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Katana 1100
Suzuki Katana 1100 User Manual
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GENERAL
INFORMATION
VIEW
OF
GSX1100F
:~~.~~~~~
~====~---:l
SERIAL
NUMBER
LOCATION.
1-
1
I
FUEL
AND
OIL
RECOMMENDA
TlON
1-
1
I
BREAK-IN
PROCEDURES
1-
2
I
CYLINDER
IDENTIFICA
TlON
1-
2
SPECIAL
MA
TERIALS
1-
3
PRECAUTIONS
AND
GENERAL
INSTRUCTIONS
1-
5
SPECIFICA
TIONS
1-
6
___
------l
2
4
Table of Contents
Group Index
2
General Information Contents
3
View of GSX1100F
4
Serial Number Location
4
Fuel and Oil Recommendation
4
Break-In Procedures
5
Cylinder Identification
5
Brake and Clutch Fluid
5
Front Fork Oil
5
Special Ma Terials
6
Precautions and General Instructions
8
Use of Genuine Suzuki Parts
8
Dimensions and Dry Mass
9
Specifica Tions
9
Table of Contents
11
Periodic Maintenance and Tune-Up Procedures Contents
11
Periodic Maintenance Schedule
12
Periodic Maintenance Chart
12
LUBRICA Tlon POINTS
13
Maintenance and Tune-Up Procedures
14
Battery
14
Cylinder Head Nuts and Exhaust Pipe Bolts
15
Cylinder Head
15
Exhaust Pipe
15
Air Cleaner
15
Valve Clearance
16
Recommended Spark Plug
18
Spark Plugs
18
Engine Oil and Oil Filter
19
Necessary Amount of Engine Oil
19
Idle RPM
20
Fuel Line
20
Carburetor
20
Clutch
20
Bleeding Air from the Clutch Fluid Circuit
21
Drive Chain Checkig
22
Drive Chain Adjusting
22
Drive Chain Cleaning and Lubricating
22
Brake Fluid Level
23
Brake Pads
23
Brakes
23
Brake Pedal Height
24
Brake Light Switches
24
Air Bleeding the Brake Fluid Circuit
24
Tires
25
Tire Pressure
26
Tire Tread Condition
26
Steering
26
Front Forks
27
Rear Suspension
27
Chassis Bolts and Nuts
28
Engine Contents
30
Compression Check
31
Compression Test Procedure
31
Engine Components Removable with the Engine in Place
32
Engine Removal and Reinstallation
33
Engine Reinstallation
38
Engine Disassembly
40
Cylinder Head Servicing
50
Engine Components Inspection and Servicing
50
Cylinder Head Distortion
51
Valve Face Wear
51
Valve Head Radial Runout
51
Valve Stem Runout
51
Valve Guide Servicing
52
Valve Stem Wear
52
Valve and Seat Condition Valve Seat Width
53
Valve Seat Servicing
53
Valve Springs
55
Valve Stem End Condition
55
Reassembly
56
Cam Wear
57
Camshaft
57
Camshaft Journal Wear
58
Cam Chain Tensioner
59
Cam Sprocket
59
Camshaft Runout
59
Cam Chain 20-Pitch Length
60
Cam Chain Guide
60
Cam Chain Idler
60
Cylinder Distortion
60
Piston Diameter
61
Piston Ring-Groove Clearance
61
Piston-Cylinder Clearance
61
Oversize Oil Ring
62
Oversize Piston Ring
62
Piston Pin and Pin Bore
62
Piston Ring Free End Gap and Piston Ring End Gap
62
Conrod Big End Side Clearance
63
Conrod Small End I.D.
63
Conrod-Crank Pin Bearing Selection
63
Bearing Selection Table
64
Bearing Assembly
65
Crankcase - Crankshaft Bearing Selection
66
Crankshaft Thrust Clearance
68
Crankshaft Runout
69
Clutch Bearing
70
Clutch Drive Plates and Driven Plates
70
Clutch Spring Free Length
70
Clutch Release Cylinder Disassembly
71
Clutch Release Cylinder Inspection
71
Clutch Release Cylinder Reassembly
71
Oil Pump
71
Transmission
72
Countershaft Disassembly
73
Driveshaft Disassembly
73
Countershaft and Driveshaft Reassembly
74
Engine Reassembly
77
Gearshift Fork-Groove Clearance
77
Fuel and Lubrication System Contents
96
Fuel Cock Removal
97
Fuel Tank, Fuel Cock and Fuel Level Gauge
97
Fuel Gauge Removal
97
Inspection and Cleaning
97
Carburetor Construction
98
I.D. No. Location
99
Diaphragm and Piston Operation
100
Slow System
101
Main System
102
Float System
103
Starter System
103
Fuel System
104
Disassembly
105
Float Height Adjustment
105
Needle Valve Inspection
105
Removal
105
Reassembly and Remounting
106
Balancing Carburetors
107
Lubrication System
109
Oil Filter
109
Oil Pressure
109
Oil Sump Filter
110
Relief Valve
110
Oil Cooler
111
Operating Pressure of Regulators
111
Engine Lubrication System Chart
112
Engine Lubrication System
113
Cylinder Head Cooling System Chart
114
Cylinder Head Cooling System
115
Emission Control Information Contents
116
Emission Control Carburetor Components
117
Evaporative Emission Control System
118
Canister Hose Routing
119
Air Suction System
120
Air Suction Hose Routing
121
Electrical System Contents
122
Charging System
123
