Suzuki GSXR-1100 1990 User manual

SUZUKI
--
-
SERVICE MANUAL
'i(/lA/ ~,otc>R<OR/'Olf.tflO\ l'H./\ltfJI\ Hr•" f}( flllftlt~) t
99600 39092.03E
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FOREWORD
Tht SUZUKI csx.nT 10() hu be11n dt:Vt:lopod 4$
• n•w gan•ut l on mo t orcyd• 10 tha GS,model!I It
1s packed with highly ddvanc(Jddes19n concepts
lncludir'lfJ n 5uLuk l Adt1'1nnd COOiing $y$ftlm , 11
now highly of fie/om t:.0mbu!ltlon IY$lOm (TSCCJ. a
fully ,r11M/$tOn.t.t1d lqnllion S~t8m and II lmtH O~IHI
lull..floe1er
rear SUS/Hnslon, Combined with pre-
clu ~onrrol 11nd H$Y handling thB GSX./11 100
p,ovidll!I e.xcr,Jfent performance (Ind ouur,nding
r1tilng comfort .
Thl ' :; serv1'ct, nu11rua l bit'$ Wen produced pdm11rlly
for • xp,uisnced m11eh11nlcs whose job is to ln -
$(MCt tul}osr, n,pa/r~nd s~rriu 1SUZUKImororcy-
cies . Appfttmlce mecnanfcs and do- 11, yourself me-
ch.tnics . will al.so rmd th;s manual 11n ttJttteruoly
vHful r1tpaJr guld.., Titi1m1nu11I contalnt th • molf
up-t<rdBUl mformation at the rim• of pfJbllcotion.
TIie rlglUs art11tnerved to update or malu t coruu:•
t,Of/$ to this mtJnUIJI ot (,ny 1lmt1.
IMPORTANT
Af/ $lra tt t-lt1g11I Su.ruJ:I mtJtorcyclos wilh t1n9/nt1
disp la c11mfl11t of 50cc or 9r1111t t1 r 11r 11 sub~l to
EnvlronmentillProtecrlon 11(lencyem1ss1on1egult1•
1io11s. r1i8$t1 1qgul1Jt10ns sot sptrcific Sf1JttlJit1ds to,
011houst omln,on ou1put lcvols as well as part1cu -
l;,r .serwcmq rttom ' rements rhl .~ m;,,n mt l mclurl tJ s
sp e cific lnform8tlon 1equi1ed to prOfHrlY ln5Pect
and sttrv i ct! GSX.fl I fO() m 11ccord.fnctt with 1111
EPA 1 11 9ul41/()()$. It,,S IJ'Ot>Oly n,comm t1 ttd(ld th.at
the ch;,plf,r on Emission Control. Periodic Servic•
lrtg 11 nd Carbut6tlOn 1111 tht:Jt'rJughly r614t1w11d btt-
fon, any "YP" of $(tt'VICtt wq1k 1$ performed
Funher I nformation concerning the EPA 11mtssfon
rttgulations 11nd U.S . Suzuki 's emission control
pro9r Mm can b• l011nd In tlf• U. S, SUZI.IX! EM/$ .
S/ON CONTROL PROGRAM MANUAUSERVICE
8VLL£TIN ,
SUZUKI MOTOR CORPORATION
Ma1orcycle Technical
Servle • Oapartm•nt
e COPYRIGHT SUZUtel MOTOR COAPORA.nO. \I ,
1990
GROUP INDEX
IGENERAL INFORMATION
PERIODIC MAINTENANCE
AND
TUNE-UP PROCEDURES
IENGINE
IFUEL AND LUBRICATION
SYSTEM
~-
IELECTRICAL SYSTEM a
ICHASSIS
El
SERVICING INFORMATION
II
EMISSIONCONTROL
II
INFORMATION
GSX-R1100L ('90-MODEL)
II
GSX -R1100M('91-MODEL)
E&J
GSX-R1100N (' 92-MODEL) m

