Suzuki GSX-R750 User manual

GSX-R750
SUZUKI MOTOR CORPORATION PRINTED IN JAPAN FEBRUARY, 2000
99500-37112-03E

GROUP INDEX
1
FOREWORD
This manual contains an introductory description
on the SUZUKI GSX-R750 and procedures for its
inspection/service and overhaul of its main com-
ponents.
Other information considered as generally known
is not included.
Read the GENERAL INFORMATION section to fa-
miliarize yourself with the motorcycle and its mainte-
nance. Use this section as well as other sections to
use as a guide for proper inspection and service.
Thismanualwillhelpyouknowthemotorcyclebet-
ter so that you can assure your customers of fast
and reliable service.
!
Inexperienced mechanics or mechanics with-
out the proper tools and equipment may not
be able to properly perform the services de-
scribed in this manual. Improper repair may
result in injury to the mechanic and may ren-
der the motorcycle unsafe for the rider and
passenger.
2
3
4
5
6
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FI SYSTEM AND INTAKE AIR
SYSTEM
COOLING AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
EMISSION
CONTROL INFORMATION
GSX-R750K1 (’01-MODEL)
GSX-R750K2 (’02-MODEL)
WIRING DIAGRAM
* This manual has been prepared on the basis
of the latest specifications at the time of pub-
lication. If modifications have been made
since then, differences may exist between the
content of this manual and the actual motor-
cycle.
* Illustrations in this manual are used to show
thebasicprinciplesofoperationandworkpro-
cedures. They may not represent the actual
motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, includ-
ing special tools, for servicing SUZUKI mo-
torcycles. If you do not have the proper knowl-
edge and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2000
IMPORTANT
All street-legal Suzuki motorcycles with engine dis-
placement of 50 cc or greater are subject to Envi-
ronmental Protection agency emission regulations.
These regulations set specific standards for exhaust
emission output levels as well as particular servic-
ing requirements. This manual includes specific
imformation required to properly inspect and ser-
vice GSXR-750 in accordance with all EPA regula-
tions. It is strongly recommended that the chapter
on Emission Control, Periodic Servicing and Carbu-
retion be thoroughly reviewed before any type of
service work is performed.
Further information concerning the EPA emission
regulations and U.S. Suzuki’s emission control pro-
gram can be found in the U.S. SUZUKI EMISSION
CONTROLPROGRAM MANUAL/SERVICEBULLE-
TIN.
7
8
9
10
11
12

HOW TO USE THIS MANUAL
TO LOCATEWHATYOU ARE
LOOKING FOR:
1.The text of this manual is divided into sections.
2.The section titles are listed in the GROUP INDEX.
3.Holding the manual as shown at the right will allow you to
find the first page of the section easily.
4.The contents are listed on the first page of each section
to help find the item and page you need.
COMPONENT PARTS ANDWORKTO BE DONE
Under the name of each system or unit, is its exploded view.Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel
!
ITEM N.m kgf.m lb-ft
A100 10.0 72.5
B23 2.3 16.5
1Brake disc
2Dust seal
3Bearing
4Spacer
5Spacer nut
6Front wheel
AFront axle
BBrake disc bolt (Front)

SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing.The meaning of each symbol is also included in the table.
Torque control required.
Data beside it indicates specified
torque.
Apply oil. Use engine oil unless
otherwise specified.
Apply SUZUKI SUPER GREASE “A”.
99000-25030 (For USA)
99000-25010(For the other countries)
Apply THREAD LOCK “1342”.
99000-32050
Apply THREAD LOCK SUPER
“1360”.
99000-32130
Apply or use brake fluid.
Apply SUZUKI BOND “1207B”.
99104-31140 (for USA)
99000-31140 (for the other coun-
tries)
Apply THREAD LOCK SUPER
“1303”.
99000-32030
Measure in voltage range.
Measure in current range.
Measure in diode test range.
Measure in continuity test range.
Use special tool.
Use engine coolant.
99000-99032-11X
Use fork oil.
99000-99001-SS8
(99000-99044-10G)
SYMBOL DEFINITION SYMBOL DEFINITION
Indication of service data.
Apply SUZUKI MOLY PASTE.
99000-25140
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKI
MOLY PASTE in a ratio of 1:1)
Apply SUZUKI BOND “1215”
99000-31110 (Except USA)

