Suzuki GS 750 Motorcycle Service Manual 1977-1978 Repair

Description

This Suzuki GS 750 Service Manual includes 188 pages of repair information for 1977-1978 Suzuki GS750 Motorcycles. This Suzuki GS 750 Service Manual is a high quality reproduction of the original out of print manual.

The 4-stroke Suzuki GS750 motorcycle, powered by a thoroughly designed engine with many new features including a double-overhead-camshaft valve mechanism, is the latest challenge of SUZUKI to cement its place of fame and distinction in the large-size category of motorcycles. Developed through years of painstaking research work and inheriting the best reliability and durability features of world-renowned SUZUKI two-stroke machines, this ambitious 750-cc machine has its chassis designed anew to equal the enormous power available from its engine. How well the user can make use of the great capability built into this machine depends largely on the way you assist him and take care of it in your shop. We hope you will study this Suzuki GS 750 Service Manual carefully to get all the information vital to the successful servicing of GS750 motorcycles. The Model GS750 made to standard specifications is taken up in the text, whereas it is possible that GS750 machines that may come to your attention should be slightly modified to meet the statutory requirements of your country; even if modified, they should present no problem to you as your skill and experience in attending to SUZUKI machines will naturally lead you to cope with those points of minor difference.

Table of Contents

General Information –
SPECIFICATIONS
FUEL AND OILS
FUEL
ENGINE OIL (for engine and transmission)
BRAKE OIL (for front and rear brakes)
FRONT FORK OIL
CYLINDER IDENTIFICATION

Engine –
DESCRIPTION
DOHC (Double-Overhead-Camshaft) Valve Mechanism
LUBRICATION
BLOWBY GAS RECYCLING
ENGINE REMOVAL AND DISMANTLING
ENGINE REMOVAL
ENGINE DISASSEMBLY
DISASSEMBLING ENGINE COMPONENTS
INSPECTION AND SERVICING
AIR CLEANER
CARBURETOR
CAMSHAFT
CAMCHAIN TENSION ADJUSTER
CYLINDER HEAD
VALVE
VALVE SEAT
VALVE SPRING
CYLINDER
PISTON AND PISTON RING
CRANKSHAFT
OIL SUMP STRAINER
OIL FILTER
OIL PUMP
CLUTCH
TRANSMISSION
ENGINE REASSEMBLY
TRANSMISSION AND KICK STARTER
CRANKSHAFT AND CRANKCASE
STARTER AND GENERATOR ROTOR
GEARSHIFT MECHANISM
OIL PUMP
CLUTCH, KICK STARTER SPRING AND
ADVANCE GOVERNOR
PISTONS
PISTON RINGS
CYLINDER BLOCK
CYLINDER HEAD
CAMSHAFTS
VALVE TIMING ADJUSTMENT
TACHOMETER DRIVE GEAR
TIMING CHAIN IDLER
TIMING CHAIN TENSION ADJUSTER
CHECKING AND ADJUSTING THE
TAPPET CLEARANCE
CYLINDER HEAD COVER
CARBURETORS
ENGINE REMOUNTING
ENGINE MOUNTING BOLTS AND NUTS
CONTACT-POINT LEAD WIRES
HIGH-TENSION CORDS
CARBURETOR AIR VENT PIPE AND
OVER FLOW PIPE
OIL DRAIN PIPE FOR AIR CLEANER
BREATHER PIPE FOR CRANKCASE
THROTTLE WIRE
DRIVE CHAIN
EXHAUST PIPES
ENGINE OIL
ENGINE TUNE-UP
COMPRESSION PRESSURE TEST
OIL PUMP PRESSURE TEST
CLUTCH ADJUSTMENT
IGNITION TIMING ADJUSTMENT
CARBURETOR ADJUSTMENT

Chassis
STEERING
DISASSEMBLY
INSPECTION
REASSEMBLY
REPLACEMENT OF STEERING STEM RACES
FRONT SUSPENSION
DISASSEMBLY
INSPECTION
REASSEMBLY
REAR SUSPENSION
DISASSEMBLY
INSPECTION
REASSEMBLY
FRONT WHEEL
DISASSEMBLY
INSPECTION
REASSEMBLY
REAR WHEEL
DISASSEMBLY
INSPECTION
REASSEMBLY
SWINGING ARM
DISASSEMBLY
INSPECTION
REASSEMBLY
FRONT-BRAKE CALIPER
DISASSEMBLY
INSPECTION
REASSEMBLY
MASTER CYLINDER ASSEMBLY
DISASSEMBLY
INSPECTION
REASSEMBLY
REAR-BRAKE CALIPER
DISASSEMBLY
INSPECTION
REASSEMBLY
MASTER CYLINDER ASSEMBLY
DISASSEMBLY
INSPECTION
REASSEMBLY
BRAKE PARTS TO BE PERIODICAL REPLACED
TIGHTENING TORQUE SPECIFICATIONS
RIDING-SAFETY INSPECTION GUIDE

