Katana 1100

Suzuki Katana 1100 User Manual

Suzuki Katana 1100

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SUZUKI

SERVICE

MANUAL

99500-39080-03E

(5€)

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Table of Contents

Group Index2
General Information Contents3
View of GSX1100F4
Serial Number Location4
Fuel and Oil Recommendation4
Break-In Procedures5
Cylinder Identification5
Brake and Clutch Fluid5
Front Fork Oil5
Special Ma Terials6
Precautions and General Instructions8
Use of Genuine Suzuki Parts8
Dimensions and Dry Mass9
Specifica Tions9
Table of Contents11
Periodic Maintenance and Tune-Up Procedures Contents11
Periodic Maintenance Schedule12
Periodic Maintenance Chart12
LUBRICA Tlon POINTS13
Maintenance and Tune-Up Procedures14
Battery14
- Cylinder Head Nuts and Exhaust Pipe Bolts15
- Cylinder Head15
- Exhaust Pipe15
Air Cleaner15
Valve Clearance16
Recommended Spark Plug18
Spark Plugs18
- Engine Oil and Oil Filter19
- Necessary Amount of Engine Oil19
- Idle RPM20
Fuel Line20
Carburetor20
Clutch20
- Bleeding Air from the Clutch Fluid Circuit21
- Drive Chain Checkig22
- Drive Chain Adjusting22
- Drive Chain Cleaning and Lubricating22
- Brake Fluid Level23
- Brake Pads23
Brakes23
- Brake Pedal Height24
- Brake Light Switches24
- Air Bleeding the Brake Fluid Circuit24
Tires25
- Tire Pressure26
- Tire Tread Condition26
Steering26
Front Forks27
Rear Suspension27
- Chassis Bolts and Nuts28
- Engine Contents30
- Compression Check31
- Compression Test Procedure31
- Engine Components Removable with the Engine in Place32
- Engine Removal and Reinstallation33
- Engine Reinstallation38
- Engine Disassembly40
- Cylinder Head Servicing50
- Engine Components Inspection and Servicing50
- Cylinder Head Distortion51
- Valve Face Wear51
- Valve Head Radial Runout51
- Valve Stem Runout51
- Valve Guide Servicing52
- Valve Stem Wear52
- Valve and Seat Condition Valve Seat Width53
- Valve Seat Servicing53
- Valve Springs55
- Valve Stem End Condition55
- Reassembly56
- Cam Wear57
- Camshaft57
- Camshaft Journal Wear58
- Cam Chain Tensioner59
- Cam Sprocket59
- Camshaft Runout59
- Cam Chain 20-Pitch Length60
- Cam Chain Guide60
- Cam Chain Idler60
- Cylinder Distortion60
- Piston Diameter61
- Piston Ring-Groove Clearance61
- Piston-Cylinder Clearance61
- Oversize Oil Ring62
- Oversize Piston Ring62
- Piston Pin and Pin Bore62
- Piston Ring Free End Gap and Piston Ring End Gap62
- Conrod Big End Side Clearance63
- Conrod Small End I.D.63
- Conrod-Crank Pin Bearing Selection63
- Bearing Selection Table64
- Bearing Assembly65
- Crankcase - Crankshaft Bearing Selection66
- Crankshaft Thrust Clearance68
- Crankshaft Runout69
- Clutch Bearing70
- Clutch Drive Plates and Driven Plates70
- Clutch Spring Free Length70
- Clutch Release Cylinder Disassembly71
- Clutch Release Cylinder Inspection71
- Clutch Release Cylinder Reassembly71
- Oil Pump71
- Transmission72
- Countershaft Disassembly73
- Driveshaft Disassembly73
- Countershaft and Driveshaft Reassembly74
- Engine Reassembly77
- Gearshift Fork-Groove Clearance77
- Fuel and Lubrication System Contents96
- Fuel Cock Removal97
- Fuel Tank, Fuel Cock and Fuel Level Gauge97
Fuel Gauge Removal97
Inspection and Cleaning97
- Carburetor Construction98
- I.D. No. Location99
- Diaphragm and Piston Operation100
- Slow System101
- Main System102
- Float System103
- Starter System103
- Fuel System104
- Disassembly105
- Float Height Adjustment105
- Needle Valve Inspection105
- Removal105
- Reassembly and Remounting106
- Balancing Carburetors107
- Lubrication System109
- Oil Filter109
- Oil Pressure109
- Oil Sump Filter110
- Relief Valve110
- Oil Cooler111
  - Operating Pressure of Regulators111
  - Engine Lubrication System Chart112
- Engine Lubrication System113
- Cylinder Head Cooling System Chart114
- Cylinder Head Cooling System115
- Emission Control Information Contents116
- Emission Control Carburetor Components117
- Evaporative Emission Control System118
Canister Hose Routing119
- Air Suction System120
- Air Suction Hose Routing121
  - Electrical System Contents122
  - Charging System123
  - Description (Generator with IC Regulator)123
