Suzuki Katana 1100 Bedienungsanleitung

SUZUKI

SERVICE

MANUAL

99500-39080-03E

(5€)

L _

.\ULLKI

.HOIOR

co,

LTD

I'RI.\TED

1.\

J'I!',I.\

O(/OREN.

'ti 7

FOREWORD

The

SUZUKI

GSX

OOF

has

been

developed

new

generation

motorcycle

the

GS-models.

packed

with

highly

advanced

design

concepts

including

Suzuki

Power

Shield,

Suzuki

Ad-

vanced

Cooling

System,

new

highly

efficient

combustion

system

(TSCCl

fully

transistorized

ignition

system

and

improved

full-floater

rear

suspension.

Combined

with

precise

control

and

easy

handling

the

GSX

100F

provides

excellent

performance

and

outstanding

riding

comfort.

This

service

manual

has

been

produced

primarily

for

experienced

mechanics

whose

job

in-

spect,

adjust,

repair

and

service

SUZUKI

motorcy-

cles.

Apprentice

mechanics

and

do-it-yourself

me-

chanics,

will

also

find

this

manual

extremely

useful

repair

guide.

This

manual

contains

the

most

up-to-date

information

the

time

publication.

The

rights

are

reserved

update

make

correc-

tions

this

manual

any

time.

IMPORTANT

All

street-legal

Suzuki

motorcycles

with

engine

displacement

50cc

greater

are

subject

Environmental

Protection

Agency

emission

regula-

tions.

These

regulations

set

specific

standards

for

exhaust

emission

output

levels

well

particu-

lar

servicing

requirements.

This

manual

includes

specific

information

required

properly

inspect

and

service

the

GSX

1 1OOF

accordance

with

all

EPA

regulations.

strongly

recommended

that

the

chapter

Emission

Control,

Periodic

Servic-

ing

and

Carburetion

thoroughly

reviewed

be-

fore

any

type

service

work

performed.

Further

information

concerning

the

EPA

emission

regulations

and

Us.

Suzuki's

emission

control

program

can

found

the

Us.

SUZUKI

EMIS-

SION

CONTROL

PROGRAM

MANUAL/SERVICE

BULLETIN.

SUZUKI

MOTOR

CO.,

LTD.

Technical

Department

Motorcycle

Service

Division

SUZUKI

MOTOR CO., LTD.

1987

GROUP

INDEX

===-

GENERAL INFORMATION

fERIODIC

MAINTENANCE

AND

--..

TUNE-UP PROCEDURES

ENGINE

IFUEL

AND

LUBRICATION

SYSTEM

17MISSION CONTROL

INFORMATION

I ELECTRICAL SYSTEM a

[CHASSIS

SERVICING INFORMATION

L_lfJ

GENERAL

INFORMATION

VIEW

GSX1100F

:~~.~~~~~

~====~---:l

SERIAL NUMBER LOCATION.

1 I

FUEL

AND

OIL RECOMMENDA

TlON

1 I

BREAK-IN PROCEDURES 1- 2 I

CYLINDER IDENTIFICA

TlON

SPECIAL

TERIALS 1- 3

PRECAUTIONS

AND

GENERAL INSTRUCTIONS

SPECIFICA TIONS

___

------l

1-1

GENERAL

INFORMATION

VIEW

GSX1100F

RIGHT SIDE LEFT SIDE

SERIAL

NUMBER

LOCATION

The

frame

serial

number

or.V.I.N.

(Vehicle

Identification

Num-

ber)

stamped

the

steering

head

pipe.

The

engine

serial

number

(2)

located

the

right

side

the

crankcase.

These

numbers

are

required

especially

for

registering

the

machine

and

ordering

spare

parts.

FUEL

AND

OIL

RECOMMENDATION

FUEL

Use

only

unleaded

low-lead

type

gasoline

least

85-95

pump

octane

method

octane

higher

rated

the

Research

Method.

ENGINE

OIL

SUZUKI

recommends

the

use

SUZUKI

PERFORMANCE

MOTOR

OIL

oil

which

rated

under

the

API

(American

Petroleum

Institute)

classification

system.

The

vis-

cosity

rating

is SAE

10W/40.

an SAE

10W/40

motor

oil

not

available,

select

alternate

according

the

following

chart.

, I

MULTIGRADE

• I I

-22

-4

lOW-3D

104

TEMP.

°C

....

.......

~_J

GENERAL

INFORMATION

1-2

BRAKE

AND

CLUTCH

FLUID

Specification

and

classification:

DOT4

WARNING:

•

Since

the

brake

system

this

motorcycle

filled

with

glycol-based

brake

fluid

the

manufacturer,

not

use

mix

different

types

fluid

such

silicone-based

and

petroleum-based

fluid

for

refilling

the

system,

otherwise

serious

damage

will

result.

•

not

use

any

brake

fluid

taken

from

old

used

unsealed

containers.

•

Never

re-use

brake

fulid

left

over

from

the

servicing

and

stored

for

long

period.

