![Suzuki GSX-R1100 (1993-1998) [15/380] Transmission](/img/pdf.png)
Suzuki GSX-R1100 (1993-1998) [15/380] Transmission
![Suzuki GSX-R1100 (1993-1998) [15/380] Transmission](/views2/1121288/page15/bgf.png)
Содержание
- Service manual 1
- Suzuki 1
- Suzuki motor corporation printed in japan november 92 1
- And tune up procedures 3
- Chassis 3
- Cooling system 3
- Electrical system 3
- Emission control 3
- Engine 3
- Foreword 3
- Fuel and lubrication 3
- General information 3
- Group index 3
- Gsx r1100wr 94 model 3
- Gsx r1100ws c95 model 3
- Gsx r1100wt 96 model 3
- Important 3
- Information 3
- Periodic maintenance 3
- Servicing information 3
- System 3
- General informa tion 5
- Fuel oil and coolant recommendation 6
- Serial number location 6
- Suzuki gsx r1100wp 93 model 6
- Anti freeze engine coolant 7
- Brake fluid 7
- Engine coolant 7
- Engine oil 7
- Front fork oil 7
- Liquid amount of water engine coolant 7
- Water for mixing 7
- Break in procedures 8
- Cylinder identification 8
- Emery cloth and the like how to use them and where to use them are described in the text of this 9
- Kept on hand for ready use they supplement such standard materials as cleaning fluids lubricants 9
- Manual 9
- Special materials 9
- The materials listed below are needed for maintenance work on the gsx r11oow and should be 9
- Precautions and general instructions 12
- Replacement parts 12
- California model only 13
- Information labels 13
- Dimensions and dry mass 15
- Engine 15
- Specifications 15
- Transmission 15
- Capacities 16
- Chassis 16
- Electrical 16
- Country or area 17
- Periodic maintenance and 19
- Tune up procedures 19
- Periodic maintenance chart 20
- Periodic maintenance schedule 20
- Before lubricating each part dean off any rusty spots and wipe off any grease oil dirt or grime 21
- Lubricate exposed parts which are subject to rust with oil or grease 21
- Lubrication points 21
- Major lubrication points are indicated below 21
- Motorcycle 21
- Proper lubrication is important for smooth operation and long life of each working part of the 21
- Air cleaner___________________________ 22
- Exhaust pipe bolts_____________________ 22
- Maintenance and tune up 22
- Procedures 22
- Tappet clearance 23
- How to use this chart 25
- M cn 0 m 25
- Periodic maintenance and tune up procedures 2 6 25
- Tappet shim selection table intake tappet shim no 1 2892 05c00 x x x tappet shim set no 12800 05820 25
- 7 periodic maintenance and tune up procedures 26
- Spi citied cl earance no adjustment required 26
- Tappet shim selection table exhaust tappet shim no 12892 05c00 x x x tappet shim set no 12800 05820 26
- To o m 26
- Spark plug 27
- Engine oil and oil filter 28
- Carburetor 29
- Fuel cock filter 29
- Fuel line 29
- Clutch 30
- Drive chain 31
- Cooling system 32
- Front fork 37
- Rear suspension 37
- Steering 37
- Chassis bolts and nuts 38
- Compression pressure check 40
- Compression test procedure 40
- Oil pressure check 41
- Oil pressure test procedure 41
- Engine 43
- Engine components removable with engine in place 44
- Engine removal 45
- Engine removal and reinstallation 45
- Engine reinstallation 52
- Engine disassembly 54
- _ up j y 62
- Bl i i if 65
- Remove the oil pump o rings and dowel pins 65
- Cylinder head service 66
- Engine components inspection and service 66
- Cylinder head distortion 67
- Valve face wear 67
- Valve head radial runout 67
- Valve stem deflection 67
- Valve stem runout 67
- Valve guide servicing 68
- Valve stem wear 68
- Valve seat servicing 69
- Valve seat width 69
- Reassembly 71
- Valve spring 71
- Camshaft 72
- Cam wear 73
- Camshaft journal wear 73
- Cam sprocket 74
- Camshaft runout 74
- Reassembly 74
- Cam chain 20 pitch length 75
