Suzuki LT-A750XP/Z Supplementary Service Manual
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Suzuki LT-A750XP/Z Supplementary Service Manual

Suzuki LT-A750XP/Z Supplementary Service Manual

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LT-A750XP/Z
USE THIS MANUAL WITH:
LT-A750X/Z SERVICE MANUAL (99500-47021-01E)
9 9 5 0 1 - 4 7 0 5 0 - 0 1 E

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Summary of Contents for Suzuki LT-A750XP/Z

  • Page 1 LT-A750XP/Z USE THIS MANUAL WITH: LT-A750X/Z SERVICE MANUAL (99500-47021-01E) 9 9 5 0 1 - 4 7 0 5 0 - 0 1 E...
  • Page 2 * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.
  • Page 3 TABLE OF CONTENTS NOTE For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same sections of the service manual mentioned in the “FOREWORD” of this manual. Precautions............... 00-i Body and Accessories..........9-i Precautions ............
  • Page 5 Table of Contents 00- i Section 00 Precautions CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........00-1 General Precautions ..........00-* Precautions for Electrical Circuit Service .....00-* Precautions............
  • Page 6 00-1 Precautions: Precautions Precautions Precautions Precautions for EPS (LT-A750XP/ZK9) • Since each component is a high-precision part, great B931G30000004 care should be taken not to apply any service impacts EPS Wiring during removal and installation. • The EPS parts are connected to various lead wires. The coupler and lead wire connections, as well as the lead wire and wire harness routings must be done correctly.

  • Page 7: General Information

    Front Differential Gear Oil Replacement ..... 0B-* Symbols ...............0A-* Final Gear Oil Inspection........0B-* Abbreviations ............0A-* Final Gear Oil Replacement........ 0B-* SAE-to-Former SUZUKI Term ......0A-* Throttle Cable Play Inspection and Vehicle Side View ..........0A-* Adjustment ............0B-* Vehicle Identification Number ......0A-* Throttle Body Inspection ........
  • Page 8 Vehicle Side View (LT-A750XP/ZK9) Left Side B931G30101013 NOTE Difference between illustration and actual motorcycles may exist depending on the markets. SUZUKI LT-A750XP (2009-model) Right Side I931G3010002-01 I931G3010001-01 Country and Area Codes (LT-A750XP/ZK9) B931G30101014 The following codes stand for the applicable country(-ies) and area(-s).
  • Page 9 General Information: 0A-2 Warning, Caution and Information Labels Location (LT-A750XP/ZK9) B931G30101015 12, 13 1, 20, 21 22, 23 15, 16 17, 18 2, 26, 27 I931H1010010-03 1. Certification plate (English) For P-24, 33 15. Front carrier warning label (English) For P-24, 33 2.

  • Page 10: Specifications

    0A-3 General Information: Specifications Specifications (LT-A750XP/ZK9) B931G30107003 NOTE These specifications are subject to change without notice. Dimensions and curb mass Item Specification Remark 2 115 mm (83.3 in) P-28, 33 Overall length 2 165 mm (85.2 in) P-17, 24 1 210 mm (47.6 in) P-28, 33 Overall width 1 250 mm (49.2 in)
  • Page 11 General Information: 0A-4 Chassis Item Specification Remark Front suspension Independent, double wishbone, coil spring, oil damped Rear suspension Independent, double wishbone, coil spring, oil damped Front wheel travel 170.5 mm (6.7 in) Rear wheel travel 195 mm (7.7 in) Caster 3.3°...
  • Page 12 Special Tool B931G30108002 09900–06107 09900–20102 09900–25008 09900–25009 09904–41010 Snap ring remover Vernier calipers (200 Multi circuit tester set Needle-point probe SUZUKI Diagnostic (Open type) system set 09924–84521 09930–30721 09930–44530 09930–82710 09930–82720 Bearing installer set Rotor remover Rotor holder Mode select switch Mode selection switch 09942–72410...

  • Page 13: Maintenance And Lubrication

    Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Repair Instructions Air Cleaner Element Inspection and Cleaning 5) Immerse the element in motor oil, and then squeeze out the excess oil leaving the element slightly wet. (LT-A750XP/ZK9) B931G30206033 Clean element Every 1 000 km (600 miles, 3 months) “A”...
  • Page 14 0B-2 Maintenance and Lubrication: 5) Measure the distances (“A” and “B”) between the front wheels. Subtract the measurement of “A” from “ a ” that of “B” to find the toe-out. If the toe-out is not within specification, adjust the tie-rod to the right or left until the toe-out is within the specified range.
  • Page 15 Maintenance and Lubrication: 0B-3 Chassis Bolt and Nut Inspection (LT-A750XP/ ZK9) B931G30206032 Tighten chassis bolt and nut Initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter Check that all chassis bolts and nuts are tightened to their specified torque.
  • Page 16 0B-4 Maintenance and Lubrication: Specifications Tightening Torque Specifications B931G30207001 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft Tie-rod lock-nut 21.0 (Page 0B-2) NOTE The specified tightening torque is described in the following. “Chassis Bolt and Nut Inspection (LT-A750XP/ZK9) (Page 0B-3)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in Section 0C (Page 0C-7)”.

