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  • Suzuki DR750 DR800 1989-1997 PDF

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    Edelcio Esposito
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    Suzuki DR750 DR800 1989-1997.pdf

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    12 views353 pages

    Suzuki DR750 DR800 1989-1997 PDF

    Uploaded by

    Edelcio Esposito

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 353
    Le HALES IS Ty MANUAL FOREWORD The SUZUKI DR760S was designed to offer super: for performance through lightweight desien, four strokepower, engine counter-balsncers, Suzuki Advanced Cooling System (SACS) and full-floating suspension. This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service Suzuki Motoreycies. Apprentice mechanics and do-it-yourself mecha- nics, will also find this manual an extremely useful repair guide, This manual contains up-to-date infor- —“Yion at the time of publication. The rights are “Yéierved to update or make corrections to this ‘manual at any time. SUZUKI MOTOR CORPORATION Motorcycle Service Department © COPYRIGHT SUZUKI MOTOR CORPORATION 1900 GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES | ENGINE FUEL AND LUBRICATION sysrew a |ELECTRICAL SYSTEM CHASSIS a SERVICING INFORMATION APPENDIX Ea DR750SK (’89-MODEL) | DR8O0OSL (’90-MODEL) DR8&OOSM ('91-MODEL) DR8OOSN ('92-MODEL) Wa ‘DRE00SP ((93-MODEL) A | DR8OOSR (’94-MODEL) ll [pReooss ((95-MODEL) 74 | , onalinar ees a | DRE0OSV (’97-MODEL) wa GENERAL INFORMATION CONTENTS- VIEW OF SUZUKI DR750SJ ('88-MODEL) SERIAL NUMBER LOCATIONS FUEL AND OIL RECOMMENDATIONS BREAK-IN PROCEDURES SPECIAL MATERIALS PRECAUTIONS AND GENERAL INSTRUCTIONS «~*~ SPECIFICATIONS ----"- | COUNTRY OR AREA esetovnee srvetsnee t ae 14 GENERAL INFORMATION VIEW OF SUZUKI DR750SJ ('88-MODEL) | LEFT SIDE \ RIAL NUMBER LOCATIONS The frame sorial number or V.I.N. (Vehicle Identification Num- ber) (Dis stamped on the stooring head pipe. The engine serial number @ is located on the crankease. These numbers are required especially for registering the machine and ordering spare parts FUEL AND OIL RECOMMENDATIONS FUEL (For Canadian model) Use only unleeded or low-load type gasoline of at least 85 — 95 pump octane (25M) method or 89 octane or higher rated by the Research Method. (For the Other models) Gasoline used should be graded 85 — 95 octane (Research Method) or higher, An unleaded or low-lead type gasoline is recommended. SR RR RPE RTS GENERAL INFORMATION 1:2 ENGINE OIL 2 comes under API classifica: Be sure that te engine ol you 17] ee ton of SE or Sand tht von wating i SAE TOW-40 I" SAE TONG movr ol is notevlae sect the olviooe | now ity according to the chart at right. pa ES EE Tah we Te 32 50 68 ete FRONT FORK OIL Use fork oil # 10, (99000-99044.106) BRAKE FLUID Specification and classification: SAE J1703, DOT3 or DOTA WARNING: * Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, 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 the previous servicing and stored for a long period. BREAK-IN PROCEDURES During manufacture only the best possible materials are used end all machined perts are finished to a very high stendard 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: 1. Keep to this break-in throttle position Up to 1600 km (1 000 miles]: Below 4/5 throttle 2. After the engine has been operated for 1 600 km (1 000 miles) the motorcycle can be subjected to full throttle operation for short periods of time. 1.3 GENERAL INFORMATION SPECIAL MATERIALS The materials listed below are needed for maintenance work on the DR750S, and should be kept on hand for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery cloth end the like. How to use them and where to use them are described in the text of this manual. ‘Material | Part Pave Part Page © Oilseas 342 |e oreke camspattand Ovirg | 624 © Throttle grip 2.2 |e Brake comand pin 628 Brake ped shaft 22 |e Shock ateorber dust sels | 690 © Gearsife ever and shaft 2.2 |e Gusiontever dust ss, 620 © Sovedometer gearbox and | 2-2 | spacers and beatings cust seal © 5 |» Swingarm dust als, 029 suzuki suPER Whoa! bearings 6-4, 23] spacers and baring GREASE "A" ¢Seaprng stem bearins 22 89000-25010 © Sprocket drum bearing 026 © Caliper aie ee % 610 SUZUKI SILICONE GREASE | 90¢0.25100 Valve stems 228 Decor. shatt a2 Counterthaft and dveshatt | 3.38 vars * Piston pin 350 © Camihett oematand.came | 2-60, 4 Rocker erm shatts an SUZUKI MOLY PASTE 99000-25140 | ca | ating surfaces o te 26 4 BP and ight halves of crankcase

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