Suzuki Katana 1100 User manual

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 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.

• PERIODIC MAINTENANCE AND
o TUNE-UP PROCEDURES
CONTENTS ~
I PERIODIC MAINTENANCE SCHEDULE 2- 1 I'
PERIODIC MAINTENANCE CHART 2- 1
I LUBRICA TlON POINTS I 2- 2
I MAINTENANCE AND TUNE-UP PROCEDURES 2- 3
BA TTERY 2- 3
CYLINDER HEAD NUTS & EXHAUST PIPE DOL TS 2- 4
AIR CLEANER 2- 4
VAL VE CLEARANCE. 2- 5
SPARK PLUGS 2- 7
ENGINE OIL AND OIL FILTER 2- 8
FUEL LINE 2- 9
CARBURETOR 2- 9
CLUTCH 2- 9
DRIVE CHAIN 2-11
BRAKES 2-12
TIRES 2-14
STEERING 2-15
FRONT FORKS 2-16
REAR SUSPENSION 2-16
CHASSIS DOL TS AND NUTS 2-17 J

2-1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
PERIODIC MAINTENANCE SCHEDULE
II\IIPORTAI\lT: The periodic maintenance intervals and service requirements have been established in
accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not
exceed emission standards and it will also ensure the reliability and performance of the motorcycle.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions however,
it is not necessary for ensuring emission level compliance.
The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating at peak performance and to maintain proper emission levels. Mileages are
expressed in terms of kilometer, miles and time for your convenience.
PERIODIC MAINTENANCE CHART
em···· Innttee~rvaall km 1000 6000 12000 18000 24000
miles 600 4000 7500 11000 15000
t
Item months 2 12 24 36 48
1
:_:_;k_C_~_~_U_ag_r:_n_c_e I-V_S __ +- ~I~ __ +_-_:Il ~I It·-III--+--R- ----1
Fuel line
(Fuel line and vapor hose ... California version only)
Engine oil and filter R
Carburetors (Idle rpm)
I
Clutch hose
---h
Clutch fluid
Drive chain
Tires
I
Steering I
Front fork I
I
Rear
suspension
Chassis bolts and nuts
T
± 1
Replace every four years
R
I
lc
I
R
I
I
R
I
I
R
I
Replace every four years
I I I I
Replace every two years
Clean and lubricate every 1000km (600 miles)
I I I I II I
Brake hoses
Replace every four years
I I I I I
Brake fluid
Replace every two years
Brakes
'T~=r='
I
IIII
I I
I I
- - I
I
-
-I I
T T T T
NOTE: T = Tighten, I = Inspect, R = Replace

PERIODIC MAINTENANCE AND TUNE-LIP PROCEDURES 2-2
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
[Q] Oil
[ill Grease
[Q] Clutch lever holder
[Q] Throttle cable and brake lever holder
/
I
[9] Brake pedal pivot and brake rod link I
[Q] Drive chain
[ill Side-stand pivot
NOTE:
• Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime .
•
Lubricate exposed parts which are subject to rust, with oil or grease.

2-3 PERIODIC MAINTENANCE AND TUNE-LIP PROCEDURES
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item
of the Periodic Maintenance requirements.
BATTERY
I Inspect Every 6000 km (4000 miles. 12 months). ~
• Remove the seat.
•
Remove the battery 8 and EB lead wires from the battery
terminals.
• Remove the battery from its case.
• Check the electrolyte for level and specific gravity. Add
distilled water, as necessary, to keep the surface of the
electrolyte above the MIN. level line but not above the MAX.
level line.
o For checking specific gravity, use a hydrometer to determine
the charged condition.
09900-28403: Hydrometer
Standard specific gravity: 1.28 at 20°C (68°F)
An S.G. reading of 1.22 (at 20°C) or under means that the
battery needs recharging. Remove the battery from the ma-
chine and charge it with a battery charger.
CAUTION:
Never charge a battery while still in the machine as damage
may result to the battery or regulator/rectifier.
• Charge at a maximum of 1.4 amps.
• To install the battery, reverse the procedure described
above.
WARNING:
When installing the battery lead wires. fix the EB lead first
and 8 lead last.
• Make sure that the breather hose is tightly secured and
undamaged, and is routed as shown in the figure.
,
Hydrometer .-
L_
_I