  • Page 17: Service Data

    Service Data: 0C-1 Service Data General Information Specifications Service Data (LT-A750XP/ZK9) B931G30307003 Valve + Valve Guide Unit: mm (in) Item Standard Limit 36.0 (1.42) — Valve diam. 33.0 (1.30) — 0.10 – 0.20 (0.004 – 0.008) — Tappet clearance (When cold) 0.20 –...
  • Page 18 0C-2 Service Data: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit Compression pressure Approx. 1 000 kPa (10.0 kgf/cm , 142 psi) — (Automatic-decomp. actuated) Piston-to-cylinder clearance 0.030 – 0.040 (0.0012 – 0.0016) 0.120 (0.0047) Nicks or Cylinder bore 104.000 –...
  • Page 19 Service Data: 0C-3 Drive Train Unit: mm (in) Except ratio Item Standard Limit Automatic transmission ratio Variable change (2.763 – 0.780) — Secondary reduction ratio 2.158 (40/21 x 17/15) — Front 3.600 (36/10) — Final reduction ratio Rear 3.600 (36/10) —...
  • Page 20 0C-4 Service Data: Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance Fuel pump discharge amount 55.5 ml (1.88/1.95 US/lmp qt) and more/10 sec. Fuel pressure regulator operating Approx.
  • Page 21 Service Data: 0C-5 Electrical Unit: mm (in) Item Specification Note NGK: CR6E Type Spark plug DENSO: U20ESR-N 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. 150 – 250 Ω CKP sensor resistance CKP sensor peak voltage 5.0 V and more Terminal –...
  • Page 22 0C-6 Service Data: Brake + Wheel Unit: mm (in) Item Standard/Specification Limit Rear brake pedal height 12.5 – 22.5 (0.5 – 0.9) — Rear brake pedal free travel 20 – 30 (0.8 – 1.2) — Front brake disc thickness — 3.0 (0.20) Front brake disc runout —...
  • Page 23 Service Data: 0C-7 Tightening Torque List (LT-A750XP/ZK9) B931G30307004 Engine Item N⋅m kgf-m lbf-ft Spark plug Initial Cylinder head cover bolt Final 10.5 Cam drive idle gear/sprocket shaft 29.5 Intake pipe bolt Cylinder head bolt (M6) Initial 18.0 Cylinder head bolt (L200) Final 27.0 Cylinder head bolt (L: 70)
  • Page 24 0C-8 Service Data: Drive Train Item N⋅m kgf-m lbf-ft 4WD/Diff-lock actuator mounting bolt 16.0 Front drive (Differential) gear case bolt 16.0 Front drive (Differential) gear case mounting nut 36.0 Front drive (Differential) gear oil level plug 0.85 Front drive (Differential) gear oil filler plug 25.5 Front drive (Differential) gear oil drain plug 23.0...
  • Page 25 Service Data: 0C-9 Chassis Item N⋅m kgf-m lbf-ft Handlebar clamp bolt 19.0 Handlebar holder nut 43.5 Rear brake lever holder clamp bolt Throttle lever case bolt Steering shaft upper nut 12.0 87.0 Steering shaft bolt 19.0 EPS control unit mounting nut EPS body assembly mounting bolt 19.0 EPS body assembly mounting nut...
  • Page 26 0C-10 Service Data: Tightening Torque Chart For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt “a” (mm) N⋅m kgf-m lbf-ft N⋅m kgf-m lbf-ft 0.15 0.23 0.45 0.55...
  • Page 27 Table of Contents 1- i Section 1 Engine CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........1-* DTC “C40” (P05057): ISC Valve Circuit Malfunction............
  • Page 28 1-ii Table of Contents Specifications............1C-* Special Tools and Equipment ......1D-* Service Data............1C-* Recommended Service Material ......1D-* Tightening Torque Specifications......1C-* Special Tool ............1D-* Special Tools and Equipment ......1C-* Engine Lubrication System ..... 1E-* Recommended Service Material ......1C-* Precautions............
  • Page 29 Table of Contents 1-iii Water Pump Removal and Installation....1F-* Repair Instructions ..........1H-* Water Pump Disassembly and Assembly ....1F-* Spark Plug Cap and Spark Plug Removal and Water Pump Related Parts Inspection ....1F-* Installation ............1H-* Spark Plug Inspection and Cleaning ....1H-* Specifications............1F-* Ignition Coil and Plug Cap Inspection ....
  • Page 30 1-iv Table of Contents Starter Motor Related Parts Inspection (LT- Battery Charging ..........1J-* A750XP/ZK9) ............. 1I-3 Battery Removal and Installation ......1J-* Battery Visual Inspection........1J-* Specifications............1I-5 Generator Removal and Installation (LT- Service Data............1I-* A750XP/ZK9) ............ 1J-1 Service Data (LT-A750XP/ZK9) ......1I-5 Battery Removal and Installation (LT- Tightening Torque Specifications......

  • Page 31: Starting System

    Starting System: 1I-1 Starting System Engine Repair Instructions Starter Motor Components (LT-A750XP/ZK9) B931G31906022 I931G3190012-03 1. O-ring 6. Starter motor case : 5 N⋅m (0.5 kgf-m, 3.5 lbf-ft) 2. Housing end (Inside) 7. Housing end (Outside) : Apply grease to sliding surface. 3.
  • Page 32 Pay attention to the following points: Disassemble the starter motor as shown in the starter • Apply grease to the starter motor O-ring. motor components diagram. Refer to “Starter Motor : Grease 99000–25010 (SUZUKI SUPER Components in related manual”. GREASE “A” or equivalent) Assembly...
  • Page 33 Starter Motor Related Parts Inspection (LT- • Apply a small quantity of moly paste to the armature shaft. A750XP/ZK9) B931G31906025 : Moly paste 99000–25140 (SUZUKI Moly Refer to “Starter Motor Disassembly and Assembly in paste or equivalent) related manual”. Carbon Brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder.
  • Page 34 1I-4 Starting System: Armature Coil Bearing Measure for continuity between each segment. Measure Check the bearing of housing end for damage. for continuity between each segment and the armature If any damage is found, replace the housing end. shaft. If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one.
  • Page 35 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B931G31908001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1I-2) /...

