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GSX-R1100 (1989-1992)
Инструкция по эксплуатации Страница: 202

Suzuki GSX-R1100 (1989-1992) [202/358] Reassembly information

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Foreword 2
Group index 2
Important 2
General information 4
Fuel and oil recommendation 5
Fuel for canadian model 5
Fuel for the other models 5
Fuel for u s a model 5
Serial number location 5
Brake and clutch fluid 6
Break in procedures 6
Cylinder identification 6
Engine oil for the other models 6
Engine oil for u s a model 6
Front fork oil 6
Materiai 7
Special materials 7
Precautions and general instructions 9
Replacement parts 9
Asbestos information 10
Dimensions and dry mass 11
Engine 11
Specifications 11
Transmission 11
Capacities 12
Chassis 12
Electrical 12
Country or area 13
Symbol country or area 13
Contents 14
Periodic maintenance and 14
Tune up procedures 14
Periodic maintenance chart 15
Periodic maintenance schedule 15
Lubrication points 16
Battery 17
Maintenance and tune up procedures 17
Cylinder head nuts and exhaust pipe bolts 18
Air cleaner 19
Caution 19
Valve clearance 19
Spark plugs 21
Engine oil and oil filter 22
Carburetors 23
Clutch 23
Fuel lines 23
Vapor hose california model only 23
Drive chain 25
Brakes 26
Caution 28
Caution 29
Duat riding 29
Steering 29
Front forks 30
Rear suspension 30
Chassis bolts and nuts 31
Nm kgm 31
Contents 33
Engine 33
Compression check 34
Compression test procedure 34
Oil pressure check 35
Oil pressure test procedure 35
Engine center 36
Engine components removable with the engine in place 36
Engine right side 36
Engine removal 37
Engine removal and reinstallation 37
Engine reinstallation 43
Spacer rh 43
40610 oil filter wrench 46
Engine disassembly 46
Cylinder head servicing 57
Engine components inspection and servicing 57
Cylinder head distortion 58
Valve face wear 58
Valve guide valve stem clearance 58
Valve head radial runout 58
Valve stem runout 58
Valve guide servicing 59
Valve stem wear 59
Valve seat servicing 60
Valve seat width 60
Valve springs 62
Valve stem end condition 62
For intake side 63
Reassembly 63
Cam wear 64
Camshaft 64
Camshaft journal wear 65
Cam chain tensioner 66
Cam sprocket 66
Camshaft runout 66
Reassembly 66
Cam chain 20 pitch length 67
Cam chain guide 67
Cam chain idler 67
Cylinder block distortion 67
Cylinder bore 67
Piston cylinder clearance 68
Piston diameter 68
Piston ring groove clearance 68
Piston pin and pin bore 69
Piston ring free end gap and piston ring end gap 69
Conrod big end side clearance 70
Conrod crank pin bearing selection 70
Conrod small end i d 70
Bearing assembly 72
Crankcase crankshaft bearing selection 73
Crankshaft thrust clearance 75
Crankshaft runout 76
Clutch bearing 77
Clutch diaphragm spring 77
Clutch drive and driven plates 77
Clutch release cylinder 78
Oil pump 78
Transmission 79
Countershaft 80
Driveshaft 80
Ing is as follows 80
Countershaft and driveshaft 81
Transmission 83
Engine reassembly 84
Gearshift fork groove clearance 84
Cylinder stud bolt location 94
13110 40c0 for no 1 102
69 engine 102
Attach the right and left oil hoses and tighten the bolts to 102
I3i40 40c0 for no 4 102
I3j20 40c0 for no 2 13130 40c0 for no 3 102
Intake pipes according to each id code 102
Note when replacing the intake pipes identify the four different 102
The specified toiqne 102
Contents 103
Fuel and lubrication system 103
Fuel cock removal 104
Fuel level indicator switch 104
Fuel tank fuel cock and fuel level indicator switch 104
Fuel tank removal 104
Inspection and cleaning 104
Remove the seal 104
Fundamental of fuel cock 105
Carburetor 106
Construction 106
Specifications 107
I d no location 108
Diaphragm and piston operation 109
Slow system 110
Main system 111
Float system 112
