Removal/Inspection/Repair
Loosening Brush Holder Fitting Screw
Checking Rotor Coil for Open and Short Circuit
Checking Stator Coil Insulation
Checking Stator Coil for Open Circuit
Carbon Brush Length
Checking Silicon Rectifier for Open
Adjusting Regulator
Measuring Alternator Output
Volmeter Connection
Wiring for Measring Output
Ignition System Operation
GT750 Ignition System Wiring Diagram
Ignition System Specification/Removal/Disassembly
Exploded View of Contact Breaker Assembly
Ignition System Inspection and Repair
Contact Point
Testing Ignition Coil/System
Condition of Spark Plug
Testing Condenser
Timing Adjustment and Test
Adjusting Point Gap
Dial Gauge
Adjusting Timing
Ignition Timing Table/Marks
Adjusting Ig. Timing for R.H. and L Cylinders
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Engine Oil (CCI Oil) and Oil Pump
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Table of
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Table of Contents
Troubleshooting
Engine troubleshooting
18
Clutch Specifications
38
Transmission Troubleshooting
43
Oil Pump Troubleshooting
55
Cooling System Specification/Troubleshooting
61
Fuel System Description/Specification/Troubleshooting
71
Engine Electrical System Troubleshooting
84
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