  • Page 36: Charging System

    Be careful not to pinch the finger between the generator cover and the crankcase. • Apply grease to the O-ring (1) and oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) I931G31A0001-01 9) Disconnect the CKP sensor coupler (5) and CAUTION generator coupler (6) and remove the clamp (7).
  • Page 37 Charging System: 1J-2 • Tighten the crankshaft spacer nut (2) to the specified 3) Disconnect the battery (–) lead wire (2). torque with the special tool. 4) Disconnect the battery (+) lead wire (3). Special tool NOTE (A): 09930–44530 (Rotor holder) Be sure to disconnect the battery (–) lead Tightening torque wire (2) first, then disconnect the battery (+)
  • Page 38 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B931G31A08001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1J-1)
  • Page 39 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........3-* Front Drive (Differential) Gear Oil Replacement .............
  • Page 40 3-ii Table of Contents Transfer Related Parts Inspection....... 3C-* Front Output Shaft Related Parts Inspection ..3D-* Transfer Related Bearing Inspection....3C-* Rear Output Shaft Components......3D-* Gear Position (GP) Switch Inspection....3C-* Rear Output Shaft Removal and Installation ..3D-* Gear Position (GP) Switch Removal and Rear Output Shaft Disassembly and Installation ............
  • Page 41 Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Driveline / Axle Repair Instructions Front Drive Shaft Components (LT-A750XP/ZK9) B931G33106009 I931H1310012-03 1. Circlip 6. Inner boot band (Small) : Apply grease. 2. Snap ring 7.
  • Page 42 3A-2 Drive Chain / Drive Train / Drive Shaft: Front Drive Shaft Disassembly and Assembly 3) Remove the outer race from the front drive shaft. (LT-A750XP/ZK9) B931G33106011 Refer to “Front Drive Shaft Assembly Removal and Installation in related manual”. Disassembly CAUTION Do not disassemble the wheel side joint.
  • Page 43 Drive Chain / Drive Train / Drive Shaft: 3A-3 Assembly 3) Install the new snap ring to the cage. CAUTION CAUTION Replace the snap ring with a new one. • Wash all parts before installation, clean the inside and outside of the boots with a Special tool cloth.
  • Page 44 3A-4 Drive Chain / Drive Train / Drive Shaft: 5) Insert the cage into the outer race and install the new stopper ring to the groove of the outer race. CAUTION • Replace the stopper ring with a new one. •...
  • Page 45 Drive Chain / Drive Train / Drive Shaft: 3A-5 Rear Drive Shaft Components (LT-A750XP/ZK9) B931G33106013 I931H1310013-04 1. Circlip 6. Inner boot band (Small) : Apply grease. 2. Snap ring 7. Drive shaft : Apply water resistance grease. 3. Stopper ring 8.
  • Page 46 3A-6 Drive Chain / Drive Train / Drive Shaft: Special Tools and Equipment Recommended Service Material B931G33108001 NOTE Required service material is also described in the following. “Front Drive Shaft Components (LT-A750XP/ZK9) (Page 3A-1)” “Rear Drive Shaft Components (LT-A750XP/ZK9) (Page 3A-5)” Special Tool B931G33108002 09900–06107...
  • Page 47 Table of Contents 4- i Section 4 Brake CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........4-* Special Tools and Equipment ......4A-5 Special Tool ............
  • Page 48 4-ii Table of Contents Parking / Rear Brake Cable Routing Diagram ..4D-* Parking / Rear Brake Lever Removal and Installation ............4D-* Repair Instructions ..........4D-* Parking / Rear Brake Light Switch Inspection ..4D-* Parking / Rear Brake Inspection and Parking / Rear Brake Relay Inspection ....

  • Page 49: Brake Control System And Diagnosis

    Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram (LT-A750XP/ZK9) B931G34102003 “A” “D” “B” “C” “D” “F” “E” “D” I931H1410043-05 1. Master cylinder 11. Suspension upper arm 2. Front brake hose No. 1 12.
  • Page 50 4A-2 Brake Control System and Diagnosis: Repair Instructions Front Brake Hose Removal and Installation (LT- Installation A750XP/ZK9) CAUTION B931G34106019 Removal The seal washers should be replaced with the new ones to prevent fluid leakage. CAUTION Make sure that the vehicle is supported 1) Install the front brake hose as shown in the front securely.
  • Page 51 Brake Control System and Diagnosis: 4A-3 Rear Brake Pedal Construction (LT-A750XP/ZK9) B931G34106020 “ b ” “ c ” “B” “A” “B” “A” “ a ” I931G3410002-01 1. Rear brake pedal 6. Rear brake pedal screw “B”: Anchoring point (Pedal side) 2.
  • Page 52 4A-4 Brake Control System and Diagnosis: 5) Remove the rear brake pedal shaft (3). Installation Install the rear brake pedal in the reverse order of 6) Remove the rear brake pedal (4) and rear brake removal. Pay attention to the following points: pedal spring (5).
  • Page 53 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B931G34108003 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160 (Page 4A-4) /...
  • Page 54 4A-6 Brake Control System and Diagnosis:...
  • Page 55 Table of Contents 6- i Section 6 Steering CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........6-1 P/S System Note (LT-A750XP/ZK9) ....6C-1 Precautions in Diagnosing Troubles (LT- Precautions.............
  • Page 56 6-ii Table of Contents DTC “C1153” EPS Control Unit Supply EPS Body Assembly Components (LT- Voltage Circuit Malfunction (LT-A750XP/ A750XP/ZK9) ..........6C-50 ZK9) ..............6C-46 EPS Body Assembly Removal and DTC “C1152”, “C1154”, “C1155” EPS Control Installation (LT-A750XP/ZK9) ......6C-50 Unit Malfunction (LT-A750XP/ZK9)....6C-47 EPS Motor Inspection (LT-A750XP/ZK9) ..6C-53 Repair Instructions ..........6C-48 Specifications .............6C-54...
  • Page 57 Precautions: Precautions Steering Precautions Precautions for Steering (LT-A750XP/ZK9) B931G36000002 Refer to “General Precautions in Section 00 in related manual” and “Precautions for EPS (LT-A750XP/ZK9) in Section 00 (Page 00-1)”.