ABBREVIATIONS MAY BE USED IN
THIS MANUAL
AABDC : After Bottom Dead Center
AC : Alternating Current
ACL : Air Cleaner, Air Cleaner Box
API : American Petroleum Institute
ATDC : After Top Dead Center
ATM Pressure : Atmospheric Pressure
Atmospheric Pressure
Sensor (APS, AP Sensor)
A/F : Air Fuel Mixture
BBBDC : Before Bottom Dead Center
BTDC : Before Top Dead Center
B+ : Battery Positive Voltage
CCKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT : Circuit
CLP Switch : Clutch Lever Position Switch
(Clutch Switch)
CMP Sensor : Camshaft Position Sensor
(CMPS)
CO : Carbon Monoxide
CPU : Central Processing Unit
DDC : Direct Current
DMC : Dealer Mode Coupler
DOHC : Double Over Head Camshaft
DRL : Daytime Running Light
EECM : Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
ECT Sensor : Engine CoolantTemperature
Sensor (ECTS), Water Temp.
Sensor (WTS)
EVAP : Evaporative Emission
EVAP Canister : Evaporative Emission
Canister (Canister)
FFI : Fuel Injection, Fuel Injector
FP : Fuel Pump
FPR : Fuel Pressure Regulator
FP Relay : Fuel Pump Relay
GGEN : Generator
GND : Ground
GP Switch : Gear Position Switch
HHC : Hydrocarbons
IIAP Sensor : Intake Air Pressure
Sensor (IAPS)
IAT Sensor : Intake AirTemperature
Sensor (IATS)
IG : Ignition
LLCD : Liquid Crystal Display
LED : Light Emitting Diode
(Malfunction Indicator Lamp)
LH : Left Hand
MMAL-Code : Malfunction Code
(Diagnostic Code)
Max : Maximum
MIL : Malfunction Indicator Lamp
(LED)
Min : Minimum
NNOx : Nitrogen Oxides
OOHC : Over Head Camshaft
OPS : Oil Pressure Switch
PPCV : Positive Crankcase Ventilation
(Crankcase Breather)
RRH : Right Hand
ROM : Read Only Memory
SSAE : Society of Automotive
Engineers
STC System : SecondaryThrottle Control
System (STCS)
ST Valve : Secondary Throttle Valve (STV)
STV Actuator : SecondaryThrottle Valve
Actuator (STVA)
TTO Sensor : Tip Over Sensor (TOS)
TP Sensor : Throttle Position Sensor
(TPS)
VVCSV : Vacuum Control Solenoid Valve
VD : Vacuum Damper
VTV : Vacuum Transmitting Valve

A
Air Cleaner ACL Air Cleaner, Air Cleaner Box
B
Barometric Pressure BARO Barometric Pressure, Atmospheric
Pressure (APS, AP Sensor)
Battery Positive Voltage B+ BatteryVoltage, +B
C
Camshaft Position Sensor CMP Sensor Camshaft Position Sensor (CMPS)
Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),
Crank Angle
D
Data Link Connector DLC Dealer Mode Coupler
Diagnostic Test Mode DTM ––––
DiagnosticTrouble Code DTC Diagnostic Code, Malfunction Code
E
Electronic Ignition El ––––
Engine Control Module ECM Engine Control Module (ECM)
Fl Control Unit, Engine Control Unit (ECU)
Engine Coolant Level ECL Coolant Level
Engine CoolantTemperature ECT Coolant Temperature, Engine CoolantTem-
perature
Water Temperature
EngineSpeed RPM Engine Speed (RPM)
Evaporative Emission EVAP Evaporative Emission
Evaporative Emission Canister EVAP Canister –––(Canister)
PurgeValve PurgeValve Purge Valve (SP Valve)
F
Fan Control FC –––
Fuel Level Sensor ––– Fuel Level Sensor, Fuel Level Gauge
Fuel Pump FP Fuel Pump (FP)
G
Generator GEN Generator
Ground GND Ground (GND,GRD)
s
SAE-TO-FORMER SUZUKITERM (ONLY FOR U.S.A.)
This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in
this manual in compliance with SAE recommendations, as well as their former SUZUKI names.
SAETERM FORMER SUZUKI TERM
FULLTERM ABBREVIATION