Starter system 112
Fuel system 113
Disassembly 114
Inspection and adjustment 114
Pilot air jet 114
Balance of carburetors 116
Balancing carburetors 118
Lubrication system 120
Oil pressure 120
Check the hale in the relief valve for clogging 121
Filter is free from any sign of rupture also wash the filter clean 121
Fuel and lubrication system 4 1b 121
Noth grease the o ring ot the oil hirer 121
Oil filter 121
Oil sump filter 121
Periodically 121
Relief valve 121
When v n wash the oil pan check to be sure that the oil sump 121
Main gallery 122
Nozzle 122
Oil pan 122
Engine lubrication system 123
Cylinder head cover 124
Oil pan 124
Cylinder head cooling system 125
Ol l cooler 126
Contents 127
Electrical system 127
Charging system 128
Description generator with ic regulator 128
Above dc1 3 5v at 129
As shown 129
Charging output check 129
Check the stator coil rectifier and ic regulator mounted in 129
Condition 129
Disconnect the generator lead wires see page 3 6 129
Electrical sysiem 5 2 129
Hold the generator driven gear to use a vise and appropriate 129
Measure the dc voltage between the battery terminals 129
Pieces of woods and remove the generator driven gear nut 129
Removal and disassembly 129
Remove the generator 129
Remove the lower lairing 129
Remove the seat 129
Start the engine and keep it running at 5 000 r min 129
Std charging output 129
The generator 129
When making this test be sure that the battety is fully charged 129
Inspection 131
Rectifier 132
Reassembly and remounting 134
Reassembly information 136
Ig1 j ig2 a a 141
Monitor 141
Revolution 141
Description 142
Removal and disassembly 142
Starter system 142
Inspection 143
O ring 144
Reassembly 144
Starter relay inspection 145
Description 146
Side stand ignition interlock system 146
Inspection 147
Combination meter 149
Inspection 149
Removal and disassembly 149
4eijîral 150
Fiectrical system 150
I pobr of 150
Muer i ig it 150
Ugh beam 150
Гем 150
Fuel level indicator 151
Inspection 151
Headlight 152
Tail brake light 152
Oil pressure switch 153
Switches 153
Turn signal light 153
Headlight relay 154
Side stand relay 154
Starter relay 154
Turn signal relay 154
Battery 155
Initial charging 155
Servicing 155
Specifications 155
Recharging operation based on s g reading 156
Service life 157
Chassis 158
Contents 158
Fairing 159
Remounting 159
Removal 159
Front wheel 160
Removal 160
Inspection and disassembly 161
Reassembly and remounting 162
Front brake 164
Brake pad replacement 165
Caliper removal and disassembly 165
Caliper and disc inspection 166
Caliper reassembly and remounting 166
Can be checked with disc and wheel in place the service limits 166
Chassis 6 166
For the thickness of the discs are shown below 166
Inspect the caliper bore wall for nicks scratches or other 166
Inspect the piston surface for any scratches or oilier damage 166
Reassemble and remount the caliper in the reverse order of 166
Removal and disassembly pay attention to the following points 166
Runout with a dial gauge as shown 166
Using a micrometer check the disc for wear its thickness 166
With the disc mounted on the wheel chock the disc for face 166
Master cylinder removal and disassembly 167
Master cylinder inspection 168
Master cylinder reassembly and remounting 168
Front fork 169
Removal 169
Disassembly 170
Inspection 171
Reassembly and remounting 172
Steering 175
Disassembly 176
Inspection 176
Removal 176
Reassembly amd remounting 177
Steering tension adjustment 179
Ignition switch 180
Rear brake 181
A suitable receptacle 182
And push out the piston by using an gun 182
Brake pad replacement 182
Cahpur 182
Caliper removal and disassembly 182
Chassis 6 24 182
Disassembly before removing the caliper mounting baits 182
Halves 182
He caliper 182