VIEW OF GSX-R1100K
RI GHT SI DE
U:FT $JOE

GE NER AL IN FORMATION
r--------- CONTENTS --------,
II
SERIAL NUMBER LOCATION ........................................... ........ ,.,
FUEL ANO OIL RECOMMENOA TION .... ............. .......... •.... 1· 1
BREAK-IN PROCEDURES..... .................. .. ............ . ............ 1· 2
CYLINDER IDENTIFICATION.........
.. ........ ..................................... f- 2
SPECIAL
MATERIALS ..................................................................................... f· 3
PRECAUTIONS
ANO GENERALINSTRUCTIONS.. .. ................................. 1• 5
SPECIFICATIONS............................
.. .............................................................. 1· 7
COUNTRY
OR AREA ......................... .. ........ ....... 1· 9
r
r

1·l G(IIIE RAl INFORMATION
SERI AL NUMBER LOCATION
The fram1111erial nu mber orV I.N jVehlc l• ldentlfica1lon Num•
ber> Cll ls st amoed on 1ne steeong head pioe. The eng i ne ur ,al
number (l) ls loca1ed on the right side of tha cr .-nkca~. Thttse
numbe,11 are required especia lly tor ,09lttc , ln9 th a machlno
and ord e 111\0 s~r • P3rt$
FU EL AND OIL RECOMMENDATION
FUEL (For U.S.A. mode l)
1. UH onty unl eaded goaollne of .it l oai.l 87 pump oc1,ne
( "t'> melhod o, 91 oeu1ne or hiohtr ra t Pd by the ,e.,.earch
me1hod .
2 Sutuk l 1ecommends thac custome rs us e alcohol freo. un--
leedod ga&ohne whono-.,•r pou1bl t.
Us l!I of blend ed ou ol me containing MTBE (Me1twl r .. ,1 , arv
Butyl Etherl Is pemiltted .
4 UH of blendo<I 90,ohno / oseohol fue l ia p<irmittod providod
th~t It cont a in~ not more 1han 10 ~ elh;itnol GASOl1ne / 11 l co -
hol fu el may conteln up to 5% methanol 11 appropno te
cosolYen1$ and c::ouoslon lnl'tiblto~ are present .
6
II lhe performa n ce of tho• vehicle Is unsabsf•c t ory while
u,slno blf'tndfld Q1tsolin,:/11lcohol fuel , you should Jwllch 10
alcohol free unleaded oasollne.
6 Foilurc to follow th0se-gu1dcli l\o0 cou ld posslblyvold oppllco -
ble w•nanty CO\'ef"aoe Check with y011r fu@I su~ll~r to b l!
sure t h&t th& tue-t you jJ'ltend to use meets the re(luuements
11$le<l {lbOvi.,.
FUEL (For Canadian modelf
Use only unleadodi g.uo11ne of a1 least a7 pump oetane fT t
method or O1ocu1ne or higher f" Ot od by tho r011oarc:h mat h od.
FUEL (For the other m odels)
Gnolh~ u,ed should be graded 85 - 95 octtno lAuurch
Method) orh ,gh-,ir An un101dod gHo t lno type ts recommended