I
Idle Speed Control ISC –––
Ignition Control IC Electronic Spark Advance(ESA)
Ignition Control Module ICM –––
Intake Air Temperature IAT Intake Air Temperature(IAT), Air Temperature
M
Malfunction Indicator Lamp MIL LED Lamp
Malfunction Indicator Lamp(MIL)
Manifold Absolute Pressure MAP Intake Air Pressure, IntakeVacuum
Mass Air Flow MAF Air Flow
O
On-Board Diagnostic OBD Self-Diagnosis Function
Diagnostic
Open Loop OL –––
P
Programmable Read Only Memory PROM –––
Pulsed Secondary Air lnjection PAIR Pulse Air Control (PAIR)
R
Random Access Memory RAM –––
Read Only Memory ROM ROM
S
Secondary Air Injection AIR –––
SecondaryThrottle Control System STCS STC System (STCS)
SecondaryThrottle Valve STV ST Valve (STV)
SecondaryThrottle Valve Actuator STVA STV Actuator (STVA)
T
Throttle Body TB Throttle Body(TB)
Throttle Body Fuel Injection TBI Throttle Body Fuel Injection(TBI)
Throttle Position Sensor TP Sensor TP Sensor(TPS)
V
Voltage Regulator VR Voltage Regulator
Volume Air Flow VAF Air Flow
SAETERM FORMER SUZUKI TERM
FULLTERM ABBREVIATION

GENERAL INFORMATION 1-1
1
GENERAL INFORMATION
CONTENTS
WARNING/CAUTION/NOTE ............................................................. 1- 2
GENERAL PRECAUTIONS .............................................................. 1- 2
SUZUKI GSX-R750Y (2000-MODEL)............................................... 1- 4
SERIAL NUMBER LOCATION ......................................................... 1- 4
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION ........... 1- 5
FUEL.............................................................................................. 1- 5
ENGINE OIL .................................................................................. 1- 5
BRAKE FLUID............................................................................... 1- 5
FRONT FORK OIL......................................................................... 1- 5
ENGINE COOLANT ...................................................................... 1- 6
WATER FOR MIXING .................................................................... 1- 6
ANTI-FREEZE/ENGINE COOLANT.............................................. 1- 6
LIQUID AMOUNT OFWATER/ENGINE COOLANT...................... 1- 6
BREAK-IN PROCEDURES............................................................... 1- 6
CYLINDER IDENTIFICATION........................................................... 1- 6
INFORMATION LABELS .................................................................. 1- 7
SPECIFICATIONS............................................................................. 1- 8
COUNTRY AND AREA CODES ....................................................... 1-10

1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.

Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-
INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you
are unsure about how to perform a particular service operation, ask a more experienced mechanic for ad-
vice.
GENERAL PRECAUTIONS

* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the motorcycle.
* When 2 or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
* When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer’s instructions.
* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until
they have cooled.
* After servicing the fuel, oil, engine coolant, exhaust or brake systems, check all lines and fit-
tings related to the system for leaks.

GENERAL INFORMATION 1-3

* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lent.
* When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order.
* Be sure to use special tools when instructed.
* Make sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricant, bond, or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable,
and cover the positive terminal with the terminal cover.
* When performing service to electrical parts, disconnect the battery negative cable unless the
service procedure requires the battery power.
* When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside working out and to the specified
tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts,
cotter pins, circlips, and certain other parts as specified, be sure to replace them with new
ones. Also, before installing these new parts, be sure to remove any left over material from the
mating surfaces.
* Never reuse a circlip.When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
* After reassembling, check parts for tightness and proper operation.
* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and
other fluids: batteries, and tires.
* To protect the earth’s natural resources, properly dispose of used motorcycles and parts.

