![Suzuki GSX-R1100 (1989-1992) [304/358] Reassembly and remounting](/img/pdf.png)
Suzuki GSX-R1100 (1989-1992) [304/358] Reassembly and remounting
![Suzuki GSX-R1100 (1989-1992) [304/358] Reassembly and remounting](/views2/1121290/page304/bg130.png)
Содержание
- 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
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10 23 GSX R1100M 91 M00EL REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly Pay attention to the following points DAMPER ROD BOLT Insert the inner rod damper rod cartridge into the inner tube and tighten the damper rod bolt to the specified torque with the special tool and hexagon wrench CAUTION Use a new damper rod bolt gasket to prevent oil leakage Damper rod bolt 34 46 N m 3 4 4 6 kg m 24 5 33 5 Ib ft 09940 54821 0994054830 Front fork assembling tool Attachment L type hexagon wrench set 09900 00401 TUBE METALS AND SEALS Hold the inner tube vertically and clean the metal groove and install the ANTI FRICTION metal by hand as shown CAUTION Use special care to prevent damage to the TEFLON coated surface of the ANTI FRICTION metal when mounting it Install the dust seal oil seal stopper ring oil seal oil seal retainer and anti friction metal onto the inner tube CAUTION When installing the dust seal and oil seal onto the inner tube protect their seal lips with a vinyl film to prevent oil seal damage Do not damage use solvents for washing to prevent oil seal Dust seal Oil seal stopper ring D Oil seal Oil seal retainer Anti friction metal outer tube Anti friction metal inner tube Insert the inner tube into the outer tube and install the oil seal and dust seal with the special tool 09940 52820 Front fork oil seal installer
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