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ENGINE OIL (For U.S .A. model)
SUZUKI re co,nmends the use ot SULUl(I PERFORMANCE 11
MOTOR OIL or an 011 which 1s rated SE or SF under the AP I
(Ame11C1ll'l Pt}1roleum Institute> class,fic,nio,1 svst-0,n. Th e vis•
cos ity rnting is SAE lOW / 40 U an SAE IOW / 40 motor oil is
not availulll <:, s el ec t rrn alternate accordin!J to th o rlfrht ~hart .
ENGINE OIL (For the other models)
B~ sure that 1h e 1;1nuioc o,I vou u se comes under API c l.:i ss ,f 1 c.>
tl rm of SE or SF an d that it s viscosity r,11u19 ir; SAE 10W/40.
If an SAE 1 OW / 40 ,t,otor o il i$ 1101 available . seluCl an (llternate
.ttcco,di,19 to the righ1 cha,L
BRAl<E AND CLUTCH FLUID
Specification and classificution : OOT4
WARNING:
GENERAL INIOAMA!ION 1 -2
MIJUllillAllf
""'
' C: ll O 10-10 0 1P 70 ~ fU)
•• + 1.l . .. •• 32 IQ &a 118 1114
S 111c o th e hr(lke !.yi. tf!m of th is mow, cyc lo is filled with a glycol-1.,ased h(a ke fl11il1 bv 1h e m,m ... ,f acl ur er,
do not us e or rn1x. 1.hf lcrc n1 lyp es of fluid such us ~ •h co 111 : bAserl and petrolemn - b;iscrt fluid for re1Hh11u
1h e- sysrnm, ot he-rwise seno us d.-r11i'.lfJ <.:- wi ll rP.MJII
Do nol use any h1i'lk <: f111icJ tflkP.n fro m old or used or 11n~P.AIP.l1 conta 1n 1;1 r s.
Nev <: , ,P- u~ e brake flun.l l ufl ove r fr an, a ptavious ser \•i1.:11•!-J. w l11 Ch h:t$ been stored ior ;) long pP.nod
FRONT FORK OIL
BREAK-IN PROCEDURES
During nrnnuf a ctur e on ly the l )<,St oossible nrntermls ure u sed Md all muchmed l)fl ns arP. fin lshu l. l to , -i
very t119h S lundo,d h111 it ,s still necess.ir~' lu ollow · th P. moYing p.irlS to "B RE/\K- IN .. b1 .doru S\lhj~cti ng th e
cn gl o i+ 10 mtlldmum st resses The hitun ~ r,ertorm .incu ~ u, (I ,clillhility of th e un<1i 1 \0 rl epP. 11d s on Hu .• c .:: u •p
und ro~t w1 11t u)(crci~ed <lu ,ing it s a arlv hf e Th,~ nen~ral rule s ,, ro ,,s follow~.
• K eep 10 th ese break-in en91nu spec<.! l11m1 s.
Initial 800 km (500 miles) ; Bolow 6000 r/ min
Up 10 1600 km ( 1000 miles•: Balow 7000 r/ mill
Over 1600 l<.m (1000mllos) : Below 11000 r /min
• Upo n reuchmf1 t1u e>de>me 1 er re.:idiog of ItiOO krn t 1000 11 1,les) y ou c;m sull1~·ct the m010, cyc lu tu r .. 11
1hro11IP. op era lion
Mowc. 1\' er . i.Jo uo 1 1:;x , ;e , ;d I 1 000 r/m in at <- mv tmw
CYLINDER IDENTIFICATION
r 11u f ou , cvhn<lers of thi~ e og1 0P. are i den uh ed ;.i s No 1, No 2. No 3 and No. 4 c ylh i< l l¼r, M, countvll fror11
IP.ft 10 fi gh t (as viewed l,y lh <.: n(I Q, <ui 1hP !.eatt

-l•l CINE
RAl IN F ORMA T ION
SPECIAL MATERIALS
Th e mat e rial s l ist ed be low are need ed for maint en an ce work on 1 he GS X·R I 100. and sho uld be k op t on
hand t or ready use. They s up pl eme nt suc h s tandard mat aria ls OS Clt)~n io9 fluid s. l~ 1bricant s, eme ry cloth
a nd • he like . How 10 us e 1h em and wh ere to use them are desc f ib ed in th e te xt of thi -s manu tiL
MAT E RIAL
F or U.S.A model For other models
SUZUKI SU PER G RE ASE ' 'A ''
9!H)(JO 25 0 ~ i0
SUZUK I SU PEA GREASE .. A ..
99000 -2&0 I0
SUZUKI
MOL Y PASTE
PART
Dr iv esha ft 01 1 sea l
• En!tin e o il pi p(J 0 - ri ng
O il filH • •·
• G (tr ~( Wll(U 0 11 sea l
• ·S t.irt e, moto r vii ~1Jt1 1
Wheel bearing
Steering stem b f.t t1ri n 1J
S pro cke1 m oun t i"Q d rum
ba;, riniJ
Swlngar ,n spacer and dusl
~l•Jill CC >lmr'
Cush io n lever bet1ri n9 ;; ind
dust seal
Valv e .s lum
Con t od b ig end bearinn
Co ur\ttr"Shafl a nd driv es h aft
C rt1nk .sh.ih jou rna l b1 :il 11 'i t1!J
Camshaft j ov rn.il
S rnm w motor a rm atuie end
Genor;, to r driv on (lcl) r
da mpe ,
c 1~11 ch l eve , push rod
PAGE
3.49
3-63
4.1A
5.7
5-17
6-4
G- 32
6 20
6 -JJ
fi . 46
3- 30
3. 39
3-48
3-6 <1
3 , 64
5,. 17
5-6
6- 48
SUZUKI MOLY PAS TE
990 00 - :Z !i 1 40
• Crank.c.ise mttting s~ut;)c;~
Clutch co v er ma 1i ng s ud 11ce
Sl arlt:r <. :1~ 11 <: h CO\•~f m at ul g
s urfa ce
9 !=10 0 0 , 25 140 0 ____ _ 11 _____________ ~
3 , 54
3-58
3-G0
SUZUKI BONO NO. 1 2078
99 104,3 11 40
SUZUl(I BONO NO. 1 2078
99000 ·3 114 0
~
cJ
THREAO LOCK S UP ER ., 1 303" TI-IA E. A.O LOCK SUP f.. R '"1 30:J ..
9900().32030 99000 -32 030
TMllEAD LOCK S UP ER .. I 36ff
99000-32 1 30
THREAD L(}CK S lJ PEB ·· 13 60' ·
99000 -3 2 1 30
011 r,, essure switch
S ig nal y rn, ~1· 11 1 01' l it .ad wli e
nr o mm ot
Cylinder head co v er
C11 m 1 H1 <t cap
C ylind er st\ 11:I bo ll
C.J m spr ocket IJ Olt
Cam ch ai n o uid e bo lt
• Di s<: 11 l arn ,n ou, , t, ng bo lt
J-58
3.
59
J- 68
J-68
3-6 1

