Suzuki kq750 2008 Manuals

Manuals and User Guides for Suzuki kq750 2008. We have 1 Suzuki kq750 2008 manual available for free PDF download: Service Manual

Suzuki kq750 2008 Service Manual (576 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 51 MB

Table of Contents

3
- Precautions
  5
- Exhaust System
  6
- Differential
  13
- Maintenance and Lubrication
  13
- Parking Brake
  13
- Service Data
  13
- General Information
  14
  - Vehicle Identification Number
    16
  - Fuel System
    22
  - Transfer
    22
  - Front Suspension
    23
  - Rear Suspension
    23
  - Maintenance and Lubrication
    28
    
    Scheduled Maintenance
    28
    
    Lubrication Points
    29
    
    Cooling System Inspection
    42
    
    Automatic Transmission
    44
    
    Tire Inspection
    48
    
    Rear Brakes
    53
    
    Service Data
    56
Section 1 Engine

67
- Emission Control Devices
  67
- Engine Electrical Devices
  67
- Engine General Information and Diagnosis
  67
- Engine Cooling System
  68
- Engine Lubrication System
  68
- Engine Mechanical
  68
- Ignition System
  69
- Starting System
  69
- Charging System
  70
- Engine General Information and Diagnosis
  72
- Fi System Parts Location
  77
- Engine General Information and
  
  83
- Specifications
  
  140
  - Service Data
    140
- Special Tools and Equipment
  
  141
- Precautions
  
  142
  - Precautions for Emission Control Devices
    142
- Repair Instructions
  
  142
  - Crankcase Breather (PCV) Hose Inspection
    142
  - Crankcase Breather (PCV) Hose Removal and Installation
    142
- 1B-1 Emission Control Devices
  
  142
- Engine Electrical Devices
  
  143
- Repair Instructions
  
  143
  - ECM Removal and Installation
    143
  - CKP Sensor Inspection
    143
  - IAP Sensor Removal and Installation
    144
  - TP Sensor Inspection
    144
  - TP Sensor Removal and Installation
    144
  - TP Sensor Adjustment
    145
  - IAT Sensor Inspection
    145
  - IAT Sensor Removal and Installation
    145
  - ECT Sensor Removal and Installation
    146
  - ECT Sensor Inspection
    146
  - TO Sensor Inspection
    147
  - TO Sensor Removal and Installation
    147
  - ISC Valve Inspection
    147
  - ISC Valve Removal and Installation
    147
  - Recommended Service Material
    149
  - Special Tool
    149
- Component Location
  
  143
  - Engine Electrical Components Location
    143
- Precautions
  
  143
  - Precautions for Engine Electrical Device
    143
- Diagnostic Information and Procedures
  
  143
  - Engine Symptom Diagnosis
    143
- Schematic and Routing Diagram
  
  150
  - Throttle Cable Routing Diagram
    150
- Engine Mechanical
  
  150
- Diagnostic Information and Procedures
  
  151
  - Engine Mechanical Symptom Diagnosis
    151
  - Compression Pressure Check
    151
- Repair Instructions
  
  152
  - Engine Components Removable with the Engine in Place
    152
  - GP Switch Inspection
    153
  - GP Switch Removal and Installation
    153
  - Air Cleaner Element Removal and Installation
    154
  - Air Cleaner Element Inspection and Cleaning
    154
  - Air Cleaner Box Removal and Installation
    154
  - Throttle Cable Removal and Installation
    155
  - Throttle Cable Inspection
    155
  - Throttle Cable Play Inspection and Adjustment
    155
  - Throttle Body Components
    156
  - Throttle Body Construction
    157
  - Throttle Body Removal and Installation
    157
  - Throttle Body Disassembly and Assembly
    159
  - Throttle Body Inspection and Cleaning
    162
  - Engine Assembly Removal
    162
  - Engine Assembly Installation
    165
  - Engine Top Side Disassembly
    166
  - Engine Top Side Assembly
    170
  - Valve Clearance Inspection and Adjustment
    176
  - Camshaft Inspection
    177
  - Camshaft Sprocket Inspection
    179
  - Cam Chain Tension Adjuster Inspection
    179
  - Cam Chain Guide Removal and Installation
    179
  - Cam Chain Guide Inspection
    179
  - Cam Chain Tensioner Inspection
    180
  - Cylinder Head Disassembly and Assembly
    180
  - Cylinder Head Related Parts Inspection
    184
  - Valve Guide Replacement
    187
  - Valve Seat Repair
    189
  - Cam Drive Idle Gear / Sprocket Thrust Clearance Inspection and Adjustment
    189
  - Cylinder Disassembly and Assembly
    190
  - Cylinder Inspection
    190
  - Piston Ring Removal and Installation
    191
  - Piston and Piston Ring Inspection
    192
  - Engine Bottom Side Disassembly
    194
  - Engine Bottom Side Assembly
    200
  - Conrod and Crankshaft Inspection
    208
  - Width between Crankshaft Webs
    209
  - Crankshaft Oil Seal Inspection
    210
  - Bearing Inspection
    210
  - Bearing Removal and Installation
    210
- Specifications
  