I remove the brake hose union bolt and catch brake fluid in 182
Note once separate the caliper halves replace the o mg with a new 182
Place a rag over the piston to prevent it from popping out 182
Remove the caliper mounting bolls 182
Remove the clips pins and springs 182
Remove the dust seal cover 182
Remove the dust seal piston and piston seal out of the 182
Remove the o ring 182
Remove the pads 182
Remove the torque link bolt and nut and take oil the caliper 182
Slightly loosen the caliper housing holts j to facilitate later 182
25 chassis 183
Caliper and disc inspection 183
Caliper reassembly and remounting 183
Caliper refer to page 6 8 183
Disc rufei tu page 6 fl 183
Piston hafer tu page 6 8 183
Rubber parts refer to page 6 h 183
Master cylinder removal and disassembly 184
Chassis 185
Damage 185
Following points 185
Inspect the cup set and each rubber pan for wear or damage 185
Inspect the cylinder bare wall for any scratches 0 other 185
Inspect the piston surface for any scratches or other damage 185
Master cylinder inspection 185
Master cylinder reassembly and remounting 185
Order of removal and disassembly pay attention to the 185
Reassemble and remount the master cylinder in the reverse 185
Remove the connector and o ring 185
Rear wheel 186
Removal 187
Inspection and disassembly 188
Reassembly and remounting 189
Remove the ear sprocket by removing the mounting nuts 189
Apply grease to the bearing and oil seal lip 190
Chassis 6 32 190
Install thp bearing by using the special tool 190
Stamped mark on the sprocket is positioned outside 190
Tighten the sprocket mounting nuts to the specified torque 190
Adjust the chain slack after rear wheel installation 191
Apply thread lock supfr 1360 ta the disc mounting 191
Bolts and tighten them ta the specified torque 191
Chassis 191
Make sure that the brake disc is clean and free of any greasy 191
Matter 191
Page 2 111 191
The tire completely 192
Tire and wheel 192
Tire removal 192
Inspection 194
Valve inspection 194
37 chassis 195
Any dust nr rust around the valve hole must be cleaned off 195
Apply a special tire lubricant or neutral soapy liquid to the 195
Arrow faces the direction of wheel rotation and align the 195
Balancing mark of the tire with the valve as shown 195
Then install the valve in the rim 195
Tire bead 195
Tire mounting 195
When installing the tire make certain that the directional 195
39 chassis 197
Item km 197
Rear suspension 197
Swingarm 197
Chassis 640 198
Shock absorber and cushion lever 198
Inspection 199
Removal 199
Disassembly 200
By using appropriate tool 201
Chassis 201
Remove the bearing by using the special tool 201
Remove the bearing stopper rings and dr ive out the bearing 201
Remove the bearing stopper rings and drive out the bearing 201
Remove the spacers and dust seals 201
Chassis б 44 202
Reassembly information 202
Final inspection and adjustment 203
Reassembly and remounting 203
Front suspension setting table 204
Rear suspension setting table 204
Suspension setting 204
Boh and disconnect the clutch hose from the master cylinder 205
Chassis 205
Clutch master cylinder 205
Disassemble and reassemble the clutch master cylinder in the 205
Disassembly and reassembly 205
Place a rug underneath the union bolt on the master cylinder 205
Removal 205
Remove the clutch master cylinder by removing its clamp 205
Remove the clutch switch statler interlock switch 205
Same manner of the front brake master cylinder 205
To catch any spilled drops of brake fluid unscrew the union 205
Servicing informa tion 206
Engine 207
Troubleshooting 207
Carburetor 209
Electrical 210
Battery 211
Chassis 212
Brakes 213
For general england norway belgium and australia models 214
Wiring diagram 214
Servicing information 215
I i ho 216
Servicing information 7 10 216
For switzerland model 217