1-4 GENERAL INFORMATION
SERIAL NUMBER LOCATION
The frame serial number orV.I.N. (Vehicle Identification Number)
Ais stamped on the right side of the steering head pipe. The
engine serial number Bis located on the rear side of the crank-
case.These numbers are required especially for registering the
machine and ordering spare parts.
* Difference between photograph and actual motorcycle depends on the markets.
RIGHT SIDE
SUZUKI GSX-R750Y (2000-MODEL)
LEFT SIDE

GENERAL INFORMATION 1-5
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL (FOR USA AND CANADA)
Use only unleaded gasoline of at least 90 pump octane ( ). Gasoline containing MTBE (Methyl Tertiary
Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion
inhibitor is permissible.
FUEL (FOR THE OTHER COUNTRIES)
Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recom-
mended.
ENGINE OIL (For U.S.A. model)
SUZUKI recommends the use of SUZUKI PERFORMANCE 4
MOTOR OIL or an oil which is rated SF or SG under the API
(American Petroleum Institute) service classification.The recom-
mended viscosity is SAE 10W/40. If an SAE 10W/40 oil is not
available, select and alternative according to the right chart.
ENGINE OIL (For the other models)
Use a premium quality 4-stroke motor oil to ensure longer ser-
vice life of your motorcycle. Use only oils which are rated SF or
SG under the API service classification.
The recommended viscosity is SAE 10W-40. If an SAE 10W-40
motor oil is not available, select an alternative according to the
right chart.
BRAKE FLUID
Use DOT4 brake fluid.

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufac-
turer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid
for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.
FRONT FORK OIL
Use fork oil SS-8 (#10) or an equivalent fork oil.
MULTIGRADE
TEMP.

1-6 GENERAL INFORMATION
ENGINE COOLANT
Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only.
WATER FOR MIXING
Use distilled water only.Water other than distilled water can corrode and clog the aluminum radiator.
ANTI-FREEZE/ENGINE COOLANT
The engine coolant perform as a corrosion and rust inhabit as well as anti-freeze. Therefore, the engine
coolant should be used at all times even though the atmospheric temperature in your area does not go down
to freezing point.
Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant.If this is not available, use an
equivalent which is compatible with an aluminum radiator.
LIQUID AMOUNT OF WATER/ENGINE COOLANT
Solution capacity (total): 2 400 ml (2.5/2.1 US/lmp qt)
For engine coolant mixture information, refer to cooling system section. (5-2)

Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce its
efficiency.If the anti-freeze/engine coolant mixing ratio is below 50%,rust inhabiting performance
is greatly reduced. Be sure to mix it above 50% even though the atmospheric temperature does
not go down to the freezing point.
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very
high standard but it is still necessary to allow the moving parts to “BREAK-IN”before subjecting the engine to
maximum stresses. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life.The general rules are as follows.
• Keep to these break-in procedures:
Initial 800 km ( 500 miles): Below 7 000 r/min
Up to 1 600 km (1 000 miles): Below 10 500 r/min
Over to 1 600 km (1 000 miles): Below 14 000 r/min
• Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle
operation. However, do not exceed 14 000 r/min at any time.
CYLINDER IDENTIFICATION
Thefourcylinders of thisengine are identified as No.1,No.2, No.3
and No.4 cylinder, as counted from left to right (as viewed by the
rider on the seat).

GENERAL INFORMATION 1-7
INFORMATION LABELS
GSX-R750 GSX-R750UD GSX-R750UF
1Noise label For E-03, 24, 33
2Information label For E-03, 24, 33
3Vacuum hose routing label For E-33
4Fuel caution label For E-02, 24
5Manual notice label For E-03, 33
6Frame caution label
7Screen warning label
8Steering warning label
9Tire pressure label
0Warning safety label
AICES Canada label For E-28
BID plate For E-02, 19, 24
CE-19 ID label
DSafety plate For E-03, 28, 33
For E-28 (French)