  • Page 58: Steering General Diagnosis

    6A-1 Steering General Diagnosis: Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis (LT-A750XP/ZK9) B931G36104002 Condition Possible cause Correction / Reference Item Heavy Steering Distorted steering shaft. Replace. Improper front wheel alignment. Adjust. Insufficiently lubricated. Lubricate. Not enough pressure in tires. Adjust.
  • Page 59 Steering / Handlebar: 6B-1 Steering / Handlebar Steering Repair Instructions Steering / Handlebars Components (LT-A750XP/ZK9) B931G36206008 “A” “A” “A” “A” I931G3620028-02 1. Handlebars 10. Lower dust seal 19. Handlebar left switch assembly 2. Handlebar upper clamp 11. Steering arm plate 20.
  • Page 60 6B-2 Steering / Handlebar: Steering / Handlebars Assembly Construction (LT-A750XP/ZK9) B931G36206009 “B” VIEW A I931H1620037-06 1. Handlebar holder nut : 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft) 2. Tie-rod end nut : 29 N⋅m (2.9 kgf-m, 21.0 lbf-ft) 3. Steering shaft lower nut : 162 N⋅m (16.2 kgf-m, 117.0 lbf-ft) 4.
  • Page 61 Steering / Handlebar: 6B-3 Handlebars Removal and Installation (LT- 6) Remove the following parts from left handlebars (left side). A750XP/ZK9) B931G36206010 a) Left grip (4) b) Left switch box (5) Removal c) Horn button (For P-17, 24) 1) Remove the auxiliary headlight cover. Refer to “Auxiliary Headlight Removal and Installation in d) Emergency switch (For P-17) Section 9B in related manual”...
  • Page 62 6B-4 Steering / Handlebar: • Install the washers (3) and bolts (4) as shown in the 9) Remove the handlebar upper clamps (7) and handlebars (8). steering/handlebars construction. Refer to “Steering / Handlebars Assembly Construction (LT-A750XP/ZK9) (Page 6B-2)”. • Set the handlebars so that its punch mark “B” aligns with the mating surface of the left handlebar holder.
  • Page 63 Steering / Handlebar: 6B-5 • Apply adhesive agent to the handlebar right and left • Install the master cylinder. Refer to “Front Brake end and right and left grip inner wall. Master Cylinder Assembly Removal and Installation in Section 4A in related manual”. : Handle grip bond (Handle Grip Bond •...
  • Page 64 6B-6 Steering / Handlebar: Steering Shaft Removal and Installation (LT- 5) Remove the steering arm plate (4) and steering shaft (5). A750XP/ZK9) B931G36206012 Removal 1) Remove the EPS control unit. Refer to “EPS Control Unit Removal and Installation (LT-A750XP/ZK9) in Section 6C (Page 6C-48)”.
  • Page 65 Steering / Handlebar: 6B-7 Installation • Apply grease to the steering shaft. Install the steering shaft in the reverse order of removal. : Grease 99000–25160 (Water resistance Pay attention to the following points: grease or equivalent) • Install the steering shaft bushing (1) along with dust seal (2) with the special tool.
  • Page 66 6B-8 Steering / Handlebar: • Install the cotter pin (8). Removal 1) Remove the tie-rod end with the special tool. Refer CAUTION to “Front Wheel Hub / Steering Knuckle Removal The removed cotter pin (8) must be replaced and Installation in Section 2B in related manual”. with a new one.
  • Page 67 Steering / Handlebar: 6B-9 4) Remove the other tie-rod end in the same manner as • Install the washers (2) and tighten the rod end nuts (3) described previously. (steering arm plate side) to the specified torque. 5) Separate the tie-rod ends (2), nuts (3), (4) and tie- Tightening torque rods (5).
  • Page 68 6B-10 Steering / Handlebar: Tie-rod End Steering Shaft Inspect the tie-rod ends for smooth movement. If there Inspect the steering shaft for distortion or bend. If any are any abnormalities, replace the tie-rod ends with new defects are found, replace the steering shaft with a new ones.
  • Page 69 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B931G36208001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160 (Page 6B-7) /...