MATERIAL
F of U.S A m odol
, __ __;-=:_
THREAD L OCK ·· 1:t4 :r
990 00 - 32 0 50
h: 11 Olh f.- r mo de ls
~
LJ
THREAD LOCI< ..134 2°
99 000- 32050
i.
f:.t ~\ ~: ·•1
'-. .=.- )
nrnt:AO LOl,; 'C t mft EA ·· 130 3 " THA E AO I O CK SIJl-'l:H ·· 130 &"
99000 .:n o~ ~o 99 000 . 321 oo
, c,, r
~ lll UJI II ~
i..1oot~
: :::::::',•
t a~• ·
SUZ UKI HAAKE f lU lO
OOTJ & DO T4
l- --'- 99 '-- 0◊0 ·23 110
fll!K
I L..,
SUZUKI FO ft K O IL ,• .r5
99000 -9$)0 44 ObG
__ .;
THREAO I OC K C E.f l/ EN1
99000 - 3204 0
SUZU KI BHAK f. FL UIO
O OT3 & OOT.t
99 000 · 231 10
SUZ UKI F Oll K OIL ,'.' 5
99 000 ·9 90 44-0S Ci
____ ,
L,
T HRE AD l OCK CE ME NT
99 000 - 32 0•10
•
•
GENERAL INF ORMATION 1•4
PART
Ge.: u~ hifl <:f1rn st oppe, bolt
O il ov mp mO ll nt! Mfl h() II
C( mol ~ rs hah b r. a, in g re tai n•
er sc rew
Gr.arsh1 ft cam !)u id ei r, 1. 1w l
l if te r 1;1: fl ) 'N
St a rt er mo10, moun t ,ny l'l f 1I '.
G,~,,e,ato, bea, inn re ui in <J r
SC ff JW
St art er mot or ho ~1 :;in {I $C(l;!w
f1< )11t lork dam per rod bolt
S tee1 in !J rla m p ~, DO Ii
Sta rt er clutch mo~mting llolt
Clu l <: h
B ra k. es
PAGE
3. ,.: ~
3.52
3. 55
3. 55
3- 60
5-8
5- 17
6-H
6 -20
3 .5 9
2 9
2-12
4 12