  - Charging Output Check124
  - Generator Removal and Disassembly124
  - Rotor Bearing Inspection125
  - Stator Coil Continuity Check125
  - Carbon Brush126
  - Rectifier126
  - Rotor Coil Continuity Check126
  - Slip Ring126
  - Generator Driven Gear Damper127
  - IC Regulator127
  - Reassembly Information129
  - Ignition System Description130
  - Ignition Coil Inspection (with Electro Tester)131
  - Ignition Coil Inspection (with Pocket Tester)131
  - Signal Generator Inspection (with Pocket Tester)131
  - Ignitor Unit132
  - Spark Plug132
  - Starter Motor Removal and Disassembly133
  - Starter System Description133
  - Commutator134
  - Starter Motor Inspection134
  - Armature Coil135
  - O-Ring135
  - Oil Seal135
  - Starter Motor Reassembly135
  - Housing End (Gear-Side)136
  - Starter Relay Inspection136
  - Combination Meter Removal and Disassembly137
  - Combination Meter Inspection138
  - Fuel Gauge Sending Unit Inspection139
  - Fuel Level Meter/Gauge139
  - Fuel Meter Inspection139
  - Battery Replacement140
  - Digital Clock140
  - Headlight140
  - Lamps140
  - Tail/Brake Light141
  - Turn Signal Light141
  - Switches142
  - Wire Color143
  - Side-Stand Relay144
  - Wind-Shield Motor Relay144
  - Battery Servicing145
  - Battery Specifications145
  - Initial Charging145
  - Rechrging Operation Based on S.G. Reading146
  - Service Life146
  - Chassis Contents147
- Fairing148
  - Fairing Removal148
  - Fairing Reinstallation149
  - Wind-Shield Removal and Disassembly150
  - Wind-Shield Reassembly and Remounting152
  - Wiring Diagram152
- Front Wheel153
  - Front Wheel Removal153
  - Axle Shaft Inspection and Disassembly154
  - Wheel Bearings Inspection and Disassembly154
  - Wheel Inspection and Disassembly154
  - Wheel Bearing Reassembly and Remounting155
  - Axle Shaft Reassembly and Remounting156
  - Brake Caliper Reassembly and Remounting156
  - Brake Disc Reassembly and Remounting156
  - Speedometer Gearbox Reassembly and Remounting156
  - Brake Pad Replacement157
- Front Brake157
  - Caliper Removal and Disassembly158
  - Caliper Inspection159
  - Caliper Reassembly and Remounting159
  - Disc Inspection160
  - Disc Servicing160
  - Master Cylinder Removal and Disassembly160
  - Master Cylinder Inspection161
  - Master Cylinder Reassembly and Remounting162
- Front Fork163
  - Front Fork Removal and Disassembly163
  - Fork Spring Inspection165
  - Damper Rod Bolt Reassembly and Remounting166
  - Damper Rod Ring Inspection166
  - Inner and Outer Tube Inspection166
  - Inner Tube Metal Reassembly and Remounting166
  - Fork Oil Reassembly and Remounting167
  - Fork Spring Reassembly and Remounting167
  - Outer Tube Metal, Oil Seal and Dust Seal Reassembly and Remounting167
  - Front Fork Cap168
  - Tightening Torque168
- Steering169
  - Steering Removal and Disassembly170
  - Steering Inspection171
  - Steering Reassembly and Remounting171
- Rear Brake173
- Cliper Removal and Disassembly174
- Rear Wheel178
- Rear Wheel Removal178
- Rear Wheel Inspection and Disassembly179
- Wheel and Sprocket Drum Bearings179
- Sprocket Drum Bearing and Sprocket Reassembly and Remounting182
- Tire and Wheel Removal183
- Valve Inspection185
- Tire Inspection185
- Wheel Inspection185
- Valve Installation186
- Tire Mounting186
- Swingarm188
REAR Suspension188
- Shock Absorber and Cushion Lever189
- Rear Suspension Removal190
- Cushion Lever/Rod Inspection and Disassembly191
- Shock Absorber Inspection and Disassembly191
- Swingarm Inspection and Disassembly192
- Cushion Lever/Rod Reassembly and Remounting193
- Swingarm Reassembly and Remounting193
- Reassembling Information194
- Final Inspection and Adjustment195
- Rear Suspension Setting195
- Setting Table195
- Clutch Master Cylinder196
- Troubleshooting198
- Wiring Diagram (California Model Only)206
- Wire, Cable and Hose Routing207
- Special Tools216
Tightening Torque219
- Tightening Torque Chart221
- Service Data222

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Suzuki Katana 1100 Specifications

General

Brand	Suzuki
Model	Katana 1100
Category	Motorcycle
Language	English

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