Electrical Equipment
CHARGING SYSTEM
CHARGING SYSTEM INSPECTION
INSPECTION OF CHARGING SYSTEM COMPONENTS
Alternator
Rectifier
Voltage regulator
STARTING SYSTEM
STARTING SYSTEM INSPECTION
INSPECTION OF COMPONENTS AND PARTS
Carbon brushes
Commutator
Armature coil
Starting motor relay
The battery
IGNITION SYSTEM
INSPECTION
Ignition coils
Spark plugs
Contact breakers
Condensers
UTILITY SWITCHES AND DEVICES
Ignition switch
Front brake lamp switch
Rear brake lamp switch
Horn
Winker switch unit
Lighting switch
Kill switch and starter switch
Passing
Oil pressure switch
Gearshifting switch and gear position indicator
Lamp wattage data
Wiring

Special Tools Needed
Valve guide reamer set
(A) 7 mm dia.
(B) 12.2 mm dia.
(C) Handle
Valve seat cutter set
(A)    45°
(B)    15°
(C)    75°    IN
(D)    75°    EX
Carburetor balancer
Oil pressure gauge
Compression gauge
Front fork assembling tool set
Hexagon wrench (4 mm)
Cylinder disassembling tool
10 mm stud installing tool
011 seal remover
Bearing puller
Bearing puller
Bearing and oil seal installing tool
Bearing and oil seal installing tool
Clutch sleeve hub holder
Snap ring opener
Special cirdip opener
Rotor remover attachment
Engine sprocket and flywheel holder
Steering stem lock nut wrench
Front fork oil seal installing tool
Spoke nipple wrench
6 mm T type cross head screw wrench
Shock driver set
Pocket tester
Engine tachometer
Timing tester
Electro tester
Hydrometer
Rotor remover shaft set
Thickness gauge

Necessary Materials
THREAD LOCK CEMENT
SUZUKI LOCK SUPER “103K”
SUZUKI BOND No. 4
SUZUKI BRAKE PAD GREASE
SUZUKI CALIPER AXLE GREASE
SUZUKI MOLY PASTE

Tightening Torque
Suzuki GS750 Engine Torque Values
Clutch sleeve hub nut
Drive sprocket nut
Starter clutch bolt
Contact breaker cam bolt
Cam chain tensioner sleeve bolt
Cam chain tensioner lock nut
Camshaft sprocket bolt
Cylinder head bolt
Cylinder Head nut
Cylinder head cover bolt
Camshaft holder bolt
Cam chain idler sprocket bolt
Oil filter cover nut
Oil pan bolt
Crankcase bolt
Crankcase bolt
Engine mounting bolt
Engine mounting plate bolt
AC generator rotor bolt

Suzuki GS 750 Chassis Torque Values
Handlebar holder bolt
Steering stem pinch bolt
Front fork tube upper pinch bolt (R.L)
Front fork tube lower pinch bolt (R.L)
Front axle nut
Front axle holder nut
Swinging arm pivot shaft nut
Rear torque link nut
Rear axle nut
Rear shock absorber bolt
Rear shock absorber nut
Front step bolt
Steering stem bolt
Front brake caliper mounting bolt
Rear brake caliper mounting bolt
Brake disc bolt
Front brake caliper axle bolt
Rear brake caliper axle bolt
Front brake master cylinder mounting bolt
Rear brake master cylinder mounting bolt
Brake hose union bolt
Brake oil bleeder bolt
Brake hose Coupler
Chain adjuster support bolt

Suzuki GS750 Engine Trouble Shooting
Engine will not start or is hard to start
Engine stalls easily
Noisy Engine
Slipping Clutch
Dragging Clutch
Transmission will not shift
Transmission will not shift back
Transmission jumps out of gear
Engine idles poorly
Engine runs poorly in high speed range
Dirt of heavy exhaust smoke
Engine lacks power
Engine overheats

Suzuki GS750 Chassis Troubleshooting
Handling feels heavy
Wobbly handling
Wobbly front wheel
Front cushions (forks) too soft
Front cushions too stiff
Noisy front cushions
Wobbly rear wheel
Rear cushions too soft.
Rear cushions too stiff
Noisy rear cushions
Poor braking (FRONT & REAR)

Suzuki GS 750 Electrical Troubleshooting
No sparking or poor sparking
Contact points burn or pits prematurely.
Spark plugs soon become fouled with carbon.
Spark plugs become fouled too soon.
Spark plug electrodes overheat or burn.
Generator does not charge.
Generator does charge, but charging rate is below the specification.
Generator overcharges.
Unstable charging
Starter button is not effective.
Battery “sulfation”
Battery discharges itself rapidly.

Service Data

Periodic Maintenance

Suzuki GS750 Wiring Diagram