Suzuki LT-A750X/P Supplementary Service Manual Download | Manualshive

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3-ii Table of Contents

Transfer Related Parts Inspection....................... 3C-*
Transfer Related Bearing Inspection................... 3C-*
Gear Position (GP) Switch Inspection................. 3C-*
Gear Position (GP) Switch Removal and

Installation......................................................... 3C-*

Gearshift Shaft No. 2 / Gearshift Cam Plate

Removal and Installation................................... 3C-*

Gearshift Linkage Inspection............................... 3C-*
Gearshift Shaft Oil Seal Removal and

Installation......................................................... 3C-*

Specifications....................................................... 3C-*

Service Data........................................................ 3C-*

Special Tools and Equipment ............................. 3C-*

Recommended Service Material ......................... 3C-*
Special Tool ........................................................ 3C-*

Propeller Shafts........................................ 3D-*

Repair Instructions .............................................. 3D-*

Front Output Shaft Components ......................... 3D-*
Front Output Shaft Removal and Installation ...... 3D-*
Front Output Shaft Disassembly and

Assembly .......................................................... 3D-*

Front Output Shaft Related Parts Inspection ...... 3D-*
Rear Output Shaft Components.......................... 3D-*
Rear Output Shaft Removal and Installation....... 3D-*
Rear Output Shaft Disassembly and

Assembly........................................................... 3D-*

Rear Output Shaft Related Parts Inspection ....... 3D-*
Rear Output Shaft Drive Bevel Gear Shim

Inspection and Adjustment................................ 3D-*

Front Propeller Shaft Components...................... 3D-*
Front Propeller Shaft Removal and

Installation ......................................................... 3D-*

Front Propeller Shaft Related Parts

Inspection.......................................................... 3D-*

Rear Propeller Shaft Components ...................... 3D-*
Rear Propeller Shaft Removal and Installation .... 3D-*
Rear Propeller Shaft Related Parts Inspection .... 3D-*

Specifications ....................................................... 3D-*

Service Data........................................................ 3D-*
Tightening Torque Specifications........................ 3D-*

Special Tools and Equipment ............................. 3D-*

Recommended Service Material ......................... 3D-*
Special Tool ........................................................ 3D-*

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Summary of Contents for LT-A750X/P

Page 1: ...LT A750XP Z USE THIS MANUAL WITH LT A750X Z SERVICE MANUAL 99500 47021 01E 9 9 5 0 1 4 7 0 5 0 0 1 E ...

Page 2: ... your customers of fast and reliable ser vice COPYRIGHT SUZUKI MOTOR CORPORATION 2009 Manual Name Manual No LT A750X ZK9 SERVICE MANUAL 99500 47021 01E This manual has been prepared on the basis of the latest specifications at the time of publication If modifi cations have been made since then differences may exist between the content of this manual and the actual vehicle Illustrations in this man...

Page 3: ...2D Driveline Axle 3 i Precautions 3 Drive Chain Drive Train Drive Shaft 3A 1 Differential 3B Transfer 3C Propeller Shafts 3D Brake 4 i Precautions 4 Brake Control System and Diagnosis 4A 1 Front Brakes 4B Rear Brakes 4C Parking Brake 4D Transmission Transaxle 5 Precautions 5 Automatic Transmission 5A Steering 6 i Precautions 6 1 Steering General Diagnosis 6A 1 Steering Handlebar 6B 1 Power Assiste...

Page 4: ......

Page 5: ...ons 00 1 Warning Caution Note 00 General Precautions 00 Precautions for Electrical Circuit Service 00 Precautions for EPS LT A750XP ZK9 00 1 NOTE For the items with asterisk in the CONTENTS below refer to the same section of the service manual mentioned in the FOREWORD of this manual ...

Page 6: ...are not properly connected the EPS may not operate correctly For connector and coupler precautions Refer to Precautions for Electrical Circuit Service in related manual EPS Control Unit EPS Body Assembly Never allow dust or water to contact the EPS control unit and EPS body assembly Since each component is a high precision part great care should be taken not to apply any service impacts during rem...

Page 7: ...g Inspection and Cleaning 0B Spark Arrester Cleaning 0B Fuel Line Inspection 0B Engine Oil and Filter Replacement 0B Front Differential Gear Oil Inspection 0B Front Differential Gear Oil Replacement 0B Final Gear Oil Inspection 0B Final Gear Oil Replacement 0B Throttle Cable Play Inspection and Adjustment 0B Throttle Body Inspection 0B Cooling System Inspection 0B Drive V belt Inspection and Repla...

Page 8: ...ce between illustration and actual motorcycles may exist depending on the markets SUZUKI LT A750XP 2009 model Right Side Left Side Country and Area Codes LT A750XP ZK9 B931G30101014 The following codes stand for the applicable country ies and area s I931G3010001 01 I931G3010002 01 Code Country or Area Effective Frame No LT A750XPK9 P 17 Sweden 5SAAR41P97100001 LT A750XPK9 P 24 Australia LT A750XPK...

Page 9: ...abel English French For P 28 6 Tire air pressure label and warning no passenger label French For P 28 20 Compliance label English For P 28 7 General warning AGE 16 label English For P 17 24 28 33 21 I D plate English For P 17 8 General warning label French For P 28 22 Cooling fan label English For P 24 33 9 Warning no passenger label English For P 17 24 28 33 23 Cooling fan label English French Fo...

Page 10: ... Item Specification Remark Type 4 stroke liquid cooled DOHC Number of cylinders 1 Bore 104 0 mm 4 094 in Stroke 85 0 mm 3 346 in Displacement 722 cm3 44 1 cu in Compression ratio 10 0 1 Fuel system Fuel injection Air cleaner Paper element Starter system Electric starter Lubrication system Wet sump Idle speed 1 300 100 r min Item Specification Remark Clutch Wet shoe automatic centrifugal type Trans...

Page 11: ... B T D C at 1 300 r min Spark plug NGK CR6E or DENSO U20ESR N Battery 12 V 64 8 kC 18 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 10 10 10 10 15 15 A EPS fuse 40 A Headlight 12 V 35 35 W x 2 Auxiliary light 12 V 35 35 W Brake light Taillight 12 V 21 5 W Reversing light 12 V 21 W P 17 Speedometer light LED Neutral indicator light LED High beam indicator light LED P 17 Coolant t...

Page 12: ...ulti circuit tester set 09900 25009 Needle point probe set 09904 41010 SUZUKI Diagnostic system set 09924 84521 Bearing installer set 09930 30721 Rotor remover 09930 44530 Rotor holder 09930 82710 Mode select switch 09930 82720 Mode selection switch 09942 72410 Tie rod end remover 09942 83110 Clip remover 09944 36011 Steering wheel remover 99565 01010 020 CD ROM Ver 20 ...

Page 13: ...ethane from element 3 Fill a wash pan of a proper size with a non flammable cleaning solvent Immerse the air cleaner element in the cleaning solvent and wash it 4 Press the air cleaner element between the palms of both hands to remove the excess solvent do not twist or wring the element or it will tear 5 Immerse the element in motor oil and then squeeze out the excess oil leaving the element sligh...

Page 14: ... and tightening the lock nuts hold the tie rod end with a open end wrench NOTE Hold the concave part a of tie rod with a wrench 2 Temporarily tighten the four lock nuts 3 Check that the distances C and D are equal as shown If the distances are not equal adjust the tie rod to the right or left until the toe out is within specification Check the toe out again by measuring distances A and B 4 If the ...