Qöqon 218
Servicing information 7 1 218
For the other models 219
Wire harness cable and hose routing 220
Wire routing 220
15 servicing information 221
Ciarrp 221
Cut al switch ead wire 221
Geneatcr lead wire 221
I cian 221
Ignitor unit gruurc wire 221
Or pressure switch lend wire 221
See st and switch 221
Sipciil generator tad wire 221
Speedometer tacnometer 221
Sue star switch ion wim 221
Terminal to starter motor 221
Tn left nandlebar switch 221
Under the battery holderl 221
Speedometer cable routing 222
17 servicing information 223
Throttle cable routing 223
Clutch hose routing 224
Oil cooler hose and air cleaner hose routing 225
Front brake hose routing 226
V m3ia 226
Rear brake hose routing 227
Fuel hose and fuel tank water drain hose routing 228
Servicing information 7 22 228
Reservoir tank hose routing 231
2 7 109 232
20bü3 bickiihhh qmiqn 232
23100 fmiorù iminr 232
Plasliqaaao 232
Servicing information 7 26 232
Special tools 232
Noilvwaojni 9ni3iahjs 233
P pu j an ран i su i обо 233
Сов o 233
345 1 3 steering w iimnllin 234
Not available in ij s a 234
Servicing information 7 28 234
Tightening torque engine 235
Chassis 236
Item n m kg m ib ft 236
Item standard limit 237
Service data 237
Valve guide 237
Camshaft cylinder head unit mm in 238
Cylinder i piston piston ring unit mm in 238
Standard 238
Conrod crankshaft 239
Clutch 240
Oil pump 240
Item standard limit 241
Transmission f drive chain 241
Carburetor 242
Specification 242
Carburetor 243
Electrical 243
Wattage 244
Brake i wheel 245
Item standard 246
Solo riding 246
Suspension 246
Tire pressure 246
Fuel oil 247
Item specification 247
Emission control information 248
3456 090 249
Emission control carburetor components 249
Air suction system only for california model 252
Emission control information 8 4 252
Contents 254
Engine mounting 9 15 cylinder head 16 steering 9 17 254
Gsx r11ool 9o model 254
Hose routing 23 throttle cable routing 9 26 254
Service data 9 3 tightening torque 9 14 254
Specifications 9 1 254
Suspension setting 9 21 wiring diagram 9 22 254
Swingarm 9 18 shock absorber and cushion lever 9 20 254
Dimensions and dry mass 255
Engine 255
Specifications 255
Transmission 255
Capacities 256
Chassis 256
Electrical 256
Item standard limit 257
Service data 257
Camshaft cylinder head 258
Cylinder piston piston 258
Item standard 259
Item standard limit 259
Clutch 260
Item standard 260
Oil pump 260
Item standard limit 261
Transmission drive chain 261
Carburetor 262
Specification 262
Carburetor 263
Electrical 263
Wattage 264
Brake i wheel 265
Standard limit 265
Standard 266
Suspension 266
Tire pressure 266
Fuel oil 267
Specification 267
Chassis 268
Tightening torque 268
Engine mounting 269
Tightening torque 269
Cylinder head 270
Cylinder head cover bolt gasket 270
Steering 271
Tightening torque 271
Swingarm 272
Left o 273
Swingarm pivot thrust clearance adjustment 273
Shock absorber and cushion lever 274
Tightening torque 274
Front suspension setting table 275
R is rebound c is compression 275
Rear suspension setting table 275
Spring adjuster 275
Suspension setting 275
Gsx r1100l 90 model 9 22 276
Hose routing 277
Oil cooler hose and air cleaner hose routing 277
Reservoir tank hose routing 278
I for californ a and wiiumland medals 280
Throttle cable routing 280
Contents 281
Gsx r1100m 91 model 281
Service data 281
Specifications 1 281
Steering 1 281
Suspension setting 10 27 wiring diagram 10 29 wire harness routing 10 35 fuel hose and fuel tank water drain hose routing 10 38 front brake hose routing 10 39 rear brake hose routing 10 40 clutch hose routing 10 41 cable routing 10 43 fairing installation 10 45 frame cover inst all a tion 10 46 engine heat protector 10 47 air suppl y system 10 48 air suppl y hose routing 10 49 high tension cord routing 10 50 281