Description (Generator with IC Regulator)
123
Charging Output Check
124
Generator Removal and Disassembly
124
Rotor Bearing Inspection
125
Stator Coil Continuity Check
125
Carbon Brush
126
Rectifier
126
Rotor Coil Continuity Check
126
Slip Ring
126
Generator Driven Gear Damper
127
IC Regulator
127
Reassembly Information
129
Ignition System Description
130
Ignition Coil Inspection (with Electro Tester)
131
Ignition Coil Inspection (with Pocket Tester)
131
Signal Generator Inspection (with Pocket Tester)
131
Ignitor Unit
132
Spark Plug
132
Starter Motor Removal and Disassembly
133
Starter System Description
133
Commutator
134
Starter Motor Inspection
134
Armature Coil
135
O-Ring
135
Oil Seal
135
Starter Motor Reassembly
135
Housing End (Gear-Side)
136
Starter Relay Inspection
136
Combination Meter Removal and Disassembly
137
Combination Meter Inspection
138
Fuel Gauge Sending Unit Inspection
139
Fuel Level Meter/Gauge
139
Fuel Meter Inspection
139
Battery Replacement
140
Digital Clock
140
Headlight
140
Lamps
140
Tail/Brake Light
141
Turn Signal Light
141
Switches
142
Wire Color
143
Side-Stand Relay
144
Wind-Shield Motor Relay
144
Battery Servicing
145
Battery Specifications
145
Initial Charging
145
Rechrging Operation Based on S.G. Reading
146
Service Life
146
Chassis Contents
147
Fairing
148
Fairing Removal
148
Fairing Reinstallation
149
Wind-Shield Removal and Disassembly
150
Wind-Shield Reassembly and Remounting
152
Wiring Diagram
152
Front Wheel
153
Front Wheel Removal
153
Axle Shaft Inspection and Disassembly
154
Wheel Bearings Inspection and Disassembly
154
Wheel Inspection and Disassembly
154
Wheel Bearing Reassembly and Remounting
155
Axle Shaft Reassembly and Remounting
156
Brake Caliper Reassembly and Remounting
156
Brake Disc Reassembly and Remounting
156
Speedometer Gearbox Reassembly and Remounting
156
Brake Pad Replacement
157
Front Brake
157
Caliper Removal and Disassembly
158
Caliper Inspection
159
Caliper Reassembly and Remounting
159
Disc Inspection
160
Disc Servicing
160
Master Cylinder Removal and Disassembly
160
Master Cylinder Inspection
161
Master Cylinder Reassembly and Remounting
162
Front Fork
163
Front Fork Removal and Disassembly
163
Fork Spring Inspection
165
Damper Rod Bolt Reassembly and Remounting
166
Damper Rod Ring Inspection
166
Inner and Outer Tube Inspection
166
Inner Tube Metal Reassembly and Remounting
166
Fork Oil Reassembly and Remounting
167
Fork Spring Reassembly and Remounting
167
Outer Tube Metal, Oil Seal and Dust Seal Reassembly and Remounting
167
Front Fork Cap
168
Tightening Torque
168
Steering
169
Steering Removal and Disassembly
170
Steering Inspection
171
Steering Reassembly and Remounting
171
Rear Brake
173
Cliper Removal and Disassembly
174
Rear Wheel
178
Rear Wheel Removal
178
Rear Wheel Inspection and Disassembly
179
Wheel and Sprocket Drum Bearings
179
Sprocket Drum Bearing and Sprocket Reassembly and Remounting
182
Tire and Wheel Removal
183
Valve Inspection
185
Tire Inspection
185
Wheel Inspection
185
Valve Installation
186
Tire Mounting
186
Swingarm
188
REAR Suspension
188
Shock Absorber and Cushion Lever
189
Rear Suspension Removal
190
Cushion Lever/Rod Inspection and Disassembly
191
Shock Absorber Inspection and Disassembly
191
Swingarm Inspection and Disassembly
192
Cushion Lever/Rod Reassembly and Remounting
193
Swingarm Reassembly and Remounting
193
Reassembling Information
194
Final Inspection and Adjustment
195
Rear Suspension Setting
195
Setting Table
195
Clutch Master Cylinder
196
Clutch Master Cylinder Disassembly and Reassembly
196
Clutch Master Cylinder Removal
196
Servicing Information Contents
197
Troubleshooting
198
Wiring Diagram (California Model Only)
206
Wire, Cable and Hose Routing
207
Front Brake Hose Routing
209
Rear Brake Hose Routing
210
Clutch Hose Routing
211
Fuel Hose/Vacuum Hose Routing
212
Fuel Tank Hose Routing
213
Other Hoses Routing
214
Battery Breather Hose Routing
215
Special Tools
216
Tightening Torque
219
Tightening Torque Chart
221
Service Data
222
5
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Suzuki Katana 1100 Specifications
General
Brand
Suzuki
Model
Katana 1100
Category
Motorcycle
Language
English
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