Page 15: ...t Upper 26 N m 2 6 kgf m 19 0 lbf ft 2 EPS body assembly mounting nut Lower 28 N m 2 8 kgf m 20 0 lbf ft 3 Steering shaft bolt 26 N m 2 6 kgf m 19 0 lbf ft a 1 I931G3020001 01 b 2 I931G3020002 01 a 3 I931G3020003 01 4 Steering shaft upper nut 120 N m 12 0 kgf m 87 0 lbf ft 5 Tie rod lock nut 29 N m 2 9 kgf m 21 0 lbf ft 6 Rear stabilizer joint nut 60 N m 6 0 kgf m 43 5 lbf ft 7 Rear brake pedal sc...

Page 16: ...ue is described in the following Chassis Bolt and Nut Inspection LT A750XP ZK9 Page 0B 3 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List LT A750XP ZK9 in Section 0C Page 0C 7 Fastening part Tightening torque Note N m kgf m lbf ft Tie rod lock nut 29 2 9 21 0 Page 0B 2 ...

Page 17: ... 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX 46 1 1 81 Valve spring tension IN EX 182 210 N 18 6 21 4 kgf 41 0 47 2 lbs at length 36 35 mm 1 43 in Item Standard Limit Cam height IN 36 330 36 380 1 4303 1 4323 36 030 1 4185 EX 35 300 35 350 1 3898 1...

Page 18: ...0059 Piston ring groove width 1st 0 83 0 85 0 0327 0 0335 1 30 1 32 0 0512 0 0520 2nd 1 01 1 03 0 0398 0 0406 Oil 2 01 2 03 0 0791 0 0799 Piston ring thickness 1st 0 76 0 81 0 0299 0 0319 1 08 1 10 0 0425 0 0433 2nd 0 97 0 99 0 0382 0 0390 Piston pin bore I D 23 002 23 008 0 9056 0 9058 23 030 0 9067 Piston pin O D 22 992 23 000 0 9052 0 9055 22 980 0 9047 Item Standard Limit Conrod small end I D ...

Page 19: ...ar backlash 0 05 0 10 0 002 0 004 Rear drive final gear backlash Without gear cover specification 0 02 0 06 0 0008 0 0024 Gear cover assembled specification 0 08 0 15 0 0031 0 0059 Front differential gear oil type Hypoid gear oil SAE 90 API grade GL 5 Rear drive gear oil type Mobil 424 or equivalent gear oil Front differential gear oil capacity 500 ml 16 9 17 6 US lmp oz Final gear oil capacity 77...

Page 20: ...V TP sensor output voltage Closed Approx 1 1 V Opened Approx 4 3 V ECT sensor input voltage 4 5 5 5 V ECT sensor output voltage 0 15 4 85 V ECT sensor resistance Approx 2 45 kΩ at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sensor output voltage 0 15 4 85 V IAT sensor resistance Approx 1 60 kΩ at 20 C 68 F TO sensor resistance 19 20 kΩ TO sensor voltage Normal 0 4 1 4 V Leaning 3 7 4 4 V When...

Page 21: ...r min Regulated voltage 13 5 15 5 V at 5 000 r min Starter motor brush length Standard 12 0 0 47 Limit 6 5 0 26 Starter torque limiter slip torque Standard 41 2 62 8 N m 4 2 6 4 kgf m 14 5 32 5 lbf ft Starter relay resistance 3 5 Ω Battery Type designation YTX20CH BS Capacity 12 V 64 8 kC 18 Ah 10 HR Fuse size Headlight HI 10 A LO 10 A Power source 10 A Ignition 15 A Fuel 10 A Fan 15 A Main 30 A E...

Page 22: ...ding Front 35 kPa 0 35 kgf cm2 5 1 psi Rear 30 kPa 0 30 kgf cm2 4 4 psi Tire size Front AT25 x 8 12 tubeless Rear AT25 x 10 12 tubeless Tire tread depth Front 4 0 0 16 Rear 4 0 0 16 Item Standard Limit Front shock absorber spring adjustor 2 5 position Rear shock absorber spring adjustor 2 5 position Item Specification Note Fuel type Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or ...

Page 23: ...e driven face ring nut 110 11 0 79 5 V belt outer cover bolt 8 0 8 6 0 V belt inner cover bolt 9 0 9 6 5 Generator rotor nut 160 16 0 115 5 Generator stator set bolt 11 1 1 8 0 Speed sensor bolt 10 1 0 7 0 Starter clutch bolt 26 2 6 19 0 Exhaust pipe nut 23 2 3 16 5 Muffler connecting bolt 23 2 3 16 5 Muffler mounting bolt 23 2 3 16 5 Engine oil drain plug 21 2 1 15 0 Engine coolant drain plug 13 ...

Page 24: ...shaft boot clamp screw 2 0 2 1 5 Final gear oil drain plug 23 2 3 16 5 Rear propeller shaft coupling nut 100 10 0 72 5 Front output shaft bolt 10 1 0 7 0 Rear output shaft nut 100 10 0 72 5 Rear output shaft drive bevel gear nut 100 10 0 72 5 Rear output shaft driven gear nut 100 10 0 72 5 Front propeller shaft boot clamp screw 1 3 0 13 1 0 Rear propeller shaft boot clamp screw 2 0 2 1 5 Item N m ...

Page 25: ...t Front and Rear 60 6 0 43 5 Front brake hose union bolt 23 2 3 16 5 Front brake air bleeder valve 6 0 6 4 5 Front brake pad mounting pin 17 1 7 12 5 Front brake caliper mounting bolt 26 2 6 19 0 Caliper holder pin 18 1 8 13 0 Caliper holder slide pin 23 2 3 16 5 Brake pipe flare nut 16 1 6 11 5 Front brake disc mounting bolt 23 2 3 16 5 Brake master cylinder mounting bolt 10 1 0 7 0 Footrest moun...

Page 26: ...rked bolt N m kgf m lbf ft N m kgf m lbf ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32 5 85 8 5 61 5 14 65 6 5 47 0 135 13 5 97 5 16 105 10 5 76 0 210 21 0 152 0 18 160 16 0 115 5 240 24 0 173 5 3 2 1 a a a I649G1030001 04 1 Conventional bolt 2 4 marked bolt 3 7 marked bolt ...

Page 27: ...ion 1A DTC C40 P05057 ISC Valve Circuit Malfunction 1A DTC C41 P230 H L FP Relay Circuit Malfunction 1A Specifications 1A Service Data 1A Special Tools and Equipment 1A Special Tool 1A Emission Control Devices 1B Precautions 1B Precautions for Emission Control Devices 1B Repair Instructions 1B Crankcase Breather PCV Hose Inspection 1B Crankcase Breather PCV Hose Removal and Installation 1B Engine ...

Page 28: ...idth Between Crankshaft Webs 1D Crankshaft Oil Seal Inspection 1D Bearing Inspection 1D Bearing Removal and Installation 1D Specifications 1D Service Data 1D Tightening Torque Specifications 1D Special Tools and Equipment 1D Recommended Service Material 1D Special Tool 1D Engine Lubrication System 1E Precautions 1E Precautions for Engine Oil 1E Schematic and Routing Diagram 1E Engine Lubrication S...

