![Suzuki GSX-R1100 (1993-1998) [202/380] Disassembly](/img/pdf.png)
Suzuki GSX-R1100 (1993-1998) [202/380] Disassembly
![Suzuki GSX-R1100 (1993-1998) [202/380] Disassembly](/views2/1121288/page202/bgca.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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7 19 CHASSIS CAUTION Bleed air from the system after reassembling the caliper Refer to page 2 16 NOTE Before remounting the caliper push the piston all the way into the caliper DISC SERVICING Remove the front and rear wheels Refer to pages 7 6 and 7 42 Remove the disc Refer to pages 7 7 and 7 44 8 Install the disc Refer to pages 7 8 and 7 46 DISC INSPECTION Using a micrometer check the disc for wear its thickness can be checked with disc and wheel in place The service limits for the thickness of the discs are shown below 09900 20205 Micrometer 0 25 mm Service Limit Front 4 5 mm 0 18 in Rear 5 5 mm 0 22 in With the disc mounted on the wheel check the disc for face runout with a dial gauge as shown 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand Service Limit 0 30 mm 0 012 in MASTER CYLINDER REMOVAL AND DISASSEMBLY 1 Remove the front brake light switch lead wires
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