-- --- -
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-4
CYLINDER HEAD NUTS AI\lD
EXHAUST PIPE BOLTS
Tighten Initially at 1000 km (600 miles. 2 months) and
Every 6000 km (4000 miles. 12 months) thereafter.
CYLINDER HEAD
• Remove the seat, frame covers and fuel tank.
I ----~"l:,.
(Refer to page 3-3.)
I ,
L __ . .. _. __
• Remove the cylinder head cover.
• First loosen and retighten the nuts to the specified torque
with a torque wrench sequentially in ascending numerical
order with the engine cold.
Cylinder head nut: 35 - 40N·m
(3.5 - 4.0 kg-m. 25.5 - 29.0 Ib-ft)
• After firmly tightening the 12 nuts, tighten the bolt and nut
(indicated as @ and ®) to the torque value below:
Cylinder head bolt @: 7 - 11 N·m
(0.7 -1.1 kg-m. 5.0 - 8.0 Ib-ft)
Cylinder head nut ®: 7 - 11 N'm
(0.7 -1.1 kg-m. 5.0 - 8.0 Ib-ft)
• When installing the cylinder head cover, apply SUZUKI Bond
No. 1207B to the head cover groove and cam end caps.
(Refer to page 3-64.)
• Tighten the head cover bolts to the specified torque.
Tightening torque: 13 - 15 N·m
(1.3 - 1.5kg-m. 9.5 - 11.0 Ib-ft)
EXHAUST PIPE
• Tighten the exhaust pipe clamp bolts to the specified torque
with a torque wrench.
Exhaust pipe clamp bolt: 9 - 12 N·m
(0.9 -1.2kg-m. 6.5 - 8.5 Ib-ft)
AIR CLEANER
Clean Every 3000 km (2000 miles) and Replace Every
12000 km (7500 miles).
• Remove the seat and frame covers.
• Remove the fuel tank bracket by removing the bolts.
• Lift up the rear end of the fuel tank and remove the air cleaner
element by removing the screws.
(Continued on next page.)
I
I
,
I
i
.J
-"--------,
~~I
__

I
2-5 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
• Carefully use air hose to blow the dust from the cleaner
element.
CAUTION:
Always use air pressure on the outside of the cleaner
element. If air pressure is used on the inside, dirt will be
forced into the pores of the cleaner element thus restricting
air flow through the cleaner element.
• Reinstall the cleaned or new cleaner element in the reverse
order of removal.
• When installing the air cleaner element in the cleaner case,
make sure that the arrow mark ® comes upward.
CAUTION:
If driving under dusty conditions, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to use the engine without the element or to
use a ruptured element. Make sure that the air cleaner is
in good
condition at all times. Life the engine depends
largely on this component!
VALVE CLEARANCE
Inspect Initially at 1000 km (600 miles, 2 months) and
Every 6000 km (4000 miles, 12 months) thereafter.
• Remove the seat, frame covers and fuel tank.
• Remove the cylinder head cover.
The valve clearance specification is the same for both intake
and exhaust valves.
Valve clearance adjustment must be checked and adjusted, 1)
at the time of periodic inspection, 2) when the valve mecha-
nism is serviced, and 3) when the camshafts are disturbed by
removing them for servicing.
Valve clearance (when cold): 0.10 - 0.15 mm
(0.004 - 0.006 in)
(Continued on next page.)
-(A)