Page 29: ...Poor Spark 1H Repair Instructions 1H Spark Plug Cap and Spark Plug Removal and Installation 1H Spark Plug Inspection and Cleaning 1H Ignition Coil and Plug Cap Inspection 1H CKP Sensor Inspection 1H CKP Sensor Removal and Installation 1H Engine Stop Switch Inspection 1H Ignition Switch Inspection 1H Ignition Switch Removal and Installation 1H Override Switch Inspection 1H Specifications 1H Service...

Page 30: ...J Regulated Voltage Inspection 1J Generator Inspection 1J Generator Removal and Installation 1J Regulator Rectifier Inspection 1J Battery Components 1J Battery Charging 1J Battery Removal and Installation 1J Battery Visual Inspection 1J Generator Removal and Installation LT A750XP ZK9 1J 1 Battery Removal and Installation LT A750XP ZK9 1J 2 Specifications 1J 3 Service Data 1J Tightening Torque Spe...

Page 31: ... 7 a b c d FWD FWD I931G3190012 03 1 O ring 6 Starter motor case 5 N m 0 5 kgf m 3 5 lbf ft 2 Housing end Inside 7 Housing end Outside Apply grease to sliding surface 3 O ring 6 N m 0 6 kgf m 4 5 lbf ft Apply moly paste to sliding surface 4 Armature 11 N m 1 1 kgf m 8 0 lbf ft Do not reuse 5 Square ring 10 N m 1 0 kgf m 7 0 lbf ft ...

Page 32: ...tery lead wire 2 and starter motor lead wire mounting nut 3 to the specified torque Refer to Wiring Harness Routing Diagram LT A750XP ZK9 in Section 9A Page 9A 4 Tightening torque Starter motor mounting bolt a 10 N m 1 0 kgf m 7 0 lbf ft Starter motor lead wire mounting nut b 6 N m 0 6 kgf m 4 5 lbf ft Starter Motor Disassembly and Assembly LT A750XP ZK9 B931G31906024 Refer to Starter Motor Remova...

Page 33: ...othness in the brush holder If either carbon brush is defective replace the brush holder set with a new one Measure the length a of the carbon brushes using a vernier calipers If the measurement is less than the service limit replace the housing end assembly with a new one Brush length a Service limit 6 5 mm 0 26 in Special tool 09900 20102 Vernier calipers 200 mm Commutator Inspect the commutator...

Page 34: ...ontinuity between the segments and shaft replace the armature with a new one Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity set Bearing Check the bearing of housing end for damage If any damage is found replace the housing end Oil Seal Check the seal lip for damage If any damage is found replace the housing end Inside A I931G3190009 02 I931G3190010 02 I931G31...

Page 35: ...T A750XP ZK9 Page 1I 1 Special Tool B931G31908002 Item Specification Note Starter motor brush length Standard 12 0 0 47 Limit 6 5 0 26 Starter torque limiter slip torque Standard 41 2 62 8 N m 4 2 6 4 kgf m 14 5 32 5 lbf ft Starter relay resistance 3 5 Ω Fastening part Tightening torque Note N m kgf m lbf ft Starter motor mounting bolt 10 1 0 7 0 Page 1I 2 Starter motor lead wire mounting nut 6 0 ...

Page 36: ...in related manual 7 Disconnect the gearshift lever arm 2 and speed sensor coupler 3 8 Remove the recoil cover 4 9 Disconnect the CKP sensor coupler 5 and generator coupler 6 and remove the clamp 7 10 Hold the left crankshaft spacer 8 with the special tool Special tool A 09930 44530 Rotor holder 11 Remove the left crankshaft spacer nut 9 and spacer 8 12 Remove the generator cover Refer to Generator...

Page 37: ... Disconnect the battery lead wire 3 NOTE Be sure to disconnect the battery lead wire 2 first then disconnect the battery lead wire 3 5 Remove the battery 4 Installation Install the battery in the reverse order of removal Pay attention to following point CAUTION Never use anything except the specified battery Tighten the battery mounting bolts securely NOTE Fit the EPS fuse bracket 2 to the mountin...

Page 38: ...d Equipment Recommended Service Material B931G31A08001 Special Tool B931G31A08002 Fastening part Tightening torque Note N m kgf m lbf ft Left crankshaft spacer nut 38 3 8 27 5 Page 1J 2 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1J 1 Thread lock cement THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 1...

Page 39: ... Oil Level Inspection 3B Front Drive Differential Gear Oil Replacement 3B Front Drive Differential Assembly Removal and Installation 3B Front Drive Differential Assembly Disassembly and Assembly 3B Front Drive Differential Related Parts Inspection 3B Breather Rubber Case Inspection 3B Front Drive Differential Gear Shim Inspection and Selection 3B 2WD 4WD Diff lock System Inspection 3B Rear Drive B...

Page 40: ...nstallation 3D Front Output Shaft Disassembly and Assembly 3D Front Output Shaft Related Parts Inspection 3D Rear Output Shaft Components 3D Rear Output Shaft Removal and Installation 3D Rear Output Shaft Disassembly and Assembly 3D Rear Output Shaft Related Parts Inspection 3D Rear Output Shaft Drive Bevel Gear Shim Inspection and Adjustment 3D Front Propeller Shaft Components 3D Front Propeller ...

Page 41: ...ve Shaft Components LT A750XP ZK9 B931G33106009 FWD FWD 1 2 3 7 6 5 4 8 9 10 I931H1310012 03 1 Circlip 6 Inner boot band Small Apply grease 2 Snap ring 7 Drive shaft Apply water resistance grease 3 Stopper ring 8 Outer boot band Small Do not reuse 4 Inner boot band Large 9 Outer boot 5 Inner boot 10 Outer boot band Large ...

Page 42: ...Remove the boot band of the differential side joint 2 Slide the boot toward the center of the front drive shaft and remove the stopper ring from the outer race 3 Remove the outer race from the front drive shaft 4 Wipe off any grease and remove the snap ring Special tool A 09900 06107 Snap ring remover Open type 5 Remove the cage from the front drive shaft 6 Remove the boot band of the small diamet...

Page 43: ...with a new one 2 Install the cage 1 on the shaft CAUTION Install the cage with the large diameter side A facing the shaft end 3 Install the new snap ring to the cage CAUTION Replace the snap ring with a new one Special tool A 09900 06107 Snap ring remover Open type 4 Apply grease to the entire surface of the cage and the inside of the outer race NOTE The tube of joint grease is included in the whe...

Page 44: ...e removed circlip must be replaced with a new one 9 Inspect the axle play by using a push and pull motion given to the axle shaft and wheel spindle Front Drive Shaft Inspection LT A750XP ZK9 B931G33106012 Inspect the front drive shaft in the following procedures 1 Remove the front drive shaft assembly Refer to Front Drive Shaft Assembly Removal and Installation in related manual 2 Check the drive ...

Page 45: ...r boot bond Rear Drive Shaft Inspection LT A750XP ZK9 B931G33106016 Refer to Rear Drive Shaft Assembly Removal and Installation in related manual Rear drive shaft inspection as the same manner of front drive shaft FWD FWD 1 4 5 6 8 9 2 7 3 10 I931H1310013 04 1 Circlip 6 Inner boot band Small Apply grease 2 Snap ring 7 Drive shaft Apply water resistance grease 3 Stopper ring 8 Outer boot band Small...