- Cam chain guide 75
- Cam chain tensioner 75
- Cylinder block distortion 75
- Cylinder bore 76
- Piston cylinder clearance 76
- Piston diameter 76
- Piston ring groove clearance 76
- Piston ring free end gap and piston 77
- Ring end gap 77
- Conrod big end side clearance 78
- Conrod small end i d 78
- Piston pin and pin bore 78
- Conrod crank pin bearing selection 79
- Bearing assembly 80
- Crankcase crankshaft bearing 81
- Selection 81
- Crankshaft thrust clearance 83
- Crankshaft runout 84
- Clutch bearing 85
- Clutch diaphragm spring 85
- Clutch drive and driven plates 85
- Clutch release cylinder 86
- Oil pump 86
- Transmission 87
- Pay attention to the directions 89
- Gearshift fork groove clearance 90
- Starter clutch 91
- Engine reassembly 93
- Fuel and lubrica tion system 113
- Fuel system 114
- Fuel cock removal 115
- Fuel tank and fuel cock 115
- Fuel tank removal 115
- Inspection and cleaning 115
- Carburetor 116
- Construction for e 03 18 33 and 39 models 116
- Construction for e 01 02 and other market models 117
- Specifications 118
- I d no location 119
- Diaphragm and piston operation 120
- Slow system 121
- Main system 122
- Float system 123
- Starter system 123
- Disassembly 124
- Removal 124
- Float height adjustment 127
- Inspection and adjustment 127
- Needle valve inspection 127
- Reassembly and remounting 127
- Balance of carburetors 128
- Lubrication system 130
- Oil filter 130
- Oil pressure 130
- Oil sump filter 130
- 4 4 m i 131
- Main gallery 131
- Oil pan 131
- Engine lubrication system 132
- Engine oil cooling system 133
- Cooling system 135
- Cooling system 136
- Description 136
- Construction 137
- Cooling solution 139
- Cooling system removal and 140
- Disassembly 140
- Radiator 140
- Water hoses and thermostat case 140
- And cooling fan thermo switch 141
- Cooling fan 141
- Engine coolant temperature gauge 141
- Thermostat 141
- Water pump 141
- Inspection 143
- Installation 143
- Radiator 143
- Removal 143
- Engine coolant temperature gauge 144
- Inspection 144
- Removal 144
- Cooling fan 145
- Cooling fan thermo switch 145
- Inspection 145
- Reassembly 145
- Removal 145
- Inspection 146
- Reassembly 146
- Removal 146
- Inspection 147
- Reassembly 147
- Removal 147
- Thermostat 147
- Inspection 148
- Reassembly 148
- Removal and disassembly 148
- Water pump 148
- Electrical system 151
- Changes the stator a c voltages to a d c voltage which appears at the generator output terminal 152
- Charging system 152
- Description generator with ic regulator 152
- Housing a rectifier bridge connected to the stator windings contains six diodes and electrically 152
- Lator voltage setting cannot be adjusted 152
- Ponents are enclosed into a solid mold and this unit is attached to the brush holder frame the regu 152
- The generator features a solid state regulator that is mounted inside the generator all regulator com 152
- The stator windings are assembled on the inside of a laminated core that forms part of the generator 152
- Two brushes carry current through the two slip rings to the rotor coil mounted on the rotor 152
- Charging output check 153
- Removal and disassembly 153
- Inspection 155
- Reassembly and remounting 156
- Reassembly information 158
- Best ignition timing from the signal of ceramic vibrator and data stored in the rom the cpu out 159
- Caution 159
- Description 159
- Engine can run over 11 000 r min without load even if the ignition cut off circuit is effective and 159
- Generator is sent to wave form arrangement circuit and cpu receives this signal and calculates the 159
- Ignition cut off circuit is incorporated in the ignitor unit to prevent over running engine if engine 159
- Ignition system digital ignitor 159