FRONT

FORK

OIL

Use

fork

oil

# 1

BREAK-IN

PROCEDURES

During

manufacture

only

the

best

possible

materials

are

used

and

all

machined

parts

are

finished

very

high

standard

but

still

necessary

allow

the

moving

parts

"BREAK-IN"

before

subjecting

the

engine

maximum

stresses.

The

future

performance

and

reliability

the

engine

depends

the

care

and

restraint

exercise

during

its

early

life.

The

general

rules

are

follows.

•

Keep

these

break-in

engine

speed

limits:.

Intial

800

(500

miles):

Below

4000

r/min

1600

(1000

miles):

Below

6000

r/min

Over

1600

OOOmiles):

Below

11300

r/min

•

Upon

reaching

odometer

reading

1600

(1000

miles)

you

can

subject

the

motorcycle

full

throttle

operation.

However,

not

exceed

11300

r/min

any

time.

CYLINDER

IDENTIFICATION

The

four

cylinders

this

engine

are

identified

No.1,

No.2,

NO.3

and

No.4

cylinder,

counted

from

left

right.

(as

viewed

the

rider

the

seat)

1-3

GENERAL

INFORMATION

SPECIAL

MATERIALS

The

materials

listed

below

are

needed

for

maintenance

work

the

GSX

OOF,

and

should

kept

hand

for

ready

use.

They

supplement

such

standard

materials

cleaning

fluids,

lubricants,

emery

cloth

and

the

like.

How

use

them

and

where

use

them

are

described

the

text

this

manual.

MATERIAL

PART

PAGE

PART

PAGE

3-45

•

Driveshaft

oil

seal •

Sprocket

mounting

drum

7-35

3-56

bearing

•

Generator

a-ring

3-56

7-46

•

Starter

motor

a-ring

•

Swingarm

bearing

and

dust

3-59

seal

•

Engine

oil

pipe

a-ring

6-6

7-46

•

Cushion

lever/rod

bearing,

•

Generator

oil

seal

6-14

and

dust

seal

•

Starter

motor

oil

seal

7-8

7-47

7-34

SUZUKI

SUPER GREASE

"A"

•

Wheel

bearing

•

Shock

absorber

dust

seal

7-25

99000-25030

•

Steering

stem

bearing

3-26

•

Valve

stem

3-35

•

Conrod

big

end

bearing

3-44

•

Countershaft

and

driveshaft

3-50

•

Crankshaft

journal

3-60

•

Camshaft

journal

6-13

•

Starter

motor

armature

end

6-5

•

Generator

damper

7-49

SUZUKI

MOLY

PASTE

99000-25140

•

Clutch

lever

push

rod

1--------------.-----+--------------f----+--------------f-----1

3-50

•

Crankcase

mating

surface

•

Signal

generator

cover

mat-

3-64

3-54

•

Clutch

cover

mating

surface

ing

surface

3-54

• Oil

pressure

switch

3-54

grommet

•

Signal

generator

lead

wire

•

Starter

clutch

cover

mating

3-56

surface

3-64

SUZUKI

BOND

NO.

1207B

•

Cylinder

head

cover

•

Cam

end

cap

99104-31140

f---------

-----------t--------------f----+--------------f-----j

3-30

•

Cam

chain

guide

bolt

THREAD LOCK SUPER

"1333B"

99000-32020

1-----

----------------+---------------+----+--------------+----1

•

Cam

sprocket

bolt

3-29

•

Starter

clutch

mounting

bolt

3-55

rr'!!~,

l~JU

1'.

-1

Ft~/

_'"7\

"i).')2.\;;:";

THREAD LOCK

SUPER"

1303"

99000-32030

GENERAL

INFORMATION

1-4

MATERIAL

PART PART

~GE

PAGE

7-9

7-35

•

Disc

plate

mounting

bolt

THREAD

LOCK

"1360"

99000-32130

~-G-e-a-r-s-h-if-t

-c-a-m--s-to-p-p-e-r-b-O--lt--j-3~

.-S-t-a-rt-e-r-m-o-t-o-r

sing

rew

6-14

7-19

•

Oil

pump

mounting

bolt

3-48

Front

fork

damper

rod

bolt

•

Countershaft

bearing

retain-

3-51

screw

3-51

lifter

screw

•

Gearshift

cam

guide/pawl

•

Starter

motor

mounting

bolt

3-56

6-6

THREAD

LOCK

"1342"

•

Generator

bearing

retainer

screw

99000-32050

--------------+-----+---------------+-------l

•

Clutch

•

Brakes

SUZUKI

BRAKE

FLUID

99000-23110

----------

------------------t----j--------------+------/

ROlf

FORK

OIL

.,11

SUZUKI

FORK

OIL

# 10 I

99000-99044-10G

-------------+---.