Page 46: ...vice Material B931G33108001 NOTE Required service material is also described in the following Front Drive Shaft Components LT A750XP ZK9 Page 3A 1 Rear Drive Shaft Components LT A750XP ZK9 Page 3A 5 Special Tool B931G33108002 09900 06107 Snap ring remover Open type Page 3A 2 Page 3A 3 ...

Page 47: ... ZK9 4A 2 Rear Brake Pedal Construction LT A750XP ZK9 4A 3 Rear Brake Pedal Removal and Installation LT A750XP ZK9 4A 3 Specifications 4A 5 Service Data 4A Tightening Torque Specifications 4A 5 Special Tools and Equipment 4A 5 Special Tool 4A Recommended Service Material 4A 5 Front Brakes 4B Precautions 4B Precautions for Front Brakes 4B Repair Instructions 4B Front Brake Components 4B Front Brake...

Page 48: ...king Rear Brake Cable Removal and Installation 4D Parking Rear Brake Lever Components 4D Parking Rear Brake Lever Removal and Installation 4D Parking Rear Brake Light Switch Inspection 4D Parking Rear Brake Relay Inspection 4D Specifications 4D Tightening Torque Specifications 4D Special Tools and Equipment 4D Recommended Service Material 4D ...

Page 49: ...se No 2 B After the brake hose union has contacted the reservoir bottom 5 Front brake caliper C Pass the brake hose behind the throttle cable 6 Frame D Fix the brake hose to the it guide firmly 7 Steering shaft E Pass the brake hose No 2 between the radiator lower hose and frame 8 Union bolt F Pass the brake hose inside of the suspension arm 9 Stopper After the brake hose union has contacted the s...

Page 50: ...diagram Refer to Front Brake Hose Routing Diagram LT A750XP ZK9 Page 4A 1 Installation CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage 1 Install the front brake hose as shown in the front brake hose routing diagram Refer to Front Brake Hose Routing Diagram in related manual 2 Tighten the brake flare nut 1 to the specified torque Tightening torque Brake pipe f...

Page 51: ...ection 9D in related manual 3 Remove the rear brake light switch spring 1 4 Disconnect the rear brake cable 2 Refer to Rear Brake Cable Removal and Installation in related manual a A b c B 3 a 5 4 2 4 1 B A b 6 I931G3410002 01 1 Rear brake pedal 6 Rear brake pedal screw B Anchoring point Pedal side 2 Rear brake light switch a 12 5 22 5 mm 0 49 0 89 in 60 N m 6 0 kgf m 43 5 lbf ft 3 Washer b 83 2 m...

Page 52: ...s 7 Installation Install the rear brake pedal in the reverse order of removal Pay attention to the following points Apply grease to the lip of dust seals and washers CAUTION Never reuse the removed dust seals with new ones Grease 99000 25160 Water resistance grease or equivalent Apply grease to the rear brake pedal shaft 1 Grease 99000 25160 Water resistance grease or equivalent 4 3 5 I931G3410010...

Page 53: ...Brake Hose Routing Diagram LT A750XP ZK9 Page 4A 1 Rear Brake Pedal Construction LT A750XP ZK9 Page 4A 3 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List LT A750XP ZK9 in Section 0C Page 0C 7 Special Tools and Equipment Recommended Service Material B931G34108003 NOTE Required service material is also described in the following Rear Brake...

Page 54: ...4A 6 Brake Control System and Diagnosis ...

Page 55: ... 1 Precautions in Diagnosing Troubles LT A750XP ZK9 6C 1 General Description 6C 2 P S System Description LT A750XP ZK9 6C 2 EPS Diagnosis General Description LT A750XP ZK9 6C 5 Self Diagnostic System Description LT A750XP ZK9 6C 5 Fail safe Function Description LT A750XP ZK9 6C 5 Schematic and Routing Diagram 6C 6 EPS Wiring Diagram LT A750XP ZK9 6C 6 EPS Control Unit Diagram LT A750XP ZK9 6C 7 EP...

Page 56: ...Control Unit Construction LT A750XP ZK9 6C 48 EPS Control Unit Removal and Installation LT A750XP ZK9 6C 48 EPS Body Assembly Components LT A750XP ZK9 6C 50 EPS Body Assembly Removal and Installation LT A750XP ZK9 6C 50 EPS Motor Inspection LT A750XP ZK9 6C 53 Specifications 6C 54 Tightening Torque Specifications 6C 54 Special Tools and Equipment 6C 54 Recommended Service Material 6C 54 Special To...

Page 57: ... 6 1 Steering Precautions Precautions Precautions for Steering LT A750XP ZK9 B931G36000002 Refer to General Precautions in Section 00 in related manual and Precautions for EPS LT A750XP ZK9 in Section 00 Page 00 1 ...

Page 58: ...Insufficiently lubricated Lubricate Not enough pressure in tires Adjust Worn or incorrect tire or wrong tire pressure Adjust or replace Malfunctioning EPS if equipped Inspect EPS system Wobbly Handlebars Distorted front steering shaft Replace Crooked tire Replace Worn or incorrect tire or wrong tire pressure Adjust or replace Worn bearing race in steering stem Replace Worn steering shaft holder bu...

Page 59: ...andlebar left switch assembly 2 Handlebar upper clamp 11 Steering arm plate 20 Handle grip 3 Handlebar holder 12 Cotter pin A Apply grip bond 4 Steering shaft plate 13 Tie rod 4 N m 0 4 kgf m 3 0 lbf ft 5 EPS body assembly 14 Tie rod end Apply thread lock to the thread part 6 Steering shaft 15 Cable guide Apply water resistance grease 7 Steering shaft bushing 16 Throttle cable Do not reuse 8 Dust ...

Page 60: ...N m 6 0 kgf m 43 5 lbf ft 2 Tie rod end nut 29 N m 2 9 kgf m 21 0 lbf ft 3 Steering shaft lower nut 162 N m 16 2 kgf m 117 0 lbf ft 4 Tie rod nut 120 N m 12 0 kgf m 87 0 lbf ft 5 Washer The conical side of washer faces outside 28 N m 2 8 kgf m 20 0 lbf ft 6 Steering shaft upper nut Apply thread lock to the thread part B Red mark Apply water resistance grease 26 N m 2 6 kgf m 19 0 lbf ft ...

Page 61: ...t the brake hose from the hose guide 5 Remove the following parts from the handlebars right side a Right grip 1 b Front brake master cylinder Front brake lever 2 CAUTION Do not turn the front brake master cylinder upside down c Throttle lever case 3 6 Remove the following parts from left handlebars left side a Left grip 4 b Left switch box 5 c Horn button For P 17 24 d Emergency switch For P 17 7 ...

Page 62: ...rque Rear brake lever holder clamp bolt a 11 N m 1 1 kgf m 8 0 lbf ft Install the washers 3 and bolts 4 as shown in the steering handlebars construction Refer to Steering Handlebars Assembly Construction LT A750XP ZK9 Page 6B 2 Set the handlebars so that its punch mark B aligns with the mating surface of the left handlebar holder Tighten the handlebar clamp bolts 4 to the specified torque NOTE Fir...