Tappet clearance adjustment 10 17 tappet shim selection table intake 10 18 tappet shim selection table exhaust 10 19 front fork 281
Tightening torque 10 14 emission control carburetor components 10 15 engine mounting 10 16 cylinder head 281
Dimensions and dry mass 282
Engine 282
Specifications 282
Transmission 282
Capacities 283
Chassis 283
Electrical 283
Service data 284
Valve guide 284
Camshaft cylinder head 285
Cylinder piston piston ring 285
Conrod crankshaft 286
Clutch 287
Oil pump 287
Carburetor 288
Transmission 4 drive chain 288
Carburetor 289
Carburetor 290
Electrical 290
Wattage unit w 291
Brake wheel 292
Suspension 293
Tire pressure 293
Fuel oil 294
Chassis 295
Tightening torque 295
3 4 5 6 7 8 296
Emission control carburetor components 296
Engine mounting 297
Cylinder head 298
Removal order 298
Tappet clearance adjustment 298
Tappet shim no 12892 41coo xxx 299
Tappet shim selection table intake 299
Tappet shim no 1 2892 41coo xxx 300
Tappet shim selection table exhaust 300
Front fork inverted telescopic type 301
Removal 301
Disassembly 302
Reassembly and remounting 304
Steering 307
For e 03 28 and 33 models 308
Front suspension setting table 308
Rear suspension setting table 308
Suspension setting 308
For the other models 309
Front suspension setting table 309
Rear suspension setting table 309
Suspension setting 309
Wiring diagram 310
Gsx r1100m si model 10 30 311
Fuel hose and fueltank water drain hose routing 319
Gsx r1100m 91m0del 10 38 319
Front brake hose routing 320
Rear brake hose routing 321
Clutch hose routing 322
For u s a switzerland and austria models 322
For the other models 323
Cable routing 324
Fairing installation 326
Frame cover installation 327
Engine heat protector 328
Air supply system 329
For california switzerland and austria models 329
Air supply hose routing 330
For california switzerland and austria models 331
High tension cord routing 331
Contents 332
Gsx r1100n 92 model 332
Dimensions and dry mass 333
Engine 333
Specifications 333
Transmission 333
Capacities 334
Chassis 334
Electrical 334
Service data 335
Valve guide 335
Camshaft cylinder head 336
Cylinder piston piston ring 336
Conrod crankshaft 337
Clutch 338
Oil pump 338
Carburetor 339
Transmission drive chain 339
Carburetor 340
Carburetor 341
Electrical 341
Wattage 342
Brake wheel 343
Suspension 344
Tire pressure 344
Fuel oil 345
Suzuki motor corporation 346
Suspension setting the standard suspension settings provide comfort able ride and good handling characteristics for general solo riding the suspension can be adjust ed for different riding conditions and rider prefer ences the following chart shows basic recommended settings for the front and rear sus pension units 352
Warning 352
A warning 353
Raise or lower the switch so that the bra 353
Rear brake light switch the rear brake light switch is located 353
Right frame cover to adjust the brake lighp 353
When the brake pedal is depressed 353
Will come on just before a pressure rise 353
A warning 357
Be sure to balance the wheel after repairing 357
Front______ rear 357
Note these wear limits will be reached be for the wear bars molded into the tire make contact with the road 357
Puncture or replacing the tire proper wheel bal ance is important to avoid vanable wheel to road contact and to avoid uneven tire wear 357
Size 120 70 zr17 160 60 zr17 357
Type michelin a69x michelin m59x 357
Use a different size or type of tire vehicle handling may be adversely affected possibly resulting in loss of vehicle control 357
When you replace a tire be sure to replace it with a tire of the size and type listed below if 357
Warning 358

Suzuki GSX-R1100 (1989-1992) [202/358] Reassembly information

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