  215
  - Service Data
    215
  - Tightening Torque Specifications
    217
- Special Tools and Equipment
  
  218
  - Recommended Service Material
    218
  - Special Tool
    218
- Precautions
  
  222
  - Precautions for Engine Oil
    222
- Schematic and Routing Diagram
  
  222
  - Engine Lubrication System Chart Diagram
    222
- Engine Lubrication System
  
  222
- Diagnostic Information and Procedures
  
  223
  - Engine Lubrication Symptom Diagnosis
    223
  - Oil Pressure Check
    223
- Repair Instructions
  
  224
  - Engine Oil and Filter Replacement
    224
  - Engine Oil Level Inspection
    224
  - Oil Sump Filter Removal and Installation
    224
  - Oil Sump Filter Inspection and Cleaning
    225
  - Oil Jet Removal and Installation
    225
  - Oil Jet Inspection
    226
  - Oil Pump Removal and Installation
    226
  - Oil Pump Inspection
    228
- Specifications
  
  228
  - Service Data
    228
  - Tightening Torque Specifications
    228
- Special Tools and Equipment
  
  229
  - Recommended Service Material
    229
  - Special Tool
    229
- Engine Cooling System
  
  230
- Precautions
  
  230
  - Precautions for Engine Cooling System
    230
  - Precautions for Engine Coolant
    230
- General Description
  
  230
  - Engine Coolant Description
    231
- Schematic and Routing Diagram
  
  231
  - Cooling Circuit Diagram
    231
  - Water Hose Routing Diagram
    232
- Diagnostic Information and Procedures
  
  233
  - Engine Cooling Symptom Diagnosis
    233
- Repair Instructions
  
  233
  - Cooling Circuit Inspection
    233
  - Radiator Cap Inspection
    234
  - Radiator Inspection and Cleaning
    234
  - Cooling Fan Assembly / Radiator Removal and Installation
    234
  - Water Hose Removal and Installation
    236
  - Cooling Fan Inspection
    236
  - Radiator Reservoir Tank Removal and Installation
    237
  - Radiator Reservoir Tank Inspection
    237
  - Water Hose Inspection
    237
  - ECT Sensor Removal and Installation
    238
  - ECT Sensor Inspection
    238
  - Cooling Fan Thermo-Switch Removal and Installation
    238
  - Cooling Fan Thermo-Switch Inspection
    239
  - Thermostat Removal and Installation
    240
  - Thermostat Inspection
    241
  - Water Pump Components
    242
  - Water Pump Removal and Installation
    242
  - Water Pump Disassembly and Assembly
    243
  - Water Pump Related Parts Inspection
    247
- Specifications
  
  248
  - Service Data
    248
  - Tightening Torque Specifications
    248
- Special Tools and Equipment
  
  249
  - Recommended Service Material
    249
  - Special Tool
    249
- Precautions
  
  250
  - Precautions for Fuel System
    250
- Fuel System
  
  250
- General Description
  
  251
  - Fuel System Description
    251
- Schematic and Routing Diagram
  
  252
  - Fuel Hose Routing Diagram
    252
  - Fuel Tank Breather Hose Routing Diagram
    253
- Diagnostic Information and Procedures
  
  254
  - Fuel System Diagnosis
    254
- Repair Instructions
  
  255
- Specifications
  
  262
  - Service Data
    262
  - Tightening Torque Specifications
    263
- Special Tools and Equipment
  
  263
  - Special Tool
    263
- General Description
  
  264
  - Override Switch Description
    264
- Ignition System
  
  264
- Schematic and Routing Diagram
  
  264
  - Ignition System Diagram
    264
  - Ignition System Components Location
    264
- Diagnostic Information and Procedures
  
  265
  - Ignition System Symptom Diagnosis
    265
  - No Spark or Poor Spark
    265
- Repair Instructions
  
  266
- Specifications
  
  271
  - Service Data
    271
  - Tightening Torque Specifications
    271
- Special Tools and Equipment
  
  271
  - Special Tool
    271
- Starting System
  
  272
- Component Location
  
  272
  - Starting System Components Location
    272
- Diagnostic Information and Procedures
  
  272
- Schematic and Routing Diagram
  
  272
  - Starting System Diagram
    272
- Repair Instructions
  
  274
- Specifications
  
  289
  - Service Data
    289
  - Tightening Torque Specifications
    289
- Special Tools and Equipment
  