Page 63: ...t Brake Master Cylinder Assembly Removal and Installation in Section 4A in related manual Align the punch mark E on the handlebars with the mating surface F of the throttle lever case Tighten the throttle lever case bolts 7 to the specified torque Tightening torque Throttle lever case bolt c 4 N m 0 4 kgf m 3 0 lbf ft Handlebars Inspection LT A750XP ZK9 B931G36206011 Refer to Handlebars Inspection...

Page 64: ...WARNING When using the tie rod end remover keep clear of the tie rod end because it may come loose with some force and could strike you CAUTION Make sure that the vehicle is supported securely Special tool A 09942 72410 Tie rod end remover 4 Remove the cotter pin 1 nut 2 and washer 3 5 Remove the steering arm plate 4 and steering shaft 5 6 Remove the lower dust seal 6 and O ring 7 7 Remove the ste...

Page 65: ...ase 99000 25160 Water resistance grease or equivalent Apply grease to the steering shaft Grease 99000 25160 Water resistance grease or equivalent Install the steering shaft When installing the steering arm plate 5 align the wide spline A of steering shaft 6 with the wide spline B of steering arm plate 5 Apply a small quality thread lock to the thread part of steering shaft Thread lock cement 99000...

Page 66: ...heel Removal and Installation in Section 2D in related manual After installing these parts adjust the toe Refer to Toe Adjustment LT A750XP ZK9 in Section 0B Page 0B 2 Tie rod Tie rod End Removal and Installation LT A750XP ZK9 B931G36206013 WARNING When using the tie rod end remover keep clear of the tie rod end because it may come loose with some force and could strike you Removal 1 Remove the ti...

Page 67: ...ue Tightening torque Tie rod end nut b 29 N m 2 9 kgf m 21 0 lbf ft Install the cotter pins 4 CAUTION The removed cotter pins 4 must be replaced with new ones Install the tie rod ends steering knuckle side Refer to Front Wheel Hub Steering Knuckle Removal and Installation in Section 2B in related manual After installed wheels inspect the toe out If the toe out is out of specification bring it into...

Page 68: ...ion or bend If any defects are found replace the steering shaft with a new one Steering Shaft Bushing and Dust Seal Inspect the steering shaft bushing 1 dust seal 2 and lower dust seal 3 for wear or damage If any defects are found replace them with new ones Specifications Service Data LT A750XP ZK9 B931G36207003 Wheel I931G3620025 01 I931H1620034 01 3 2 1 I931H1620035 01 Item Standard Limit Steeri...

Page 69: ...ion LT A750XP ZK9 Page 6B 2 Special Tool B931G36208002 Fastening part Tightening torque Note N m kgf m lbf ft Rear brake lever holder clamp bolt 11 1 1 8 0 Page 6B 4 Handlebar clamp bolt 26 2 6 19 0 Page 6B 4 Throttle lever case bolt 4 0 4 3 0 Page 6B 5 Steering shaft lower nut 162 16 2 117 0 Page 6B 7 Tie rod lock nut 29 2 9 21 0 Page 6B 9 Tie rod end nut 29 2 9 21 0 Page 6B 9 Material SUZUKI rec...

Page 70: ...se a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of these parts Precautions in Diagnosing Troubles LT A750XP ZK9 B931G36300003 Take a note of DTC indicated on the SDS tool or EPS indicator light Before inspection be sure to read Precautions for Electrical Circuit Service in Section 00 in related manual...

Page 71: ... the vehicle speed signal from speed sensor 9 The EPS control unit runs the motor so as to assist the operation of the handlebars 1 Take a note of DTC indicated on the EPS indicator light The EPS diagnoses troubles which may occur in the area including the following components when the ignition switch is ON and the engine is running When the EPS control unit detects any malfunction it stops the mo...

Page 72: ... wheel each torque sensor main and sub output is 2 5 V and in this state the EPS control unit determines the steering torque as 0 During operating the handlebars the EPS control unit processes the main torque sensor input signal to determine the steering torque required for the current condition The relation between the steering direction of the EPS control unit and the output voltage is as follow...

Page 73: ... the speed sensor This is the fundamental control necessary for the P S system Convergence control This control prevents convergence from deteriorating at a high speed by making current compensating current flow in the direction to keep the steering from turning thereby improving vehicle maneuvering stability Maximum current control If the steering input is sustained at a standstill the motor cont...

Page 74: ...ss of the condition of the P S control system This is only to check if the EPS warning light is operated properly If the areas monitored by the EPS control unit is free from any trouble after the engine start while engine is running the EPS warning light turns OFF When the EPS control unit detects a trouble which has occurred in the monitored areas the EPS warning light comes ON while the engine i...

Page 75: ...RCE 10 A 10 A 10 A 15 A 15 A 10 A STARTER MOTOR STARTER RELAY 1 MAIN 30 A BATTERY SPEEDOMETER ECM EPS UNIT EPS MOTOR TORQUE SENSOR O O O Y O Y O R R R O Y O O O Bl B Bl B Bl B Y Y Gr R Gr R W R W R W R W R Gr R Gr R B W B W Bl B Bl B Bl B Gr R W R W R Gr R B W B W B W B W B W B W B W Bl B Bl B Bl B Y Y Gr R Gr R Gr R W R W R W R R B R B R B B W B W O Y O Y O Y B W B W B W R R R R W W W W R B R B R...

Page 76: ...rcuit EPS countrol unit SDS Mode selsct switch Torque sensor 4 5 1 31 6 3 7 9 10 8 2 12 11 14 13 Y W Bl B R G W B O Y R B B R B W Gr R W R I931G3630071 01 10 9 8 7 1 2 3 4 5 6 11 12 13 14 I931H1630092 01 1 Engine speed signal 8 Power source 2 Ignition signal for EPS control unit 9 Motor output 3 Mode select switch 10 Motor output 4 EPS warning light 11 Torque sensor signal Main 5 Vehicle speed sig...

Page 77: ...ram LT A750XP ZK9 B931G36302003 Refer to Wiring Harness Routing Diagram LT A750XP ZK9 in Section 9A Page 9A 4 Component Location EPS Components Location LT A750XP ZK9 B931G36303001 1 2 3 4 I931G3630002 02 1 EPS control unit 3 Fuse EPS 2 EPS body assembly 4 Mode select coupler ...

Page 78: ...efer to EPS System Check LT A750XP ZK9 Page 6C 12 4 Output the DTCs stored in the EPS control unit Refer to DTC Diagnostic Trouble Code Output LT A750XP ZK9 Page 6C 19 5 Perform appropriate troubleshooting procedures according to the DTCs output Refer to DTC Table LT A750XP ZK9 Page 6C 25 If troubleshooting procedures cannot be performed try to determine the cause of the malfunction according to t...

Page 79: ...steering system should be inspected prior to performing any electrical checks These inspections may find problems that the EPS could not detect thus shortening repair time Tire Tire type Tire type Front DUNLOP KT411 Rear DUNLOP KT415 Tire pressure Refer to Tire Inspection in Section 0B in related manual CAUTION The standard tire fitted on this vehicle is AT25 x 8 12 for front and AT25 x 10 12 for ...

Page 80: ... circuit tester set Tester knob indication Voltage Battery voltage 12 0 V and more 4 Reinstall the seat EPS control unit ground wire inspection 1 Turn the ignition switch OFF 2 Remove the seat Refer to Seat Removal and Installation in Section 9D in related manual 3 Disconnect the battery lead wire 4 Remove the front fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D i...