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-6
.-._-- .. _----_.- --~
NOTE:
• The
cam must be at positions, ® or @, in order to check the
'C
I
I
valve clearance or to adjust valve clearance. Clearance
readings should not be taken with the cam in any other
position than these two positions.
• The clearance specification is for COLD state.
I
• To tum the crankshaft for clearance checking, be sure to use
c I
a 19-mm wrench and to rotate in the normal running
~~~~I
direction. All spark plugs should be removed.
• Turn crankshaft to bring the "T" mark on the rotor to the
center of pick-up coil and also to bring the notches CD in the
right ends of both camshafts (Ex and In) to the positions
shown. In this condition, read the valve clearance at the
valves © (In and Ex of NO.1 cylinder, Ex of No.2 and In of
l\lo. 3).
I
I~
I
I
I. _____.
l .. _ _ J
• Use a thickness gauge between the adjusting screw and the
valve stem end. If the clearance is off the specification, bring
it into the specified range by using the special tool.
09900-20803: Thickness guage
09917-14910: Valve adjust driver
CAUTION:
Both the right and left valve clearances, should be as
closely set as possible.
• Turn the crankshaft 360
0
(one rotation) to bring the'T' mark
on the rotor to the center of pick-up coil and also to bring
I
the notches CD to the positions shown.
I - :
• Read the clearance at the remaining valves @ and adjust the
clearance if necessary.
(Continued on next page.)
I
L.... __ .. . . .. . 1
._------------,
I
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I
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r ;"'1:'
.: "
Ir--tJ-l--"H )'J1;====='==~==~) J';;~I
II

I
2-7 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
.
Notch
CD
position
Cam Position
---
-----------._.
+
Intake Camshaft Exhaust Camshaft
--------------- - -- ----------- ----
8
© E)
---------_ .. _--
·--t---
-- .. --8 E)@
• When installing the cylinder head cover, apply SUZUKI Bond
No. 1207B to the head cover groove and cam end caps.
(Refer to page 3-64.)
• Tighten the head cover bolts to the specified torque.
Tightening torque: 13 - 15 N·m
(1.3 - 1.5 kg-m, 9.5 - 11.0 Ib-ft)
SPARK PLUGS
!lnsp;~-t-~;-6000-km(4(;OO miles, 12 months), 18000 k~
(11000 miles, 36 months) and Replace Every 12000 km
! (7500 miles, 24 months).
• Remove the seat, frame covers and fuel tank mounting bolts.
• Slide the fuel tank backward and lift up the front end of the
fuel tank.
• Remove the spark plugs with spark plug wrench.
CAUTION:
Take care not to damage the fuel hoses when raising the
fuel tank.
The plug gap is adjusted to 0.6 - 0.7 mm (0.02 - 0.03 in)
The gap is correctly adjusted by using a thickness gauge. When
carbon is deposited 011 the spark plug, remove the carbon with
a s~ark plug cleaning machine or by carefully using a tool with
a pointed end. If the electrodes are extremely worn or burnt,
replace the plug. Also replace the plug if it has a broken
insulator, damaged thread, etc.
NGK JR9B as listed in the table should be used as the standard
plug. However, the heat range of the plug should be selected
to meet the requirements of speed, actual load, fuel, etc. If the
plugs need be replaced, it is recommended that ones having
a heat range closest to the standard plug in the table be
selected. Remove the plugs and inspect the insulators. Proper
heat range would be indicated if all insulators were light brown
in color. If they are baked white, they should be replaced by
a cold type NGK JR 1OB
Recommended spark plug
.
Standard Cold type
._--- -
----------
-'-''"''i
---------
--------
NGK
JR9B
or J9B JR10B
orJ10B
:
09930-13210: Spark plug socket wrench
09930-14530: Universal joint
09914-24510: T hand Ie
09900-20803: Thickness gauge
,-----------------------
I
l . . . ----"
_·_-1
I
!
i
~~~_.10e - 0' "'''',
fl002 - 003 In)
______J
CAUTION:
Confirm the thread size and reach
when replacing the plug. If the reach
is too short, carbon will be deposited
on the screw portion of the plug hole
and engine damage may result.
NOTE:
uR" type spark plug is installed for
some specifications. "R" type spark
plug has a resister located at the center
electrode to prevent radio noise.