  289
  - Recommended Service Material
    289
  - Special Tool
    290
- Diagnostic Information and Procedures
  
  291
  - Charging System Symptom Diagnosis
    291
  - Battery Runs down Quickly
    292
- Component Location
  
  291
  - Charging System Components Location
    291
- Schematic and Routing Diagram
  
  291
  - Charging System Diagram
    291
- Charging System
  
  291
- Repair Instructions
  
  293
  - Battery Current Leakage Inspection
    293
  - Regulated Voltage Inspection
    293
  - Generator Inspection
    293
  - Generator Removal and Installation
    294
  - Regulator / Rectifier Inspection
    298
  - Battery Components
    299
  - Battery Charging
    299
  - Battery Removal and Installation
    302
  - Battery Visual Inspection
    302
- Specifications
  
  302
  - Service Data
    302
  - Tightening Torque Specifications
    303
- Special Tools and Equipment
  
  303
  - Recommended Service Material
    303
  - Special Tool
    303
- Precautions
  
  304
  - Precautions for Exhaust System
    304
- Repair Instructions
  
  304
  - Exhaust System Construction
    304
  - Exhaust Pipe / Muffler Removal and Installation
    305
  - Exhaust System Inspection
    306
  - Spark Arrester Inspection
    306
- Exhaust System
  
  304
- Specifications
  
  307
  - Tightening Torque Specifications
    307
Section 2 Suspension

309
- Suspension General Diagnosis
  309
- Wheels and Tires
  309
- Precautions
  
  310
  - Precautions for Suspension
    310
- Diagnostic Information and Procedures
  
  311
  - Suspension and Wheel Symptom Diagnosis
    311
- Suspension General Diagnosis
  
  311
- Front Suspension
  
  312
- Repair Instructions
  
  312
- Special Tools and Equipment
  
  326
  - Recommended Service Material
    326
  - Special Tool
    327
- Specifications
  
  326
  - Service Data
    326
  - Tightening Torque Specifications
    326
- Rear Suspension
  
  328
- Repair Instructions
  
  328
- Specifications
  
  343
  - Service Data
    343
  - Tightening Torque Specifications
    343
- Special Tools and Equipment
  
  343
  - Recommended Service Material
    343
  - Special Tool
    344
- Wheels and Tires
  
  345
- Precautions
  
  345
  - Precautions for Wheel and Tire
    345
- Repair Instructions
  
  345
- Specifications
  
  348
  - Service Data
    348
  - Tightening Torque Specifications
    348
Section 3 Driveline / Axle

349
- Propeller Shafts
  350
- Precautions
  
  351
  - Precautions for Driveline / Axle
    351
- Repair Instructions
  
  352
- Diagnostic Information and Procedures
  
  352
  - Drive Shaft Symptom Diagnosis
    352
- Drive Chain / Drive Train / Drive Shaft
  
  352
- Special Tools and Equipment
  
  358
  - Recommended Service Material
    358
  - Special Tool
    358
- Differential
  
  359
- Diagnostic Information and Procedures
  
  359
  - Drive Train Symptom Diagnosis
    359
  - DTC "C20" (P1752) Diff-Lock Relay Circuit Malfunction
    359
- Repair Instructions
  
  360
- Specifications
  
  392
  - Service Data
    392
  - Tightening Torque Specifications
    392
- Special Tools and Equipment
  
  393
  - Recommended Service Material
    393
  - Special Tool
    393
- Transfer
  
  395
- Diagnostic Information and Procedures
  
  395
  - Transfer Symptom Diagnosis
    395
- Repair Instructions
  
  396
- Specifications
  
  412
  - Service Data
    412
  - Front Output Shaft Components
    413
  - Front Output Shaft Removal and Installation
    413
- Special Tools and Equipment
  
  412
- Propeller Shafts
  
  413
- Repair Instructions
  
  413
- Special Tools and Equipment
  
  435
  - Recommended Service Material
    435
  - Special Tool
    436
- Specifications
  
  435
  - Service Data
    435
  - Tightening Torque Specifications
    435
Section 4 Brake

437
- Brake Control System and Diagnosis
  437
- Front Brakes
  437
- Precautions
  
  439
  - Precautions for Brake System
    439
  - Brake Fluid Information
    439
- Schematic and Routing Diagram
  
  440
  - Front Brake Hose Routing Diagram
    440
  - Rear Blake Cable Routing Diagram
    441
- Brake Control System and Diagnosis
  
  440
- Diagnostic Information and Procedures
  
  442
  - Brake Symptom Diagnosis
    442
- Repair Instructions
  
  443
- Specifications
  
  454
  - Service Data
    454
  - Tightening Torque Specifications
    454
- Special Tools and Equipment
  
  455
  - Recommended Service Material
    455
  - Special Tool
    455
- Front Brakes
  