- Ings of the ignition coil which is turned off and on accordingly thus it induces the secondary current 159
- It may cause engine damage do not run the engine without load over 11 000 r min at anytime 159
- Microcomputer and ceramic 4mhz vibrator ignition coils and spark plugs the charac 159
- On the ignition coil secondary windings and produce the spark between spark plug gaps 159
- Puts signal to the transistor of the i g coil output circuit which is connected to the primary wind 159
- R min reaches 11 000 r min this circuit cuts off the ignition primary current for all spark plugs 159
- Teristic of the ignition timing is programmed and stored in the rom read only memory of 159
- The fully transistorized ignition system consists of a signal generator ignitor unit including 8 bit 159
- The ignitor unit 159
- The signal generator comprises the rotor tip and pickup coil 159
- The signal generator is mounted at the right end of the crankshaft the induced signal in the signal 159
- Inspection 160
- Revolution 163
- Description 164
- Removal and disassembly 164
- Starter system 164
- Inspection 165
- Reassembly 166
- Starter relay inspection 167
- Description 168
- Side stand ignition interlock system 168
- Inspection 169
- Combination meter 171
- Inspection 171
- Removal and disassembly 171
- Engine coolant temperature meter 173
- Inspection 173
- Fuel level indicator 174
- Inspection 174
- Oil pressure switch 177
- Switches 177
- Turn signal light 177
- Side stand relay 178
- Starter relay 178
- Turn signal relay 178
- Battery 179
- Initial charging 179
- Specifications 179
- Servicing 180
- Recharging operation 181
- Chassis 183
- Frame cover and cowling 184
- Removal 185
- Front wheel 189
- Removal 189
- Inspection and disassembly 190
- Reassembly and remounting 191
- Cause of this we recommend using a tire changer which is also more efficient than tire levers 194
- For tire removal the following tools are required 194
- Mark the tire with chalk to note the position of the tire 194
- On the rim and rotational direction of the tire 194
- Remove the valve core from the valve stem and deflate 194
- The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead be 194
- The tire completely 194
- Tire and wheel 194
- Tire removal 194
- Inspection 196
- Tire mounting 197
- Brake pad replacement 199
- Front brake 199
- Remove the brake pad spring by removing the bolts 199
- Caliper removal and disassembly 200
- Caliper and disc inspection 201
- Caliper reassembly and remounting 201
- Disassembly 202
- Disc inspection 202
- Disc servicing 202
- Master cylinder removal and 202
- Master cylinder inspection 204
- Master cylinder reassembly and 204
- Remounting 204
- Front fork 205
- Removal and disassembly 205
- Inspection 208
- Reassembly and remounting 208
- Suspension setting 212
- Inspection 213
- Removal 213
- Steering damper 213
- Removal and disassembly 214
- Steering 214
- Disassembly 215
- Inspection 215
- Reassembly and remounting 216
- Steering tension adjustment 217
- Combination meter 218
- Ignition switch 218
- Brake pad replacement 219
- Rear brake 219
- Caliper removal and disassembly 220
- Caliper inspection 221
- Caliper reassembly and remounting 222
- Disassembly 222
- Master cylinder removal and 222
- Master cylinder inspection 223
- Master cylinder reassembly and 224
- Remounting 224
- Rear wheel 225
- Removal and disassembly 225
- Inspection and disassembly 227
- Reassembly and remounting 228
- Rear suspension 231
- Swingarm 231
- Shock absorber and cushion lever 232
- Removal 233
- Inspection 235
- Reassembly and remounting 237
- Reassembly onto frame 237
- Adjustment 238
- Swingarm pivot thrust clearance 238
- Final inspection and adjustment 240
- Suspension setting 240