-1-5
GENER/IL INFORMATION
PRECAUTIONS AND GENERAL INSTRUCTIONS
Obsurve tha following ite ms w ith out fai l wh en servicing. dis;:,sso rnblhl g a nd rc.lsse:mb li n9 motor cyc les.
L Do not run engine i ndoors with littl e or no ve ntil at ion.
L Be
sure to re pl ace packings , gaske ts , c ir cli ps, 0 - rings and co tter pi ns wi th new 0 11 (;)$ ,
CAUTION :
N ever r'8U$8 a circlip . After' a clrclip has been f' emove<I from~ sh af t. it i;hould be discarded and a new
circlip must be in sta lled .
When installing a new circ lip , caro rnust be taken not 10 expand the end gap l arger than required
to slip the circ lip over the shaft .
After installing a ci rc l ip, alway s in sure thM it is comp letely seated in its groove and securely fitt<Jd,
7 Tiflht en cy l incler head and ca se bolt s a nd nut s, beginn i ng w i th l< ir 9e, diamet er and e nding with sma ll er
diiJmetur. from i 11 s1d c lO ou t.side clianon~ llv , 10 the s pecif i ed tight e nin g toraue
LI Us e spec ial too ls wh ern specit i P.d .
LI U se genuine pa ns and recomm e nd ed oils.
□ Wh an 2 or mo re pe rs on s wo r k. tog e th er. puy att e nti on tu t h0 safo tv of coch other
D Afttn th e re.isse mbly , ch ec k parts to r ti gh tn ess and operation.
LI T reat gaso lin e, whi ch is extremely flamm ab le and hi gh ly exp l os iv e. w ,t h SJ reatast caro. N ev e, u se
9,:1so lin e as cl ean in g so lv ent
W;irnin 9, Ca ut ion a nd N ote are i nc l ude d in thi s man ual occas ion ally, desc ribin g thP. foll ow i ng c ont en ts.
WARNING ............... Th e per son-:'I sa fety of che rid er or bystanrters may be i nvo lv ed. Disr eg ard 1 ny th ,s
111 forrn~1tion could re s ult m pe rsona l i njur y
CAUT ION .. ............... Th ese in!'.tructions po int out sp ecia l ser vi ce p ro c edures or precautions th at mu st be
r on owod 10 avok l lf.:im oy, 11 !) the n,a ch h ,o .
NO TE ......................... Thi s prov id es specfal inform a tion to mak e ma inte nanc e eas ier o, im po, wnt u)S l• 'l•C•
tio ns cl ct 1101 ·.
REPLACEMENT PARTS
When you ,e plac e ~uw pt111s . ~• so on ly oeooi ne SUZ UK I
re1>l acemo,n p~ r lS, or their e quiv.il e nt. Gen ui ne SUZUKI parts
ur u hi gh qua lit y parts whi ch ar~ rt es ii:ined fi nd h11ilt speci fi ca ll y
for SUZUKI ve hicl es .
CAUTIO N:
Use of ,eplacemen t parts w hich arc rtOlOQl•ivalo nt io qualitv
to gcnulno SUZ UKI parts can lead to performance probfems
and damage .

ASBESTOS INFORMATION
Note the lo ll ow in g wh en h;.m(ll in{I a su pp ly p.:art with this
WARNING LA BE l , or MY p;irt in the parts l isl which co nt il in s
.:isbostos.
• Qp e,a te ii possible o ut of doors in a we ll v en tilat ed pla ce.
• Prcfo n )b ly us e h and too ls or low s peed tool s OQl1 ipped, if
necess ary, v, it h an .Jppropriat<: d~•St e)(tr3ctor faci lity . If
hi9h spee d T O() l s. are u se d. t hey s hould .Jlwavs he S()
equi pped.
• If possib le, dampen belore c utting or d(ilhO!),
• Damp en du sl .:ind place il i" a proper ly closed nn;upWCIC
and
dispose ()f it &Rfe ly .
Any domestic asbestos pr od uCl 10 -.vh ic h the ;i bove do es
,,ot ;)l) ply, but whi ch is lik e lv to re l ease f ib res <h .1rin9 use
shou ld be rep la ced bV n uw 0 11 <! wh en worn .
I . Bruu
th (:1 co vor 9 as k et
1.
C lu t ch co ve r gas ket
3.
Si gna l gun er.)t o, co vor c,asket
4 . Sl il •ter !l ea, cove r gaske t
5. O
il pan g;isket
6.
Cam ch a in tension ~< liu ster gas k et
7, fl(tia ust pipe gai; kP.t
8. O il st rai ner pr otecto r 9a Skc t
9. Srnl'l
C' 1'0 01-0r
1 0. Fuel co ck gasket
11 . F
uul l.:ink. h ¢3 l s hi eld
-
-
GENERAL I NFORUA T ION Hi
-
-
WA.f!H!NG
CONTU,S
ASIIESTOS
.... "' .... -,,.
... .. . .......... ...
,.. _"