  • Page 70: Power Assisted Steering System

    6C-1 Power Assisted Steering System: Power Assisted Steering System Steering Precautions Precautions for EPS (LT-A750XP/ZK9) B931G36300001 Refer to “General Precautions in Section 00 in related manual” and “Precautions for EPS (LT-A750XP/ZK9) in Section 00 (Page 00-1)”. NOTE When repairing EPS system, remove the front fender. Refer to “Front Side Exterior Parts Removal and Installation in Section 9D in related manual”.
  • Page 71 Power Assisted Steering System: 6C-2 General Description P/S System Description (LT-A750XP/ZK9) B931G36301001 This electronic power steering (EPS) system consists of a EPS control unit (2), a torque sensor (3), a EPS motor (4). In this system, the EPS control unit determines the level and direction of the assist force for the handlebars (1) according to the signal from the torque sensor and the vehicle speed signal from speed sensor (9).
  • Page 72 6C-3 Power Assisted Steering System: Detecting Principle The column shaft is connected to the input shaft by means of serration. The output shaft and input shaft are connected via torsion bar. When torque is inputted from the column shaft, a relative angular displacement occurs between the input shaft and the output shaft due to twist of the torsion bar.
  • Page 73 Power Assisted Steering System: 6C-4 Control System In the EPS control unit, the steering assist control determines the basic power assist force and the convergence control improves the steering operation feeling. The controller determines the target motor current by the calculation of these controls and the maximum current limiting control and it also regulates the motor current so that the target motor current and the actual current are matched.
  • Page 74 6C-5 Power Assisted Steering System: EPS Diagnosis General Description (LT-A750XP/ZK9) B931G36301002 The P/S system in this vehicle is controlled by the EPS control unit. The EPS control unit has an self diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of “Self Diagnostic System Description (LT-A750XP/ZK9) (Page 6C-5)”...
  • Page 75 Power Assisted Steering System: 6C-6 Schematic and Routing Diagram EPS Wiring Diagram (LT-A750XP/ZK9) B931G36302001 Refer to “Wire Color Symbols in Section 0A in related manual”. I931G3630070-01...
  • Page 76 6C-7 Power Assisted Steering System: EPS Control Unit Diagram (LT-A750XP/ZK9) B931G36302002 Refer to “Wire Color Symbols in Section 0A in related manual”. Ignition EPS countrol unit switch 30 A Speedometer MAIN 40 A Fail-safe relay Bl/B Speed sensor (Vehicle speed) TACHO motor Motor drive circuit...
  • Page 77 Power Assisted Steering System: 6C-8 EPS System Wiring Harness Routing Diagram (LT-A750XP/ZK9) B931G36302003 Refer to “Wiring Harness Routing Diagram (LT-A750XP/ZK9) in Section 9A (Page 9A-4)”. Component Location EPS Components Location (LT-A750XP/ZK9) B931G36303001 I931G3630002-02 1. EPS control unit 3. Fuse (EPS) 2.
  • Page 78 6C-9 Power Assisted Steering System: Diagnostic Information and Procedures EPS Troubleshooting (LT-A750XP/ZK9) CAUTION B931G36304001 The EPS is equipped with a self-diagnosis function. The Each time a resistance is measured, the detected malfunction is stored as a diagnostic trouble ignition switch should be set to OFF. code which causes the EPS indicator light to light up or flash in set patterns to indicate the malfunction.
  • Page 79 AT25 x 10 – 12 Tire for rear. The use of tires other than those Tire type specified may cause instability. It is highly Tire type recommended to use a SUZUKI Genuine Tire. Front: DUNLOP KT411 Rear: DUNLOP KT415...
  • Page 80 6C-11 Power Assisted Steering System: Steering Related Parts 4) Remove the front fender. Refer to “Front Side Refer to “Steering Parts Inspection in Section 6B in Exterior Parts Removal and Installation in Section related manual”. 9D in related manual”. 5) Disconnect the EPS control unit coupler (1). Battery Battery voltage inspection 1) Turn the ignition switch OFF.
  • Page 81 Power Assisted Steering System: 6C-12 EPS System Check (LT-A750XP/ZK9) B931G36304003 WARNING Carry out test drive in light traffic area to prevent an accident. Step Action 1) Perform “Customer Complaint Analysis”. Go to Step 2. Perform customer complaint analysis. Was customer complaint analysis performed according to instruction? 1) Check for operation of the “EPS”...
  • Page 82 6C-13 Power Assisted Steering System: Step Action (The EPS indicator light does not light up) Go to Step 5. Inspect the wire harness. (Faulty ignition 1) Turn the ignition switch OFF. or ground wire) 2) Disconnect the EPS control unit coupler (1) and (2). I931G3630008-01 3) Turn the ignition switch ON with the EPS control unit coupler disconnected, measure the voltage between...
  • Page 83 Power Assisted Steering System: 6C-14 Step Action 1) Turn the ignition switch ON with the EPS control unit Go to Step 6. • Inspect the wire coupler disconnected, measure the voltage between harness. (Faulty terminal “A” and terminal “B” at the coupler. indicator light wire) •...