- Clutch master cylinder 241
- Disassembly inspection and 241
- Reassembly 241
- Removal 241
- Servicing informa tion 243
- Engine 244
- Troubleshooting 244
- Electrical 246
- Battery 247
- Chassis 248
- Brakes 249
- 9 servicing information 250
- B y bl b 250
- Black blue 250
- Black with yellow tracer blue with black tracer 250
- Br brown y yellow g y green with yellow tracer w b white with black tracer 250
- G green b bi black with blue tracer o b orange with black tracer w bi white with blue tracer 250
- Gr gray b br black with brown tracer o bi orange with blue tracer w r white with red tracer 250
- Lbl light blue b g black with green tracer o g orange with green tracer y b yellow with black tracer 250
- Lg light green b r black with red tracer o r orange with red tracer y g yellow with green tracer 250
- O y r b 250
- Orange b w black with white tracer o w orange with white tracer y w yellow with white tracer 250
- Orange with yellow tracer red with black tracer 250
- Red white 250
- Wire color в bl 250
- M cn cn 251
- Side stand switch 253
- Wire harness routing 253
- Wire routing 254
- Wire routing 255
- Ignition coil no 4 256
- Wire routing 256
- Speedometer cable routing 258
- Seat lock cable routing 259
- Fuel system hose routing 260
- Uel hose no 1 260
- Calif model only 261
- The air cleaner drain hose by removing the drain plug 261
- When you dean the air deaner element drain water from 261
- Cooling system hose routing 262
- Oil cooler 262
- Clutch hose routing 264
- Front brake hose routing 265
- Clamp the brake hose firmly 266
- Rear brake hose routing 266
- Pair hose routing only for california model 269
- Frame cover cushion 272
- Frame cover set up 272
- Inside of frame covers 272
- F o m 3 o o 273
- Inside of cowlings 273
- Right side 273
- Special tools 275
- When ordering the special tool please confirm whether it is available or not 277
- Engine 278
- Tightening torque 278
- Chassis 279
- Conventional bolt 4 marked bolt 7 marked bolt 280
- For other bolts and nuts listed previously refer to this chart 280
- Tightening torque chart 280
- Service data 281
- Valve guide 281
- Camshaft cylinder head 282
- Cylinder piston piston ring 282
- Conrod crankshaft 283
- Oil pump 283
- Clutch 284
- Thermostat radiator fan 284
- Transmission drive chain 284
- Carburetor 285
- Electrical 286
- Wattage 286
- Brake wheel 287
- Fuel oil engine coolant 288
- Suspension 288
- Tire pressure 288
- Emission control informa tion 291
- Emission control carburetor components 292
- Ibb b b 292
- Pair hose routing only for california model 296
- Gsx r1wowr 94 mo del 299
- C34 muüeu 300
- Dimensions and dry mass 300
- Drive chain 300
- Specifications 300
- Transmission 300
- Service data 301
- Valve guide 301
- Camshaft cylinder head 302
- Cylinder piston piston ring 302
- Conrod crankshaft 303
- Oil pump 303
- Clutch 304
- Thermostat radiator fan 304
- Transmission drive chain 304
- Carburetor 305
- Electrical 307
- Wattage 307
- Brake wheel 308
- Fuel oil engine coolant 309
- Suspension 309
- Tire pressure 309
- Foreword 311
- Gsx r1100ws 95 model 311
- Dimensions and dry mass 312
- Engine 312
- Specifications 312
- Transmission 312
- Capacities 313
- Chassis 313
- Electrical 313
- Service data 314
- Valve guide 314
- Camshaft cylinder head 315
- Cylinder piston piston ring 315
- Conrod crankshaft 316
- Oil pump 316
- Clutch 317
- Thermostat radiator fan 317
- Transmission drive chain 317
- Carburetor 318
- Electrical 320
- Wattage 320
- Brake wheel 321
- Fuel oil engine coolant 322
- Suspension 322
- Tire pressure 322
- Service information 324
- Special tools 324
- Exhaust pipe muffler mounting 325
- Radiator cap and outlet water pipe 325
- Starter clutch 326