1-8 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length................................................................ 2 040 mm (80.3 in)
Overall width ................................................................. 715 mm (28.1 in)
Overall height................................................................ 1 135 mm (44.7 in)
Wheelbase.................................................................... 1 410 mm (55.5 in)
Ground clearnce ........................................................... 130 mm (5.1 in)
Seat height.................................................................... 830 mm (32.7 in)
Dry mass....................................................................... 167 kg (368 lbs) ..... For E-33
166 kg (366 lbs) ..... For the others
ENGINE
Type............................................................................... Four-stroke, Liquid-cooled, DOHC, TSCC,
Number of cylinders...................................................... 4
Bore .............................................................................. 72.0 mm (2.834 in)
Stroke............................................................................ 46.0 mm (1.811 in)
Piston displacement ..................................................... 749 cm3(45.7 cu. in)
Compression ratio......................................................... 12.0 : 1
Fuel system .................................................................. Fuel injection
Air cleaner..................................................................... Paper element
Starter system............................................................... Electric
Lubrication system........................................................ Wet sump
TRANSMISSION
Clutch............................................................................ Wet multi-plate type
Transmission ................................................................. 6-speed, constant mesh
Gearshift pattern........................................................... 1-down, 5-up
Primary reduction ratio ................................................. 1.857 (78/42)
Gear ratios, Low .......................................................... 2.785 (39/14)
2nd........................................................... 2.052 (39/19)
3rd ........................................................... 1.681 (37/22)
4th............................................................ 1.450 (29/20)
5th............................................................ 1.304 (30/23)
Top........................................................... 1.181 (26/22)
Final reduction ratio ...................................................... 2.470 (42/17)
Drive system ................................................................. RK 525ROZ4, 110 links

GENERAL INFORMATION 1-9
CHASSIS
Front suspension .......................................................... Inverted telescopic, coil spring, spring pre-load fully
adjustable, rebound and compression damping
force fully adjustable.
Rear suspension........................................................... Link type system, gas/oil damped, coil spring,
spring pre-road fully adjustable, rebound and com-
pression damping force fully adjustable.
Caster ........................................................................... 24°
Trail................................................................................ 96 mm (3.8 in)
Steering angle .............................................................. 29° (right & left)
Turning radius ............................................................... 3.2 m (10.5 ft)
Front brake.................................................................... Disc brake, twin
Rear brake .................................................................... Disc brake
Front tire size ................................................................ 120/70 ZR17 (58 W), tubeless
Rear tire size................................................................. 180/55 ZR17 (73 W), tubeless
ELECTRICAL
Ignition type .................................................................. Electronic ignition (Transistorized)
Ignition timing................................................................ #1, #4: 4° B.T.D.C.at 1 200 rpm
#2, #3: 13° B.T.D.C. at 1 200 rpm
(Engine coolant temp.: 80°C)
Spark plug..................................................................... NGK CR9E, DENSO U27ESR-N
Battery .......................................................................... 12V 36.0 kC(10 Ah)/10HR
Generator...................................................................... Three-phase A.C. Generator
Main fuse ...................................................................... 30A
Fuse .............................................................................. 15/15/15/15/10/10A
Headlight....................................................................... 12V 55+55/55W (H7)
Position light.................................................................. 12V 5W .........Except for E-03, 24, 28, 33 models
Turn signal light............................................................. 12V 21W
Brake light/Taillight ........................................................ 12V 21/5W × 2
Combination meter light................................................ LED
Neutral indicator light.................................................... LED
High beam indicator light .............................................. LED
Turn signal indicator light.............................................. LED
Fuel level indicator light ................................................ LED
FI/Oil pressure/Engine coolant temp. indicator light..... LED
CAPACITIES
Fuel tank, including reserve ......................................... 18 L (4.8/4.0 US/lmp gal)
Engine oil, oil change ................................................... 2 800 ml (3.0/2.5 US/lmp qt)
with filter change......................................... 3 100 ml (3.3/2.7 US/lmp qt)
overhaul ...................................................... 3 400 ml (3.6/3.0 US/lmp qt)
Coolant.......................................................................... 2 400 ml (2.5/2.1 US/lmp qt)
Front fork oil (each leg)................................................. 473 ml (16.0/16.7 US/lmp oz)
These specifications are subject to change without notice.