  • Page 84 6C-15 Power Assisted Steering System: Step Action (The EPS indicator light does not go off) Go to Step 8. Replace the EPS fuse. 1) Remove the seat. Refer to “Seat Removal and Installation in Section 9D in related manual”. 2) Open the fuse box and inspect the ignition fuse (1). CAUTION If a fuse is blown, find the cause of the problem and correct it before replacing the fuse.
  • Page 85 Power Assisted Steering System: 6C-16 Step Action 1) Turn the ignition switch OFF. Go to Step 9. Inspect the wire harness. (Faulty ignition 2) Disconnect the EPS control unit coupler (1) and (2). or ground wire) I931G3630008-01 3) Turn the ignition switch ON with the EPS control unit coupler disconnected, measure the voltage between terminal “A”...
  • Page 86 6C-17 Power Assisted Steering System: Step Action 1) Turn the ignition switch ON with the EPS control unit Go to Step 10. Inspect the wire coupler disconnected, measure the voltage between harness. (Faulty terminal “A” and terminal “B” at the coupler. indicator light wire) Special tool (A): 09900–25008 (Multi circuit tester set)
  • Page 87 Power Assisted Steering System: 6C-18 Step Action 10 1) Turn the ignition switch OFF. Replace the EPS Inspect the wire control unit. harness. (Faulty mode 2) Short the mode select coupler terminals using the select switch wire) special tool. Special tool (A): 09930–82710 (Mode select switch) I931G3630013-01 3) Check for continuity between terminal “A”...
  • Page 88 6C-19 Power Assisted Steering System: DTC (Diagnostic Trouble Code) Output (LT- 4) Switch the special tool to ON. A750XP/ZK9) B931G36304004 NOTE • Even through the EPS is operating correctly, a DTC is memorized in any of the following conditions. – Previous malfunctions were repaired, but the DTCs were not deleted.
  • Page 89 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) NOTE Special tool • Don’t disconnect couplers from EPS (A): 09904–41010 (SUZUKI Diagnostic control unit, the battery cable from the system set) battery, EPS control unit ground wire (B): 99565–01010–020 (CD-ROM Ver.20)
  • Page 90 6C-21 Power Assisted Steering System: I931H1630032-01 4) Close the SDS tool and turn the ignition switch OFF. DTC (Diagnostic Trouble Code) Deleting (LT- A750XP/ZK9) B931G36304005 Use of Mode Select Switch 1) Remove the seat. Refer to “Seat Removal and Installation in Section 9D in related manual”. I705H1110116-03 3) Read the DTC (Diagnostic Trouble Code) and show data when trouble (displaying data at the time of...
  • Page 91 Special tool : 09904–41010 (SUZUKI Diagnostic system 6) Afterwards, start the engine and turn the handlebars set) to check that the EPS activates correctly.
  • Page 92 6C-23 Power Assisted Steering System: 5) Click the “EPS” button (1). 8) Click “Clear” (3) to delete history code (Past DTC). NOTE The DTC is memorized in the EPS control unit also when the wire coupler of any sensor is disconnected. Therefore, when a wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.
  • Page 93 Code) Deleting (LT-A750XP/ZK9) (Page 6C-21)”. • A number of different data under a fixed condition as shown should be saved or filed as sample. Special tool : 09904–41010 (SUZUKI Diagnostic system set) : 99565–01010–020 (CD-ROM Ver.20) DATA sampled from EPS system...
  • Page 94 6C-25 Power Assisted Steering System: Scroll the screen I931G3630066-01 DTC Table (LT-A750XP/ZK9) B931G36304007 Indicator Malfunction cause Reference status None Normal ON * — Refer to “DTC “C1111”: Torque C1111 Torque sensor (main) circuit voltage failure Sensor (Main) Circuit Malfunction (LT-A750XP/ZK9) (Page 6C-26)”. Refer to “DTC “C1113”: Torque Torque sensor (main) and (sub) circuit voltage Sensor (Main / Sub) Circuit...
  • Page 95 Power Assisted Steering System: 6C-26 DTC “C1111”: Torque Sensor (Main) Circuit Malfunction (LT-A750XP/ZK9) B931G36304008 Possible Cause • Faulty torque sensor signal circuit. • Faulty torque sensor. • Faulty EPS control unit. Troubleshooting CAUTION Never remove the torque sensor to prevent accident and damage. NOTE •...
  • Page 96 6C-27 Power Assisted Steering System: Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the 2) Check the torque sensor coupler for loose or poor torque sensor. contact. If OK, measure the torque sensor input voltage. •...
  • Page 97 Power Assisted Steering System: 6C-28 Step Action 1) Turn the ignition switch OFF. • Replace the EPS • R wire terminal or G control unit with a wire terminal circuit 2) Connect the torque sensor coupler. known good one, and open (torque sensor 3) Insert the needle-point probes to lead wire coupler.
  • Page 98 6C-29 Power Assisted Steering System: DTC “C1113”: Torque Sensor (Main / Sub) Circuit Correlation Malfunction (LT-A750XP/ZK9) B931G36304009 Possible Cause • Faulty torque sensor signal circuit. • Faulty torque sensor. • Faulty EPS control unit. Troubleshooting CAUTION Never remove the torque sensor to prevent accident and damage. NOTE •...
  • Page 99 Power Assisted Steering System: 6C-30 Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the 2) Check the torque sensor coupler for loose or poor torque sensor. contact. If OK, measure the torque sensor input voltage. •...
  • Page 100 6C-31 Power Assisted Steering System: Step Action 6) Next, measure the voltage between G wire “C” and Go to Step 2. • Loose or poor ground, G wire “C” and B wire “B”, W wire “D” and contacts on the ground and W wire “D”...