- Engine mounting 329
- Item nm kg m ib ft 329
- Length 329
- Tightening torque 329
- Ignitor unit 330
- Piston oil jet 330
- Signal generator rotor 330
- 95 model 332
- The windscreen fitting method has been changed from pin type to bolt type 332
- Upper cowling 332
- Windscreen 332
- Front axle 333
- Torque link rod 333
- Front fork 334
- Swingarm pivot thrust clearance adjustment 335
- Lock nut 60 70 n m 6 7 kg m 336
- Pivot nut 85 11 5 n m 8 11 kg m 336
- Front suspension setting 337
- Rear suspension setting 338
- Drive chain 339
- Drive chain adjustment 342
- Carburetor 343
- Drive chain cover set up 343
- Cd ел s o o m 344
- Cd сэ s сл 344
- En сл 344
- G j oj 344
- О о гп 344
- On off ос к 345
- Tul oli hi nii fu tur 345
- Г йй1 345
- Eg engine coolant temp gauge 346
- Handlebar switch u 346
- Main jua 346
- Rear turn signal light r 346
- Ней 346
- Bl blue r red b y black with yellow tracer o y orange with yellow tracer 347
- Br brown w white bl b blue with black tracer r b red with black tracer 347
- G green y yellow g y green with yellow tracer w b white with black tracer 347
- Gr gray b bi black with blue tracer o b orange with black tracer y b yellow with black tracer 347
- I 4íhu4 347
- Lbl light blue b br black with light brown tracer o bi orange with blue tracer y g yellow with green tracer 347
- Lg light green b g black with green tracer o g orange with green tracer y w yellow with white tracer 347
- Main jua 347
- Orange b r black with red tracer o r orange with red tracer 347
- Tfar turn signai light irl 347
- В black p pink b w black with white tracer 0 w orange with white tracer 347
- Ог к 347
- Lighi ihi 348
- Switch 348
- Wire color 348
- Втт пт 348
- О о m 348
- П о л о i ze m x 348
- Cn m 33 o 349
- M w to d o 349
- View a 349
- M to to 30 o 350
- Forward 353
- Speedometer cable routing 353
- Fuel system hose routing 354
- Cooling system hose routing 355
- Clutch hose routing 358
- Front brake hose routing 359
- Clamp the brake hose firmly 360
- Rear brake hose routing 360
- Pair air supply system hose routing only for california model 362
- Canister hose routing only for california model 364
- Gsx r1100wt 96 model 365
- Dimensions and dry mass 366
- Engine 366
- Specifications 366
- Transmission 366
- Capacities 367
- Chassis 367
- Electrical 367
- Service data 368
- Valve guide 368
- Camshaft cylinder head 369
- Cylinder piston piston ring 369
- Unit mm in 369
- Conrod crankshaft 370
- Oil pump 370
- Clutch 371
- Thermostat radiator fan 371
- Transmission drive chain 371
- Carburetor 372
- Electrical 374
- Lo 55 x 2 374
- Turn signal light 21 374
- Wattage 374
- _____ ___ 374
- Brake wheel 375
- Fuel oil engine coolant 376
- Suspension 376
- Tire pressure 376
- Suzuki motor corporation 378
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GENERAL INFORMATION 1 10 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length 2 130 mm 83 9 in 755 mm 29 7 in Overall width Overall height 1 190 mm 46 9 in Wheelbase 1 485 mm 58 5 in Ground clearance 130 mm 5 1 in 233 kg 514 lbs For E 33 model Dry mass 231 kg 509 lbs For E 03 model ENGINE Type Four stroke Water cooled DOHC TSCC Number of cylinders 4 75 5 mm 2 972 in Bore Stroke 60 0 mm 2 362 in 1074 cm3 65 5 cu in Piston displacement Carburetor MIKUNI BST36 Non woven fabric element Air cleaner Electric starter Starter system Lubrication system Wet sump TRANSMISSION Clutch Wet multi plate type Transmission 5 speed constant mesh Gearshift pattern 1 down 4 up 1 565 72 46 Primary reduction ratio 2 800 42 15 Final reduction ratio Gear ratios Low 2 714 38 14 2nd 1 809 38 21 3rd 1 409 31 22 4th 1 181 26 22 5th 1 038 27 26 Drive chain TAKASAGO RK532GSV2 114 links
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