Page 81: ...warning lamp when turning the ignition switch ON 2 If OK start engine run it idle and check EPS warning lamp remains ON continuously Is EPS warning lamp remains ON continuously Go to Step 3 Go to Step 4 DTC output Refer to DTC Diagnostic Trouble Code Output LT A750XP ZK9 Page 6C 19 3 The EPS indicator light lights up 1 Start the engine Does the EPS indicator light go off Normal No DTC exists DTC o...

Page 82: ...isconnected measure the voltage between terminal A and terminal B at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value A B Battery voltage 12 0 V and more EPS control unit coupler Vehicle harness end Is the voltage between A and B normal Go to Step 5 Inspect the wire harness Faulty ignition or ground wire Step Action Yes No 1 2 I931G3630008...

Page 83: ... the voltage between A and B normal Go to Step 6 Inspect the wire harness Faulty indicator light wire Indicator light is blown 6 1 Turn the ignition switch OFF 2 Check for continuity between terminal A at the coupler and body ground Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity EPS control unit coupler Vehicle harness end Are there continuity between A and b...

Page 84: ...emoval and Installation in Section 9D in related manual 2 Open the fuse box and inspect the ignition fuse 1 CAUTION If a fuse is blown find the cause of the problem and correct it before replacing the fuse EPS fuse 40 A Is the ignition fuse OK Go to Step 8 Replace the EPS fuse Step Action Yes No 1 I931H1630016 01 ...

Page 85: ...he voltage between terminal A and terminal B at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value A B Battery voltage 12 0 V and more EPS control unit coupler Vehicle harness end Is the voltage between A and B normal Go to Step 9 Inspect the wire harness Faulty ignition or ground wire Step Action Yes No 1 2 I931G3630008 01 A A ޓ B A I931G36...

Page 86: ...rminal A and terminal B at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value A B 1 0 V and more EPS control unit coupler Vehicle harness end Is the voltage between A and B normal Go to Step 10 Inspect the wire harness Faulty indicator light wire Step Action Yes No A A ޓ B A I931G3630012 01 ...

Page 87: ...Check for continuity between terminal A and terminal B at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity EPS control unit coupler Vehicle harness end Is there continuity between A and B Replace the EPS control unit Inspect the wire harness Faulty mode select switch wire Step Action Yes No A A I931G3630013 01 A A ޓ B A I931G3630014 01 ...

Page 88: ...OFF 2 Remove the seat Refer to Seat Removal and Installation in Section 9D in related manual 3 Connect the special tool to the mode select coupler 1 Special tool A 09930 82710 Mode select switch 4 Switch the special tool to ON 5 Turn the ignition switch ON The EPS indicator light starts flashing to indicate the DTC Refer to DTC Table LT A750XP ZK9 Page 6C 25 NOTE If there is a DTC the EPS indicato...

Page 89: ...gine or main fuse before confirming the malfunction code self diagnostic trouble code stored in memory Such disconnection may erase the memorized information in EPS control unit memory DTC stored in EPS control unit memory can be checked by the SDS 1 Remove the seat Refer to Seat Removal and Installation in Section 9D in related manual 2 Set up the SDS tool Refer to the SDS operation manual for fu...

Page 90: ...manual for further details When DTC is checked DTC C1122 is displayed with ignition switch turned ON However if the engine is started and the display disappears it is not a trouble 4 Close the SDS tool and turn the ignition switch OFF DTC Diagnostic Trouble Code Deleting LT A750XP ZK9 B931G36304005 Use of Mode Select Switch 1 Remove the seat Refer to Seat Removal and Installation in Section 9D in ...

Page 91: ...EPS activates correctly 7 Disconnect the mode select switch and reinstall the seat Use of SDS 1 Remove the seat Refer to Seat Removal and Installation in Section 9D in related manual 2 After repairing the trouble turn OFF the ignition switch 3 Set up the SDS tool Refer to the SDS operation manual for further details Special tool 09904 41010 SUZUKI Diagnostic system set 99565 01010 020 CD ROM Ver 2...

Page 92: ...PS control unit also when the wire coupler of any sensor is disconnected Therefore when a wire coupler has been disconnected at the time of diagnosis erase the stored malfunction history code using SDS 9 Follow the displayed instructions 10 Check that both Current DTC 4 and Past DTC 5 are deleted NIL 11 Close the SDS tool and turn the ignition switch OFF 12 Disconnect the SDS tool and install the ...

Page 93: ...re taking the sample of data check and clear the Past DTC Refer to DTC Diagnostic Trouble Code Deleting LT A750XP ZK9 Page 6C 21 A number of different data under a fixed condition as shown should be saved or filed as sample Special tool 09904 41010 SUZUKI Diagnostic system set 99565 01010 020 CD ROM Ver 20 DATA sampled from EPS system Handlebars is Handlebars is center position center position Che...

Page 94: ...21 Vehicle speed signal not input OFF Refer to DTC C1121 Vehicle Speed Signal Circuit Malfunction LT A750XP ZK9 Page 6C 38 C1122 Engine speed signal circuit failure 1 ON Refer to DTC C1122 Engine Speed Signal Circuit Malfunction LT A750XP ZK9 Page 6C 41 C1141 EPS motor circuit voltage abnormal ON Refer to DTC C1141 C1142 C1143 C1145 EPS Motor Circuit Malfunction LT A750XP ZK9 Page 6C 44 C1142 EPS ...

Page 95: ...accident and damage NOTE After repairing the trouble clear the DTC using a SDS tool or mode coupler switch Refer to DTC Diagnostic Trouble Code Deleting LT A750XP ZK9 Page 6C 21 DTC C1111 and C1113 are indicated at the same time due to the malfunction of the same torque sensor circuit Possible Cause Faulty torque sensor signal circuit Faulty torque sensor Faulty EPS control unit ...

Page 96: ...and ground If OK then measure the voltage at the R wire A and B wire B Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Torque sensor input voltage 5 0 V Is voltage OK Go to Step 2 Loose or poor contacts on the torque sensor Power supply circuit R wire or ground circuit B wire open If check result is not satisfactory replace the EPS control unit with a new one Ref...

Page 97: ...b indication Voltage Torque sensor main voltage Handlebars is left turn Approx 3 0 V Handlebars is right turn Approx 2 0 V Is voltage OK Replace the EPS control unit with a known good one and inspect it again Refer to EPS Control Unit Removal and Installation LT A750XP ZK9 Page 6C 48 R wire terminal or G wire terminal circuit open torque sensor side If check result is not satisfactory replace the ...

Page 98: ...prevent accident and damage NOTE After repairing the trouble clear the DTC using a SDS tool or mode coupler switch Refer to DTC Diagnostic Trouble Code Deleting LT A750XP ZK9 Page 6C 21 DTC C1113 and C1115 are indicated at the same time due to the malfunction of the same torque sensor circuit Possible Cause Faulty torque sensor signal circuit Faulty torque sensor Faulty EPS control unit ...

Page 99: ... at the R wire A and B wire B Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Torque sensor input voltage 5 0 V Go to Step 2 Loose or poor contacts on the torque sensor Power supply circuit R wire open Power source or power supply circuit shorted to torque sensor main or sub circuit Torque sensor main or sub circuit open If check result is not satisfactory replac...