  • Page 101 Power Assisted Steering System: 6C-32 Step Action 1) Turn the ignition switch OFF. • G, W and B wire open If check result is not or shorted to ground satisfactory, replace the 2) Connect the torque sensor coupler. or poor torque sensor torque sensor (EPS 3) Insert the needle-point probes to lead wire coupler.
  • Page 102 6C-33 Power Assisted Steering System: DTC “C1114”: Torque Sensor Power Supply Circuit Malfunction (LT-A750XP/ZK9) B931G36304010 Possible Cause • Faulty torque sensor signal circuit. • Faulty torque sensor. • Faulty EPS control unit. Troubleshooting CAUTION Never remove the torque sensor to prevent accident and damage. NOTE After repairing the trouble, clear the DTC using a SDS tool or mode coupler switch.
  • Page 103 Power Assisted Steering System: 6C-34 Step Action 1) Turn the ignition switch OFF. • If wire and • Power supply circuit connection are OK, (R wire) shorted to 2) Check the EPS control unit power source couplers for intermittent trouble or ground.
  • Page 104 6C-35 Power Assisted Steering System: DTC “C1115”: Torque Sensor (Sub) Circuit Malfunction (LT-A750XP/ZK9) B931G36304011 Possible Cause • Faulty torque sensor signal circuit. • Faulty torque sensor. • Faulty EPS control unit. Troubleshooting CAUTION Never remove the torque sensor to prevent accident and damage. NOTE After repairing the trouble, clear the DTC using a SDS tool or mode coupler switch.
  • Page 105 Power Assisted Steering System: 6C-36 Step Action 1) Turn the ignition switch OFF. Go to step 2. • Loose or poor contacts on the 2) Check the torque sensor coupler for loose or poor torque sensor. contact. If OK, measure the torque sensor input voltage. •...
  • Page 106 6C-37 Power Assisted Steering System: Step Action 1) Turn the ignition switch OFF. • Replace the EPS • R wire terminal or W control unit with a wire terminal circuit 2) Connect the torque sensor coupler. known good one, and open (torque sensor 3) Insert the needle-point probes to lead wire coupler.
  • Page 107 Power Assisted Steering System: 6C-38 DTC “C1121”: Vehicle Speed Signal Circuit Malfunction (LT-A750XP/ZK9) B931G36304012 Possible Cause • Faulty vehicle speed signal circuit. • Faulty speed sensor. • Faulty EPS control unit. Troubleshooting NOTE After repairing the trouble, clear the DTC using a SDS tool or mode coupler switch. Refer to “DTC (Diagnostic Trouble Code) Deleting (LT-A750XP/ZK9) (Page 6C-21)”.
  • Page 108 6C-39 Power Assisted Steering System: Step Action 3) Disconnect the EPS control unit coupler [B], speed Go to step 2. Bl/B wire open. sensor coupler [C] and combination meter coupler [A]. Refer to “Speed Sensor Removal and Installation in Section 9C in related manual” and “Combination Meter Removal and Installation in Section 9C in related manual”.
  • Page 109 Power Assisted Steering System: 6C-40 Step Action 1) Connect the combination meter coupler and speed Go to step 3. Bl/B wire shorted to sensor coupler. ground. 2) Turn the ignition switch ON. 3) Measure the voltage between the Bl/B wire “A” and ground.
  • Page 110 6C-41 Power Assisted Steering System: DTC “C1122”: Engine Speed Signal Circuit Malfunction (LT-A750XP/ZK9) B931G36304013 Possible Cause • Faulty engine speed signal circuit. • Faulty ECM. • Faulty EPS control unit. Troubleshooting NOTE Start the engine after repairing the DTC and check that the indicator light is turned OFF. Refer to “Precautions in Diagnosing Troubles (LT-A750XP/ZK9) (Page 6C-1)”.
  • Page 111 Power Assisted Steering System: 6C-42 Step Action 1) Turn the ignition switch OFF. Go to step 3. W wire open. 2) Check the EPS control unit coupler for loose or poor contact. If OK, then measure the engine speed signal lead wire continuity.
  • Page 112 6C-43 Power Assisted Steering System: Step Action 1) Connect the ECM coupler. Replace the EPS Replace the ECM with a control unit with a new new one. Refer to “EPS 2) Start the engine. one. Refer to “EPS Control Unit Removal 3) Measure the voltage between W wire “A”...
  • Page 113 Power Assisted Steering System: 6C-44 DTC “C1141”, “C1142”, “C1143”, “C1145” EPS Motor Circuit Malfunction (LT-A750XP/ZK9) B931G36304014 Possible Cause • Faulty EPS motor circuit. • Faulty EPS motor. • EPS control unit malfunction. Troubleshooting Step Action 1) Turn the ignition switch OFF. Go to step 2.
  • Page 114 6C-45 Power Assisted Steering System: Step Action 1) Turn the ignition switch OFF. Replace the EPS Replace the EPS motor control unit with a (EPS body assembly) 2) Disconnect the EPS motor coupler. known good one, and with a new one. Refer to inspect it again.
  • Page 115 Power Assisted Steering System: 6C-46 DTC “C1153” EPS Control Unit Supply Voltage Circuit Malfunction (LT-A750XP/ZK9) B931G36304015 Possible Cause • Faulty regulator/rectifier. • Faulty EPS control unit. • Faulty wire harness, etc. Troubleshooting Step Action 1) Remove the seat. Refer to “Seat Removal and Go to Step 2.
  • Page 116 6C-47 Power Assisted Steering System: Step Action 1) Turn the ignition switch OFF. Replace the EPS Inspect the wire control unit. harness. (Faulty ignition 2) Check the EPS control unit coupler for loose or poor or ground wire) contacts. If OK, then disconnect the EPS control unit coupler.
