Suzuki kq750 Manuals

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

Suzuki kq750 Service Manual (711 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 52.92 MB

Section 0 General Information

14
- 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
- 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
- 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
- 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
- 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
- Repair Instructions
  
  276
- 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
- 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
  
  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
- Specifications
  
  345
  - Service Data
    345
  - Tightening Torque Specifications
    345
- Special Tools and Equipment
  
  345
  - Recommended Service Material
    345
  - Special Tool
    346
- Repair Instructions
  
  347
- 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
- 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
- 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
- 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
- Specifications
  
  414
  - Service Data
    414
- Special Tools and Equipment
  
  414
  - Recommended Service Material
    414
  - Special Tool
    414
- Repair Instructions
  
  415
- 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
- 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
- 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 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
- 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
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
- 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
- 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
- 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

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Suzuki kq750 Manuals

Suzuki kq750 Service Manual (711 pages)

Table of Contents

Section 0 General Information

General Description

Maintenance and Lubrication

Precautions

Scheduled Maintenance

Repair Instructions

Special Tools and Equipment

Service Data

Specifications

Section 1 Engine

Precautions

General Description

Engine General Information and Diagnosis

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Precautions

Emission Control Devices

Repair Instructions

Repair Instructions

Diagnostic Information and Procedures

Component Location

Precautions

Engine Electrical Devices

Specifications

Schematic and Routing Diagram

Engine Mechanical

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Lubrication System

Precautions

Schematic and Routing Diagram

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

Fuel System

Precautions

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

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Diagnostic Information and Procedures

Component Location

Charging System

Schematic and Routing Diagram

Repair Instructions

Specifications

Special Tools and Equipment