Engine Mechanical; Engine Lubrication System; Engine Cooling System - Suzuki kq750 Service Manual

1-ii Table of Contents
Service Data........................................................1C-6
Tightening Torque Specifications........................1C-6
Special Tools and Equipment .............................1C-7
Recommended Service Material .........................1C-7
Special Tool ........................................................1C-7
Engine Mechanical .................................. 1D-1
Schematic and Routing Diagram........................1D-1
Throttle Cable Routing Diagram..........................1D-1
Diagnostic Information and Procedures............1D-2
Engine Mechanical Symptom Diagnosis.............1D-2
Compression Pressure Check ............................1D-2
Repair Instructions ..............................................1D-3
Engine Components Removable with the
Engine in Place .................................................1D-3
Air Cleaner Element Removal and Installation ....1D-5
Air Cleaner Element Inspection and Cleaning ....1D-5
Air Cleaner Box Removal and Installation...........1D-5
Throttle Cable Removal and Installation .............1D-6
Throttle Cable Inspection ....................................1D-6
Throttle Cable Play Inspection and
Adjustment ........................................................1D-6
Throttle Body Components .................................1D-7
Throttle Body Construction..................................1D-8
Throttle Body Removal and Installation ..............1D-9
Throttle Body Disassembly and Assembly........1D-10
Throttle Body Inspection and Cleaning .............1D-13
Engine Assembly Removal ...............................1D-13
Engine Assembly Installation ............................1D-16
Engine Top Side Disassembly ..........................1D-17
Engine Top Side Assembly ...............................1D-21
Valve Clearance Inspection and Adjustment ....1D-27
Camshaft Inspection .........................................1D-28
Camshaft Sprocket Inspection ..........................1D-30
Cam Chain Tension Adjuster Inspection...........1D-30
Cam Chain Guide Removal and Installation .....1D-30
Cam Chain Guide Inspection ............................1D-30
Cam Chain Tensioner Inspection......................1D-31
Cylinder Head Disassembly and Assembly ......1D-31
Cylinder Head Related Parts Inspection ...........1D-35
Valve Guide Replacement ................................1D-38
Valve Seat Repair .............................................1D-40
Cam Drive Idle Gear / Sprocket Thrust
Clearance Inspection and Adjustment ............1D-40
Cylinder Disassembly and Assembly ................1D-41
Cylinder Inspection............................................1D-41
Piston Ring Removal and Installation ...............1D-42
Piston and Piston Ring Inspection ....................1D-43
Engine Bottom Side Disassembly .....................1D-45
Engine Bottom Side Assembly..........................1D-51
Conrod and Crankshaft Inspection....................1D-59
Width Between Crankshaft Webs .....................1D-60
Crankshaft Oil Seal Inspection..........................1D-61
Bearing Inspection ............................................1D-61
Bearing Removal and Installation .....................1D-61
Specifications.....................................................1D-66
Service Data......................................................1D-66
Tightening Torque Specifications......................1D-68
Special Tools and Equipment ...........................1D-69
Recommended Service Material .......................1D-69
Special Tool ......................................................1D-69
Engine Lubrication System .................... 1E-1
Precautions...........................................................1E-1
Precautions for Engine Oil ..................................1E-1
Schematic and Routing Diagram ........................1E-1
Engine Lubrication System Chart Diagram .........1E-1
Diagnostic Information and Procedures ............1E-2
Engine Lubrication Symptom Diagnosis .............1E-2
Oil Pressure Check .............................................1E-2
Repair Instructions ..............................................1E-3
Engine Oil and Filter Replacement .....................1E-3
Engine Oil Level Inspection.................................1E-3
Oil Sump Filter Removal and Installation ............1E-3
Oil Sump Filter Inspection and Cleaning .............1E-4
Oil Jet Removal and Installation..........................1E-4
Oil Jet Inspection.................................................1E-5
Oil Pump Removal and Installation .....................1E-5
Oil Pump Inspection ............................................1E-7
Specifications .......................................................1E-7
Service Data........................................................1E-7
Tightening Torque Specifications........................1E-7
Special Tools and Equipment .............................1E-8
Recommended Service Material .........................1E-8
Special Tool ........................................................1E-8
Engine Cooling System ...........................1F-1
Precautions........................................................... 1F-1
Precautions for Engine Cooling System.............. 1F-1
Precautions for Engine Coolant .......................... 1F-1
General Description ............................................. 1F-1
Engine Coolant Description................................. 1F-1
Schematic and Routing Diagram ........................ 1F-2
Cooling Circuit Diagram ...................................... 1F-2
Water Hose Routing Diagram ............................. 1F-3
Diagnostic Information and Procedures ............ 1F-4
Engine Cooling Symptom Diagnosis ................... 1F-4
Repair Instructions .............................................. 1F-4
Cooling Circuit Inspection ................................... 1F-4
Radiator Cap Inspection...................................... 1F-5
Radiator Inspection and Cleaning ....................... 1F-5
Cooling Fan Assembly / Radiator Removal
and Installation .................................................. 1F-5
Water Hose Removal and Installation ................. 1F-7
Cooling Fan Inspection ....................................... 1F-7
Radiator Reservoir Tank Removal and
Installation ......................................................... 1F-8
Radiator Reservoir Tank Inspection .................... 1F-8
Water Hose Inspection........................................ 1F-8
ECT Sensor Removal and Installation ................ 1F-9
ECT Sensor Inspection ....................................... 1F-9
Cooling Fan Thermo-switch Removal and
Installation ......................................................... 1F-9
Cooling Fan Thermo-switch Inspection ............. 1F-10
Thermostat Removal and Installation................ 1F-11
Thermostat Inspection....................................... 1F-12
Water Pump Components................................. 1F-13
Water Pump Removal and Installation .............. 1F-13