  • Page 117 Power Assisted Steering System: 6C-48 Repair Instructions EPS Control Unit Construction (LT-A750XP/ZK9) B931G36306001 “B” “A” I931H1630056-02 1. EPS control unit 4. Torque sensor coupler 2. EPS control unit plate : 12 N⋅m (1.2 kgf-m, 8.5 lbf-ft) 3. Cushion “B”: Install the clip of the torque sensor coupler to the hole “A” of the EPS control unit plate.
  • Page 118 6C-49 Power Assisted Steering System: 4) Disconnect the torque sensor coupler (1). 7) Remove the fastener (4) and bolt (5). 8) Remove the EPS control unit (6) along with the EPS control unit plate (7). I931G3630042-01 5) Remove the clamp (2) and release the EPS motor lead wire (3).
  • Page 119 Power Assisted Steering System: 6C-50 • Connect the EPS motor coupler (3) and clamp (4). 5) Remove the center cover (2). • Connect the other EPS control unit couplers. I931G3630050-01 6) Remove the handlebar holder (3) by removing the I931G3630048-01 nuts (4).
  • Page 120 6C-51 Power Assisted Steering System: 9) Remove the front brake hose union (7) and throttle 13) Remove the EPS body assembly. cable (8) from the cable guide (9). CAUTION Never disassemble the EPS body assembly. I931G3630053-01 10) Remove the steering shaft bolt (10). I931G3630057-02 Installation Refer to “Steering / Handlebars Assembly Construction...
  • Page 121 Power Assisted Steering System: 6C-52 • Install the cable guide (1) and tighten the bolts (2) to • Install the front brake hose union (5) and throttle cable the specified torque. (6) to the cable guide. Tightening torque EPS body assembly mounting bolt (a): 26 N·m ( 2.6 kgf-m, 19.0 lbf-ft) I931G3630062-02 •...
  • Page 122 6C-53 Power Assisted Steering System: EPS Motor Inspection (LT-A750XP/ZK9) • Install the handlebar holder (8) and tighten the nuts to the specified torque. B931G36306005 1) Disconnect the EPS motor coupler. Tightening torque 2) First, check for insulation with the tester between Handlebar holder nut (e): 60 N·m (6.0 kgf-m, 43.5 terminals “A”...
  • Page 123 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B931G36308001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160 (Page 6C-51) /...
  • Page 124 (Page 6C-44) / (Page 6C-46) / (Page 6C-46) / (Page 6C-47) / (Page 6C-53) / (Page 6C-53) 09904–41010 09930–82710 SUZUKI Diagnostic system Mode select switch (Page 6C-20) / (Page 6C-18) / (Page 6C-22) / (Page 6C-19) (Page 6C-24) 09930–82720 09942–83110...
  • Page 125 Table of Contents 9- i Section 9 Body and Accessories CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........9-* Combination Meter Removal and Installation ..
  • Page 126 9-ii Table of Contents Front Carrier Removal and Installation ....9E-* Body Frame Construction (LT-A750XP/ZK9) ..9E-1 Rear Carrier Removal and Installation ....9E-* Specifications ............9E-* Front Grip Bar Construction ........ 9E-* Tightening Torque Specifications......9E-* Front Grip Bar Removal and Installation ..... 9E-* Special Tools and Equipment ......9E-1 Trailer Towing Construction ........
  • Page 127 Wiring Systems: 9A-1 Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram (LT-A750XP/ZK9) B931G39102003 Refer to “Wire Color Symbols in Section 0A in related manual”.
  • Page 128 9A-2 Wiring Systems: For P-17 I931G3910901-02...
  • Page 129 Wiring Systems: 9A-3 For P-24, 28, 33 I931G3910902-03...
  • Page 130 9A-4 Wiring Systems: Wiring Harness Routing Diagram (LT-A750XP/ZK9) B931G39102004 “ a ” “ b ” “ c ” “D” “ b ” “C” “A” “B” VIEW A I931G3910905-02 1. Clamp 9. Throttle cable 2. Clamp “B”: Pass the wiring harness and cooling fan lead wire over the radiator : Bind the wiring harness and hose with the clamp.
  • Page 131 Wiring Systems: 9A-5 “E” “D” VIEW A “C” VIEW F “F” “B” “A” I931G3910903-02 1. Starter motor 14. Injector coupler 2. Starter motor terminal 15. TP sensor coupler 3. Engine earth 16. ISC valve coupler 4. Clamp 17. TO sensor : Bind the wiring harness and rear brake cable with the clamp.
  • Page 132 9A-6 Wiring Systems: “A” “C” “B” VIEW “A” “ a ” “D” I931H1910903-05 1. Clamp 10. ECM : Bind the left handlebar switch lead wire, rear brake lever switch lead wire, horn lead wire (For P-17, 24) and emergency switch lead wire (For P-17) with the clamp.
  • Page 133 Wiring Systems: 9A-7 “ a ” I931G3910904-01 1. Starter motor 3. Generator stator 5. Grommet “a”: 90° 2. Gear position switch 4. Ground wire 6. Clamp Specifications Tightening Torque Specifications B931G3910S002 NOTE The specified tightening torque is described in the following. “Wiring Harness Routing Diagram (LT-A750XP/ZK9) (Page 9A-4)”...
  • Page 134 9E-1 Body Structure: Body Structure Body and Accessories Repair Instructions Body Frame Construction (LT-A750XP/ZK9) B931G39506011 I931G3950001-04 1. Frame 3. Washer : Apply thread lock to the thread part. 2. Battery plate 4. Spacer Special Tools and Equipment Recommended Service Material B931G39508001 NOTE Required service material is also described in the following.
  • Page 135 Prepared by March, 2009 Part No. 99501-47050-01E Printed in Japan...
  • Page 136 Printed in Japan...

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