1-10 GENERAL INFORMATION
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
MODEL CODE COUNTRY or AREA
E-02 U.K.
E-03 USA (Except for california)
GSX-R750 E-19 EU
E-24 Australia
E-28 Canada
E-33 California (USA)
GSX-R750UD E-19 EU
GSX-R750UF E-19 EU

PERIODIC MAINTENANCE 2-1
2
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE ......................................... 2- 2
PERIODIC MAINTENANCE CHART............................................. 2- 2
LUBRICATION POINTS ................................................................ 2- 3
MAINTENANCE ANDTUNE-UP PROCEDURES............................. 2- 4
AIR CLEANER .............................................................................. 2- 4
SPARK PLUG ................................................................................ 2- 5
VALVE CLEARANCE .................................................................... 2- 8
ENGINE OIL AND OIL FILTER ..................................................... 2-13
FUEL HOSE .................................................................................. 2-15
ENGINE IDLE SPEED ................................................................... 2-15
THROTTLEVALVE SYNCHRONIZATION..................................... 2-15
THROTTLE CABLE PLAY............................................................. 2-16
CLUTCH ........................................................................................ 2-17
COOLING SYSTEM ...................................................................... 2-18
DRIVE CHAIN................................................................................ 2-20
BRAKE .......................................................................................... 2-22
TIRE............................................................................................... 2-25
STEERING..................................................................................... 2-26
FRONT FORK ............................................................................... 2-27
REAR SUSPENSION .................................................................... 2-27
EXHAUST PIPE BOLT AND NUT ................................................. 2-27
CHASSIS BOLT AND NUT ........................................................... 2-28
COMPRESSION PRESSURE CHECK ............................................. 2-30
OIL PRESSURE CHECK .................................................................. 2-31
CONTENTS

2-2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the motorcycle operating at peak performance and economy.Maintenance intervals are expressed in terms of
kilometer, miles and months, and are dependant on whichever comes first.
IMPORTANT (USA only):
The periodic maintenance intervals and service requirements have been established in accordance with EPA
regulations. Following these instructions will ensure that the motorcycle will not exceed emission standards
and it will also ensure the reliability and performance of the motorcycle. The chart below lists the recom-
mendedintervalsfor all therequired periodicservice work necessaryto keepthemotorcycle operatingat peak
performance and economy. Mileages are expressed in terms of kilometer, miles and time for your conve-
nience.
NOTES:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Interval km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 15 000
Item months 1 6 12 18 24
Air cleaner element - I I R I
Spark plugs - I R I R
Valve clearance - - - - I
Engine oil R RRRR
Engine oil filter R - - R -
Fuel line - I I I I
Replace fuel hose every 4 years.
Idle speed I I I I I
Throttle valve synchronization I-I-I
(E-33 only)
Evaporative emission control system - - I - I
(E-33 only) Replace vapor hose every 4 years.
PAIR (air supply) system - - I - I
Throttle cable play I I I I I
Clutch - I I I I
Radiator hoses - I I I I
Engine coolant Replace every 2 years.
Drive chain I I I I I
Clean and lubricate every 1 000 km (600 miles).
Brakes IIIII
Brake hoses - I I I I
Replace every 4 years.
Brake fluid - I I I I
Replace every 2 years.
Tires - I I I I
Steering I - I - I
Front forks - - I - I
Rear suspension - - I - I
Exhaust pipe bolts and muffler bolt and nut T - T - T
Chassis bolts and nuts T T T T T
I = Inspect and adjust, clean, lubricate or replace as necessary.
R = Replace
T = Tighten

PERIODIC MAINTENANCE 2-3
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts which are subject to rust, with a rust preventative spray, especially whenever the
motorcycle has been operated under wet or rainy conditions.
Brake leverholder
Brake pedal pivot and footrest pivot
Clutchlever holder
Side-standpivot
andspring hook Footrest pivot
and gearshift
lever pivot Drive chain