-C-a-rb-u-r-e-to-r-s-e-t-p-I-a-te-s-c-re-w--+-

-----

-I-

I I

THREAD

LOCK

CEMENT

99000-32040

1-5

GENERAL

INFORMATION

PRECAUTIONS

AND

GENERAL

INSTRUCTIONS

Observe

the

following

items

without

fail

when

servicing,

disassembling

and

reassembling

motorcycles.

not

run

engine

indoors

with

little

ventilation.

D Be

sure

replace

packings,

gaskets,

circlips,

O-rings

and

cotter

pins

with

new

ones.

CAUTION:

Never

reuse

circlip.

After

circlip

has

been

removed

from

shaft,

should

discarded

and

new

circlip

must

installed.

When

installing

new

circlip,

care

must

taken

not

expand

the

end

gap

larger

than

required

slip

the

circlip

over

the

shaft.

After

installing

circlip,

always

insure

that

completely

seated

its

groove

and

securely

fitted.

Tighten

cylinder

head

and

case

bolts

and

nuts

beginning

with

larger

diameter

and

ending

with

smaller

diameter,

and

from

inside

out-side

diagonally,

the

specified

tightening

torque.

Use

special

tools

where

specified.

Use

genuine

parts

and

recommended

oils.

When

persons

work

together,

pay

attention

the

safety

each

other.

After

the

reassembly,

check

parts

for

tightness

and

operation.

Treat

gasoline,

which

extremely

flammable

and

highly

explosive,

with

greatest

care.

Never

use

gasoline

cleaning

solvent.

Warning,

Caution

and

Note

are

included

this

manual

occasionally,

describing

the

following

contents.

WARNING

When

personal

safety

the

rider

involved,

disregard

the

information

could

result

injury.

CAUTION

For

the

protection

the

motorcycle,

the

instruction

rule

must

strictly

adhered

to.

NOTE

Advice

calculated

facilitate

the

use

the

motorcycle

given

under

this

heading.

USE OF

GENUINE

SUZUKI

PARTS

replace

any

part

the

machine,

use

genuine

SUZUKI

replacement

part.

Imitation

parts

supplied

from

any

other

source

than

SUZUKI,

used

replace

SUZUKI

parts

can

reduce

the

machine's

performance

and,

even

worse,

could

induce

costly

mechanical

troubles.

GENERAL

INFORMATION

1-6

SPECIFICATIONS

DIMENSIONS

AND

DRY

MASS

Overall

length

2185

(86.0

in)

Overall

width

765

(30.1

in)

Overall

height..................................................................

1290

(50.8

in)

Wheelbase

1490

(58.7

in)

Ground

clearance

130

(5.1 in)

Dry

mass

244

(537

Ibs)

246

(542

Ibs).....

California

model

only

ENGINE

Type

Four-stroke,

Air-Cooled

with

SACS,

DOHC,

TSCC

l\lumber

cylinders

Bore

78.0

(3.07

in)

Stroke

59.0

(2.32

in)

Piston

displacement

1127cm

(68.8

cu.in)

Carburetor

MIKUNI

BST34SS,

four

Air

cleaner

Polyester

fiber

element

Starter

system

Electric

Lubrication

system

Wet

sump

TRANSMISSION

Clutch

Wet

multi-plate

type

Transmission

5-speed

constant

mesh

Gearshift

pattern

1-down,4-up

Primary

reduction

1.522

(67/44)

Final

reduction

3.466

(52/15)

Gear

ratios,

Low

2.384

(31/13)

2nd

1.631

(31/19)

3rd

1.250

(25/20)

4th

1.045

(23/22)

Top

0.913

(21/23)

Drive

chain

DAIDO: 0.1.0.

532ZLV

118

links

1-7

GENERAL

INFORMATION

CHASSIS

Front

suspension

Telescopic,

coil

spring,

oil

damped

Rear

suspension

Full-floating

suspension

system,

spring

preload

fully

adjustable,

damping

force

4-way

adjustable

Steering

angle

34°

(right

left)

Caster

62°00'

Trail.

112

(4.4in)

Turning

radius

3.0

(9.8ft)

Front

brake

Disc

brake,

twin

Rear

brake

Disc

brake

Front

tire

size

120/80V

V250

Rear

tire

size

150/80V

V250

Front

fork

stroke

140mm

(5.5in)

Rear

wheel

travel...........................................................

125mm

(4.9in)

ELECTRICAL

Ignition

type

Fully

Transistorized

Ignition

timing

13°

B.T.D.C.

below

1500

r/min

and

32°

B.T.D.C.

above

375

r/min

Spark

plug

N.G.K.:

JR9B

J9B

Battery

12V

50.4

kC (14Ah)/IOHR

Generator

Three-phase

A.C.

Generator

Fuse 10/10/10/10/10A

Circuit

breaker

30A

CAPACITIES

Fuel

tank

21.0

(5.5

US gal)

19.5

(5.2

US gal)......

California

model

only

Engine

oil, Oil

change

with

oil

filter

change

4.5

(4.8

US qt)

Front

fork

oil

478

(16.2

oz)

These

specifications

are

subject

change

without

notice.

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