Suzuki Katana 1100 User manual

SUZUKI
SERVICE MANUAL
99500-39080-03E
(5€)
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.\ULLKI .HOIOR co, LTD I'RI.\TED 1.\ J'I!',I.\ O(/OREN. 'ti 7

FOREWORD
The SUZUKI GSX 11 OOF has been developed as
a new generation motorcycle to the GS-models. It
is packed with highly advanced design concepts
including a Suzuki Power Shield, a Suzuki Ad-
vanced Cooling System, a new highly efficient
combustion system (TSCCl a fully transistorized
ignition system and a improved full-floater rear
suspension. Combined with precise control and
easy handling the GSX 1 100F provides excellent
performance and outstanding riding comfort.
This service manual has been produced primarily
for experienced mechanics whose job is to in-
spect, adjust, repair and service SUZUKI motorcy-
cles. Apprentice mechanics and do-it-yourself me-
chanics, will also find this manual an extremely
useful repair guide. This manual contains the most
up-to-date information at the time of publication.
The rights are reserved to update or make correc-
tions to this manual at any time.
IMPORTANT
All street-legal Suzuki motorcycles with engine
displacement of 50cc or greater are subject to
Environmental Protection Agency emission regula-
tions. These regulations set specific standards for
exhaust emission output levels as well as particu-
lar servicing requirements. This manual includes
specific information required to properly inspect
and service the GSX 1 1OOF in accordance with all
EPA regulations. It is strongly recommended that
the chapter on Emission Control, Periodic Servic-
ing and Carburetion be thoroughly reviewed be-
fore any type of service work is performed.
Further information concerning the EPA emission
regulations and Us. Suzuki's emission control
program can be found in the Us. SUZUKI EMIS-
SION CONTROL PROGRAM MANUAL/SERVICE
BULLETIN.
SUZUKI MOTOR CO., LTD.
Technical Department
Motorcycle Service Division
© COPYRIGHT SUZUKI MOTOR CO., LTD. 1987
GROUP INDEX
===- GENERAL INFORMATION
fERIODIC MAINTENANCE AND --..
TUNE-UP PROCEDURES ~
ENGINE
IJ
IFUEL AND LUBRICATION
SYSTEM
II
17MISSION CONTROL
INFORMATION
~
I ELECTRICAL SYSTEM a
[CHASSIS
1&
SERVICING INFORMATION
I
L_lfJ

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

1-1 GENERAL INFORMATION
VIEW OF GSX1100F
RIGHT SIDE LEFT SIDE
SERIAL NUMBER LOCATION
The frame serial number or.V.I.N. (Vehicle Identification Num-
ber) CD is stamped on the steering head pipe. The engine serial
number (2) is located on the right side of the crankcase. These
numbers are required especially for registering the machine
and ordering spare parts.
FUEL AND OIL RECOMMENDATION
FUEL
Use only unleaded or low-lead type gasoline of at least 85-95
pump octane (\ M) method or 89 octane or higher rated by the
Research Method.
ENGINE OIL
SUZUKI recommends the use of SUZUKI PERFORMANCE 4
MOTOR OIL or an oil which is rated SE or SF under the API
(American Petroleum Institute) classification system. The vis-
cosity rating is SAE 10W/40. If an SAE 10W/40 motor oil is
not available, select an alternate according to the following
chart.
, I
MULTIGRADE
• I I
-22 -4
lOW-3D
14 32 50 68 86 104
TEMP.
°C
OF
'- .. .... ~~ ....... ~_J