  456
- Precautions
  
  456
  - Precautions for Front Brakes
    456
- Repair Instructions
  
  456
- Specifications
  
  463
  - Service Data
    463
  - Tightening Torque Specifications
    464
- Special Tools and Equipment
  
  464
  - Recommended Service Material
    464
  - Special Tool
    464
- Precautions
  
  465
  - Precautions for Rear Brake
    465
- Rear Brakes
  
  465
- Repair Instructions
  
  465
- Specifications
  
  473
  - Service Data
    473
  - Tightening Torque Specifications
    473
- Special Tools and Equipment
  
  474
  - Recommended Service Material
    474
  - Special Tool
    474
- Parking Brake
  
  475
- Schematic and Routing Diagram
  
  475
  - Parking / Rear Brake Cable Routing Diagram
    475
- Repair Instructions
  
  477
Section 5 Transmission / Transaxle

481
- Precautions
  
  482
  - Precautions for Transmission / Transaxle
    482
- Automatic Transmission
  
  483
- Schematic and Routing Diagram
  
  483
  - Drive Train System
    483
- Diagnostic Information and Procedures
  
  484
  - Automatic Transmission Symptom Diagnosis
    484
- Repair Instructions
  
  485
- Specifications
  
  508
  - Service Data
    508
  - Tightening Torque Specifications
    509
- Special Tools and Equipment
  
  509
  - Recommended Service Material
    509
  - Special Tool
    510
Section 6 Steering

511
- Steering General Diagnosis
  511
- Precautions
  
  512
  - Precautions for Steering
    512
- Steering General Diagnosis
  
  513
- Diagnostic Information and Procedures
  
  513
  - Steering Symptom Diagnosis
    513
- Repair Instructions
  
  514
- Steering / Handlebar
  
  514
- Specifications
  
  524
  - Service Data
    524
  - Tightening Torque Specifications
    525
- Special Tools and Equipment
  
  525
  - Recommended Service Material
    525
  - Special Tool
    525
Section 9 Body and Accessories

527
- Precautions
  
  529
  - Precautions for Electrical System
    529
- Component Location
  
  529
  - Electrical Components Location
    529
- Schematic and Routing Diagram
  
  530
  - Wiring Diagram
    530
  - Wiring Harness Routing Diagram
    533
- Wiring Systems
  
  530
- Specifications
  
  535
  - Service Data
    535
- Repair Instructions
  
  536
- Lighting Systems
  
  536
- Specifications
  
  543
  - Service Data
    543
- Special Tools and Equipment
  
  543
  - Special Tool
    543
- Combination Meter / Fuel Meter / Horn
  
  544
- General Description
  
  544
  - Combination Meter System Description
    544
- Repair Instructions
  
  545
- Specifications
  
  551
  - Service Data
    551
  - Tightening Torque Specifications
    551
- Special Tools and Equipment
  
  552
  - Recommended Service Material
    552
  - Special Tool
    552
- Exterior Parts
  
  553
- Repair Instructions
  
  553
- Body Structure
  
  566
- Repair Instructions
  
  566
  - Body Frame Construction
    566
  - Footrest Construction
    566
  - Footrest Removal and Installation
    567
  - Carrier Construction
    568
  - Front Carrier Removal and Installation
    569
  - Rear Carrier Removal and Installation
    570
  - Front Grip Bar Construction
    571
  - Front Grip Bar Removal and Installation
    571
  - Trailer Towing Construction
    572
  - Trailer Towing Removal and Instruction
    572
  - Recommended Service Material
    573
- Specifications
  
  573
- Special Tools and Equipment
  
  573

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Suzuki kq750 2008 Manuals

Suzuki kq750 2008 Service Manual (576 pages)

Table of Contents

Table of Contents

Section 1 Engine

Engine General Information and

Specifications

Special Tools and Equipment

Precautions

Repair Instructions

1B-1 Emission Control Devices

Engine Electrical Devices

Repair Instructions

Component Location

Precautions

Diagnostic Information and Procedures

Schematic and Routing Diagram

Engine Mechanical

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Precautions

Schematic and Routing Diagram

Engine Lubrication System

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Cooling System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Precautions

Fuel System

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

General Description

Ignition System

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Starting System

Component Location

Diagnostic Information and Procedures

Schematic and Routing Diagram

Repair Instructions

Specifications

Special Tools and Equipment

Diagnostic Information and Procedures

Component Location

Schematic and Routing Diagram

Charging System

Repair Instructions

Specifications

Special Tools and Equipment

Precautions

Repair Instructions

Exhaust System

Specifications

Section 2 Suspension

Precautions

Diagnostic Information and Procedures

Suspension General Diagnosis

Front Suspension

Repair Instructions

Special Tools and Equipment

Specifications

Rear Suspension

Repair Instructions