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-8
ENGII\lE OIL AI\lD OIL FILTER
lReplace Initially at 1000 km (600 miles, 2 months) andl
[ Every 6000 km (4000 miles, 12 months) thereafter. ~
Oil should be changed while the engine is hot. Oil filter
replacement at the above intervals should be done together
with engine oil change.
• Keep the motorcycle upright and remove the lower fairing.
(Page 7-1)
• Place an oil pan below the engine and drain oil by removing
the drain plug CD and filler cap (3).
• Remove the oil filter ® by using the oil filter wrench. (Special
tool @)
• Apply engine oil lightly to the gasket of the new filter before
installation.
• Install the new filter turning it by hand until you feel that the
filter gasket contacts the mounting surface. Then tighten 2
turns using the oil filter wrench. (Special tool @)
09915-40611: Oil filter wrench
NOTE:
To properly tighten the filter, use the spacial tool. Never tighten
the filter by hand.
• Fit the drain plug CD securely, and add fresh oil through the
oil filler. The engine will hold about 4.5 L (4.8 US qt) of oil.
Use an API classification of SE or SF oil with SAE 10W/40
viscosity.
• Start up the engine and allow it to run for several seconds
at idling speed.
• Turn off the engine and wait about one minute, then check
the oil level through the inspection window 8). If the level
is below mark"F", add oil to that level.
NECESSARY AMOUNT OF ENGINE OIL
Oil change: 4.3 L (4.5 US qt)
Filter change: 4.5 L (4.8 US qt)
Overhaul engine: 5.5 L (5.8 US qt)
CAUTION:
Use SUZUKI MOTORCYCLE GENUI.N OIL FILTER only, since
the other make's genuine filters and after-market parts may
differ in thread specifications (thread diameter and pitch),
filtering performance and durability, which could cause
engine damage or oil leaks. Suzuki automobile genuine oil
filter is also not usable for the motorcycles.
2
Special tool A
After contac.tlng the ga::'Ket,
tighten 2 turns
11 .. 1.2_

2-9 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
FUEL LINE (FUEL LINE AND VAPOR
HOSE ... California Version only)
~-;-~~~;-;t-I-~iti~-IY at 1000 km (600 miles.- 2 months) and
Every 6000 km (4000 miles. 12 months) thereafter.
I
i Replace Every four years.
L_______________ _ _
CARBURETOR
IDLE RPM (Idling adjustment)
Inspect Initially at 1000 km- (600~iles~2-mon~hs) and
Every 6000 km (4000 miles. ~~ months~~_~r_:~~:r JI
NOTE:
Make this adjustment when the engine is hot.
• Connect a tachometer.
• Start up the engine and set its speed at anywhere between
1000 and 1200 r/min by turning throttle stop screw CD.
Engine idle speed: 11 00 t~ 100 r/min
THROTTLE CABLE PLAY
There should be 0.5 - 1.0 mm (0.02 - 0.04 in) play ® on the
throttle cable. Adjust the throttle cable play with the following
procedure.
• Loosen the lock nut and turn the adjuster ® in or out until
the specified play is obtained.
• Tighten the lock nut while holding the adjuster.
Throttle cable play @: 0.5 - 1.0mm (0.02 - 0.04in)
WARNING:
After the adjustment is completed. check that handlebar
rnovemen t does not raise the engine idle speed and that the
throttle grip returns smoothly and automatically.
CLUTCH
Inspect Initially at 1000 km (600 miles. 2 months) and
Every 6000 km (4000 miles, 12 months) thereafter.
Replace hose every four years. Replace fluid every two
I
years.
_____________________ JI
CLUTCH FLUID LEVEL
• Keep the motorcycle upright and place the handlebars
straight.
• Check the clutch fluid level in the reservoir.
• If the level is found to be lower than the lower mark, replenish
with BRAKE Fl UID that meets the following specification.
Specification and classification: DOT4
(Continued 011 next page.)