GENERAL INFORMATION 1-2
BRAKE AND CLUTCH FLUID
Specification and classification: DOT4
WARNING:
• Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer,
do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling
the system, otherwise serious damage will result.
• Do not use any brake fluid taken from old or used or unsealed containers.
• Never re-use brake fulid left over from the previous servicing and stored for a long period.
FRONT FORK OIL
Use fork oil # 1 O.
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a
very high standard but it is still necessary to allow the moving parts to "BREAK-IN" before subjecting the
engine to maximum stresses. The future performance and reliability of the engine depends on the care
and restraint exercise during its early life. The general rules are as follows.
• Keep to these break-in engine speed limits:.
Intial 800 km (500 miles): Below 4000 r/min
Up to 1600 km (1000 miles): Below 6000 r/min
Over 1600 km (1 OOOmiles): Below 11300 r/min
• Upon reaching an odometer reading of 1600 km (1000 miles) you can subject the motorcycle to full
throttle operation.
However, do not exceed 11300 r/min at any time.
CYLINDER IDENTIFICATION
The four cylinders of this engine are identified as No.1, No.2, NO.3 and No.4 cylinder, as counted from
left to right. (as viewed by the rider on the seat)

1-3 GENERAL INFORMATION
SPECIAL MATERIALS
The materials listed below are needed for maintenance work on the GSX 11 OOF, and should be kept on
hand for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery cloth
and the like. How to use them and where to use them are described in the text of 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
I
THREAD LOCK "1360"
I
99000-32130
~-G-e-a-r-s-h-if-t -c-a-m--s-to-p-p-e-r-b-O--lt--j-3~
I
.-S-t-a-rt-e-r-m-o-t-o-r h ou sing sc rew
6-14
7-19
• Oil pump mounting bolt 3-48 I. Front fork damper rod bolt
• Countershaft bearing retain- 3-51
er 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 J'
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--+- 4- 10 r- ----- -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.
D Do not run engine indoors with little or no ventilation.
D Be sure to replace packings, gaskets, circlips, O-rings and cotter pins with new ones.
CAUTION:
Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new
circlip must be installed.
When installing a new circlip, care must be taken not to expand the end gap larger than required
to slip the circlip over the shaft.
After installing a circlip, always insure that it is completely seated in its groove and securely fitted.
D Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller
diameter, and from inside to out-side diagonally, to the specified tightening torque.
D Use special tools where specified.
D Use genuine parts and recommended oils.
D When 2 or more persons work together, pay attention to the safety of each other.
D After the reassembly, check parts for tightness and operation.
D Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use
gasoline as cleaning solvent.
Warning, Caution and Note are included in this manual occasionally, describing the following contents.
WARNING When personal safety of the rider is involved, disregard of the information could result
in injury.
CAUTION For the protection of the motorcycle, the instruction or rule must be strictly adhered
to.
NOTE Advice calculated to facilitate the use of the motorcycle is given under this heading.
USE OF GENUINE SUZUKI PARTS
To replace any part of the machine, use a genuine SUZUKI
replacement part. Imitation parts or parts supplied from any
other source than SUZUKI, if used to replace SUZUKI parts can
reduce the machine's performance and, even worse, could
induce costly mechanical troubles.
~
L __

GENERAL INFORMATION 1-6
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length 2185 mm (86.0 in)
Overall width 765 mm (30.1 in)
Overall height.................................................................. 1290 mm (50.8 in)
Wheelbase 1490 mm (58.7 in)
Ground clearance 130 mm (5.1 in)
Dry mass 244 kg (537 Ibs)
246 kg (542 Ibs)..... California model only
ENGINE
Type Four-stroke, Air-Cooled with SACS, DOHC, TSCC
l\lumber of cylinders 4
Bore , 78.0 mm (3.07 in)
Stroke 59.0 mm (2.32 in)
Piston displacement 1127cm
3
(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 mm (4.4in)
Turning radius 3.0 m (9.8ft)
Front brake Disc brake, twin
Rear brake Disc brake
Front tire size 120/80V 16 V250
Rear tire size 150/80V 16 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 2 375 r/min
Spark plug N.G.K.: JR9B or 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 L (5.5 US gal)
19.5 L (5.2 US gal)...... California model only
Engine oil, Oil change with oil filter change 4.5 L (4.8 US qt)
Front fork oil 478 ml (16.2 US oz)
These specifications are subject to change without notice.