Page 100: ...nob indication Voltage Measuring voltage 0 V Is voltage OK Go to Step 2 Loose or poor contacts on the torque sensor Power supply circuit R wire open Power source or power supply circuit shorted to torque sensor main or sub circuit Torque sensor main or sub circuit open If check result is not satisfactory replace the EPS control unit with a new one Refer to EPS Control Unit Removal and Installation...

Page 101: ...bars left turn Main Approx 3 0 V Handlebars left turn Sub Approx 2 0 V Handlebars right turn Main Approx 2 0 V Handlebars right turn Sub Approx 3 0 V Is voltage OK G W and B wire open or shorted to ground or poor torque sensor coupler connection If wire and connection are OK intermittent trouble or faulty EPS control unit Replace the EPS control unit with a known good one and inspect it again Refe...

Page 102: ...hooting CAUTION Never remove the torque sensor to prevent accident and damage NOTE After repairing the trouble clear the DTC using a SDS tool or mode coupler switch Refer to DTC Diagnostic Trouble Code Deleting LT A750XP ZK9 Page 6C 21 Possible Cause Faulty torque sensor signal circuit Faulty torque sensor Faulty EPS control unit ...

Page 103: ...cial tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Torque sensor input voltage 5 0 V Is voltage OK If wire and connection are OK intermittent trouble or faulty EPS body assembly Replace the EPS body assembly with a known good one and inspect it again Refer to EPS Body Assembly Removal and Installation LT A750XP ZK9 Page 6C 50 Power supply circuit R wire shorted to grou...

Page 104: ...ing CAUTION Never remove the torque sensor to prevent accident and damage NOTE After repairing the trouble clear the DTC using a SDS tool or mode coupler switch Refer to DTC Diagnostic Trouble Code Deleting LT A750XP ZK9 Page 6C 21 Possible Cause Faulty torque sensor signal circuit Faulty torque sensor Faulty EPS control unit ...

Page 105: ...asure the input voltage between R wire A and B wire B Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle point probe set Tester knob indication Voltage Torque sensor input voltage 5 0 V Is voltage OK Go to step 2 Loose or poor contacts on the torque sensor Power supply circuit R wire or ground circuit B wire open If check result is not satisfactory replace the EPS control uni...

Page 106: ...dication Voltage Torque sensor Sub voltage Handlebars is left turn Approx 2 0 V Handlebars is right turn Approx 3 0 V Is voltage OK Replace the EPS control unit with a known good one and inspect it again Refer to EPS Control Unit Removal and Installation LT A750XP ZK9 Page 6C 48 R wire terminal or W wire terminal circuit open torque sensor side If check result is not satisfactory replace the torqu...

Page 107: ... coupler switch Refer to DTC Diagnostic Trouble Code Deleting LT A750XP ZK9 Page 6C 21 Possible Cause Faulty vehicle speed signal circuit Faulty speed sensor Faulty EPS control unit Step Action Yes No 1 1 Turn the ignition switch OFF 2 Check the EPS control unit connector for loose or poor contact If OK then check the vehicle speed signal lead wire continuity Go to step 2 Bl B wire open I931G36300...

Page 108: ...ection 9C in related manual 4 Check the continuity between the Bl B wire of EPS control unit coupler B and Bl B wire of speed sensor C Also check the continuity between the Bl B wire of EPS control unit coupler B and Bl B wire of combination meter A Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle point probe set Tester knob indication Continuity Is continuity OK Go to step...

Page 109: ...tep 3 Bl B wire shorted to ground 3 1 Remove the engine side cover Refer to Rear Side Exterior Parts Removal and Installation in Section 9D in related manual 2 Inspect the speed sensor Refer to Speed Sensor Inspection in Section 9C in related manual Is speed sensor OK Replace the EPS control unit Refer to EPS Control Unit Removal and Installation LT A750XP ZK9 Page 6C 48 Replace the speed sensor R...

Page 110: ... Diagnosing Troubles LT A750XP ZK9 Page 6C 1 Possible Cause Faulty engine speed signal circuit Faulty ECM Faulty EPS control unit Step Action Yes No 1 1 Setup the SDS tool Refer to the SDS operation manual for further details or connect the mode select switch 2 Click Engine and check the DTC code Is not DTC C12 P0335 displayed Go to step 2 Inspect the CKP sensor Refer to DTC C12 P0335 CKP Sensor C...

Page 111: ...signal lead wire continuity 3 Disconnect the EPS control unit coupler and ECM coupler 4 Check the continuity between the W wire A and terminal 31 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle point probe set Tester knob indication Continuity Is continuity OK Go to step 3 W wire open Step Action Yes No I931G3630031 01 B A 31 B I931H1630052 02 ...

Page 112: ... tester set Tester knob indication Voltage Engine speed signal voltage It changes between 0 12 V Is voltage OK Replace the EPS control unit with a new one Refer to EPS Control Unit Removal and Installation LT A750XP ZK9 Page 6C 48 Replace the ECM with a new one Refer to EPS Control Unit Removal and Installation LT A750XP ZK9 Page 6C 48 Step Action Yes No A A I931G3630035 01 ...

Page 113: ...ler for loose or poor contact If OK measure the EPS motor voltage 3 Insert the needle point probes to lead wire coupler 4 Start the engine and turn the handlebars left turn 5 Measure the voltage between R wire A and B wire B Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle point probe set Tester knob indication Voltage EPS motor voltage Approx 7 0 V Is voltage OK Go to step...

Page 114: ...Inspection LT A750XP ZK9 Page 6C 53 Is continuity OK Replace the EPS control unit with a known good one and inspect it again Refer to EPS Control Unit Removal and Installation LT A750XP ZK9 Page 6C 48 Replace the EPS motor EPS body assembly with a new one Refer to EPS Body Assembly Removal and Installation LT A750XP ZK9 Page 6C 50 Step Action Yes No I931G3630038 01 ...

Page 115: ...ti circuit tester Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Battery voltage 12 0 V and more Is the voltage over 12 V Go to Step 2 Charge or replace the battery 2 1 Start the engine at 5 000 r min with the dimmer switch set to HI 2 Measure the voltage between the and battery terminals Special tool 09900 25008 Multi circuit tester set Tester knob indication V...

Page 116: ... control unit coupler 3 Start the engine at 5 000 r min with the dimmer switch set to HI 4 Measure the voltage between terminal A and terminal B at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage same as Step 2 Replace the EPS control unit Inspect the wire harness Faulty ignition or ground wire Step Action Yes No A B A A ޓ I931G3630040 ...

Page 117: ...tallation LT A750XP ZK9 in Section 1J Page 1J 2 2 Remove the front fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D in related manual 3 Disconnect the EPS control unit couplers 1 2 3 3 B 4 A a FWD FWD I931H1630056 02 1 EPS control unit 4 Torque sensor coupler 2 EPS control unit plate 12 N m 1 2 kgf m 8 5 lbf ft 3 Cushion B Install the clip of the torque sensor coupl...

Page 118: ...PS control unit 6 from the EPS control unit plate 7 as shown in the EPS control unit construction Refer to EPS Control Unit Construction LT A750XP ZK9 Page 6C 48 Installation Install the EPS control unit in the reverse order of removal Pay attention to the following points Tighten the EPS control unit mounting nut 1 to the specified torque Tightening torque EPS control unit mounting nut a 12 N m 1...

Page 119: ...2 Removal 1 Remove the handlebars Refer to Handlebars Removal and Installation LT A750XP ZK9 in Section 6B Page 6B 3 2 Remove the combination meter Refer to Combination Meter Removal and Installation in Section 9C in related manual 3 Remove the front fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D in related manual 4 Remove the auxiliary headlight 1 Refer to Auxili...

Page 120: ...tion Refer to Steering Handlebars Assembly Construction LT A750XP ZK9 in Section 6B Page 6B 2 Install the EPS body assembly in the reverse order of removal Pay attention to the following points Apply grease to the spline of the EPS body assembly Grease 99000 25160 Water resistance grease or equivalent When installing the EPS body assembly align the marking A of the EPS output shaft and slide B of ...

Page 121: ...equivalent Tightening torque Steering shaft bolt c 26 N m 2 6 kgf m 19 0 lbf ft Install the front brake hose union 5 and throttle cable 6 to the cable guide Apply grease to the spline of the EPS body assembly Grease 99000 25160 Water resistance grease or equivalent Install the steering shaft plate 7 and tighten the steering shaft upper nut to the specified torque CAUTION Never use an impact wrench...

Page 122: ...n LT A750XP ZK9 B931G36306005 1 Disconnect the EPS motor coupler 2 First check for insulation with the tester between terminals A and B If continuity does not exist replace the EPS body assembly with a new one Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity 3 Next check for insulation with the tester between terminal A and body ground C and terminal B and body...

Page 123: ...vice Material B931G36308001 Fastening part Tightening torque Note N m kgf m lbf ft EPS control unit mounting nut 12 1 2 8 5 Page 6C 49 EPS body assembly mounting bolt 26 2 6 19 0 Page 6C 52 EPS body assembly mounting nut 28 2 8 20 0 Page 6C 52 Steering shaft bolt 26 2 6 19 0 Page 6C 52 Steering shaft upper nut 120 12 0 87 0 Page 6C 52 Handlebar holder nut 60 6 0 43 5 Page 6C 53 Material SUZUKI rec...

Page 124: ...C 37 Page 6C 39 Page 6C 40 Page 6C 42 Page 6C 43 Page 6C 44 Page 6C 46 Page 6C 46 Page 6C 47 Page 6C 53 Page 6C 53 Page 6C 28 Page 6C 32 Page 6C 36 Page 6C 37 Page 6C 39 Page 6C 42 Page 6C 44 09904 41010 09930 82710 SUZUKI Diagnostic system set Mode select switch Page 6C 20 Page 6C 22 Page 6C 24 Page 6C 18 Page 6C 19 09930 82720 09942 83110 Mode selection switch Clip remover Page 6C 21 Page 6C 49 ...

Page 125: ...bination Meter Components 9C Combination Meter Removal and Installation 9C Combination Meter Disassembly and Assembly 9C Combination Meter Inspection 9C Engine Coolant Temperature Indicator Light Inspection 9C Engine Coolant Temperature Removal and Installation 9C Fuel Level Indicator Inspection 9C Fuel Level Gauge Inspection 9C Speedometer Inspection 9C Speed Sensor Removal and Installation 9C Sp...

Page 126: ...ront Grip Bar Construction 9E Front Grip Bar Removal and Installation 9E Trailer Towing Construction 9E Trailer Towing Removal and Instruction 9E Body Frame Construction LT A750XP ZK9 9E 1 Specifications 9E Tightening Torque Specifications 9E Special Tools and Equipment 9E 1 Recommended Service Material 9E 1 ...

Page 127: ...Wiring Systems 9A 1 Body and Accessories Wiring Systems Schematic and Routing Diagram Wiring Diagram LT A750XP ZK9 B931G39102003 Refer to Wire Color Symbols in Section 0A in related manual ...

Page 128: ...W B W R Br W Br W B Br B Br R B R B Bl B Bl B B W B W Y R Y R B W B W B W R Br W B Br R B Bl B B W Y B Y B Y B B B Y R B W O Y O Y W B W B O Y O Y W B W B B W B W B W B W W B W B W B W B B W B W W B O Y O Y O B O B O B B Y B W B W O Y O Y Bl Bl Bl R Bl R B B W Bl R Y Bl O Y O W B W B B B W B B B O Y Bl Y Bl O W O W O W R B R B W B W B Gr W Gr W O W O W R B R B B R B R R B W B W W Y W Y Bl G Bl G B...

Page 129: ...R Y R B W B W B W R Br W B Br R B Bl B B W Y B Y B Y B B B Y R B W O Y O Y W B W B O Y O Y W B W B B W B W B W B W W B W B W B W B B W B W W B O Y O Y O B O B O B B Y B W B W O Y O Y Bl Bl Bl R Bl R B B W Bl R Y Bl O Y O W B W B B B W B B B O Y Bl Y Bl O W O W O W R B R B W B W B Gr W Gr W O W O W R B R B B R B R R B W B W W Y W Y Bl G Bl G Br W Br W B Bl B Bl B G B G B Y R G R G G B Lg B Lg B Y B...

Page 130: ...ess and cooling fan lead wire over the radiator hose 3 Clamp Bind the wiring harness and cooling fan thermo switch with the clamp C To power source 4 Clamp Bind the wiring harness and back up relay For P 17 with the clamp D Pass the wiring harness under of the throttle cable 5 Clamp Bind the EPS motor lead wire and EPS control unit lead wires a 60 80 mm 2 4 3 2 in 6 EPS control unit b 20 30 mm 0 8...

Page 131: ... the clamp 18 Horn For P 17 24 6 Clamp Bind the diff lock actuator lead wire and rear brake switch lead wire with the clamp 19 IAP sensor 7 Clamp Bind the rear brake switch lead wire with the clamp B To rear fender top 8 Clamp Bind the wiring harness generator lead wire and gear position switch lead wire C Slack the read wire 9 Speed sensor lead wire D Pass the horn lead wire inside of the stay 10...

Page 132: ...emergency switch lead wire For P 17 with the clamp Cut the tip of clamp after clamping 11 Fuse box 3 Clamp Bind the front brake switch lead wire and 2WD 4WD diff lock switch lead wire with the clamp Cut the tip of clamp after clamping 12 Fuse EPS 4 Clamp Bind the combination meter lead wire 2WD 4WD diff lock lead wire and front brake switch lead wire with the clamp 13 Combination meter lead wire 5...

Page 133: ... following Wiring Harness Routing Diagram LT A750XP ZK9 Page 9A 4 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List LT A750XP ZK9 in Section 0C Page 0C 7 1 2 3 a 4 5 6 6 I931G3910904 01 1 Starter motor 3 Generator stator 5 Grommet a 90 2 Gear position switch 4 Ground wire 6 Clamp ...

Page 134: ...9 B931G39506011 Special Tools and Equipment Recommended Service Material B931G39508001 NOTE Required service material is also described in the following Body Frame Construction LT A750XP ZK9 Page 9E 1 FWD FWD 3 2 4 4 1 I931G3950001 04 1 Frame 3 Washer Apply thread lock to the thread part 2 Battery plate 4 Spacer ...

Page 135: ...Prepared by March 2009 Part No 99501 47050 01E Printed in Japan 132 ...

Page 136: ...Printed in Japan K9 ...

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