Suzuki GSX-R1100 (1986-1988) [43/295] Engine reinstallation

Содержание

• Gsx nod 1
• Suzuki 1
• Foreword 2
• Suzuki motor co ltd 2
• General information 6
• Engine oil 7
• Fuel and oil 7
• Number location 7
• Recommendation 7
• Serial 7
• Brake and clutch fluid 8
• Break in procedures 8
• Cylinder identification 8
• Front fork oil 8
• Special materials 9
• Ork oil 10
• Precautions and general instructions 11
• Use of genuine suzuki parts 11
• Capacities 12
• Chassis 12
• Dimensions and 12
• Electrical 12
• Engine 12
• Fuel tank including 12
• L 4 u qt 12
• Specifications 12
• Transmission 12
• Country or areas 13
• General 13
• Note t tighten impact r repine 15
• 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
• Valve clearance 20
• Spark plugs 22
• Engine oil and oil filter 23
• Carburetor 24
• Fuel line 24
• Clutch 25
• Drive chain 26
• Caution 27
• Brakes 28
• Warning 28
• For tut 31
• Front forks 32
• Rear suspension 32
• Steering 32
• Chassis bolts and nuts 33
• Engine 35
• Compression check 36
• Engine removal 38
• Engine removal and reinstallation 38
• Engine reinstallation 43
• Engine disassembly 46
• Cylinder head servicing 58
• Engine components inspection and servicing 58
• Cylinder head distortion 59
• Valve stem runout 59
• Valve and seat condition valve seat width 62
• Valve seat servicing 62
• Valve stem end condition 64
• Reassembly 65
• Valve springs 65
• Camshaft 67
• Cam height 68
• Cam wear 68
• Camshaft journal wear 68
• Cam sprocket 69
• Camshaft runout 69
• Cam chain 20 pitch length 70
• Cam chain tensioner 70
• Cam chain guide 71
• Cylinder bore 71
• Cylinder distortion 71
• Piston cylinder clearance 72
• Piston diameter 72
• Piston ring groove clearance 72
• Piston ring free end gap and piston ring end gap 73
• Conrod 74
• Conrod small end i d 74
• Piston pin and pin bore 74
• Thrust clearance 74
• Bearing assembly 77
• Caution 77
• Crankshaft thrust clearance 81
• Clutch bearing 82
• Clutch release cylinder 82
• Caution 83
• Oil pump 83
• Transmission 84
• Countershaft 85
• Countershaft and driveshaft 86
• Driveshaft 86
• Gearshift fork groove clearance 89
• Engine reassembly 90
• Cautio 91
• On it be sure to bring the marked side to top when fitting it to the piston but top ring and oil ring do not have any designations and may be fit in either way 101
• The 2nd ring has the letter r top marked 101
• Disassembly 4 10 111
• Fuel and lubrication system 111
• Fuel tank and fuel cock removal 112
• Warning 112
• Fuel cock 113
• Id no location 115
• Specifications 115
• Slow system 117
• Float system 119
• Starter system 119
• Fuel system 120
• Disassembly 121
• 15 fuel лчо tvww 126
• Reassembly 127
• Fuel level inspection 130
• Balancing carburetors 131
• Lubrication system oil pressure 133
• Oil filter 134
• Oil sump filter 134
• Relief valve 134
• Oil cooler 135
• R l c sä s x süsk sää 136
• Contents 138
• Electrical system 138
• 1 electrical system 139
• A c voltages to a d c voltage which appears at the generator output terminal 139
• A rectifier bridge connected to the stator windings contains six diodes and electrically changes the stator 139
• Are enclosed into a solid mold and this unit is attached to the brush holder frame the regulator voltage 139
• Charging system 139
• Description generator with ic regulator 139
• Setting cannot be adjusted two brushes carry current through the two slip rings to the rotor coil mounted on the rotor the stator windings are assembled on the inside of a laminated core that forms part of the generator housing 139
• The generator features a solid stale regulator that is mounted inside the generator all regulator components 139
• Charging output check 140
• Generator removal and disassembly 140
• Inspection 142
• Reassembly and remounting 145
• Reassembly information 146
• Ignition system 147
• Inspection 147
• Description 150
• Starter motor removal and disassembly 150
• Starter system 150
• Starter motor inspection 151
• Starter motor reassembly 152
• Starter relay inspection 153
• Combination meter 154
• Removal and disassembly 154
• Inspection 155
• Ignition switch 157
• Switches 157
• Turn signal light 157
• Dimmer switch 158
• Lighting switch 158
• Passing light switch 158
• Turn signal switch 158
• Clutch switch 159
• Inqini stop and start switch 159
• Ront brake switch 159
• Heck sw 160
• Neutral indicator switch 160
• O o w n 160
• Oil pressure switch 160
• Rear brake switch 160
• Side stan 160
• Wont coi oh 160
• Headlight relay 161
• Inspection 161
• Neas relay 161
• Neas solenoid coil inspection 161
• Battery specifications 162
• Initial charging 162
• Recharging operation based on s g reading 163
• Servicing 163
• Service life 164
• Brake pad replacement 165
• Caution 165
• Oi ircico 165
• Rear brake 165
• Caliper removal and disassembly 166
• Chassis 167
• Removal 168
• Bf rtaacnfir 169
• Tvrfje q vit r j q 169
• Л vjt i 169
• Ъ то л r rjf t rc 169
• Front wheel 170
• Removal and disassembly 170
• Inspection 172
• Caution 173
• Reassembly and remounting 173
• Wheel bearing 173
• Caliper 174
• Brake pad replacement 176
• Caution 176
• Front brake 176
• Caliper removal and disassembly 177
• Caliper and disc inspection 178
• Rubber part 178
• Caliper reassembly and remounting 179
• Master cylinder removal and disassembly 180
• Master cylinder inspection 181
• Master cylinder reassembly and remounting 182
• Front fork 183
• Removal and disassembly 183
• Inspection 186
• Reassembly and remounting 187
• Ооо 187
• Front fork suspension setting 190
• Ni нпо ff 191
• Vjaisas dnih331s 191
• М м iviunow ммгч h 191
• Removal and disassembly 192
• Inspection 193
• Reassembly and remounting 194
• Steering tension adjustment 196
• Brake pad replacement 198
• Caution 198
• Rear brake 198
• Caliper removal and disassembly 199
• Inspection 200
• Reassembly and remounting 200
• Chassis 834 201
• Master cylinder removal and disassembly 201
• J w06 tos s m 9 p m 202
• Inspection 203
• Reassembly and remounting 203
• Tightening torque 203
• And take off the caliper with torque link 204
• Rear wheel 204
• Remo the rear brake caliper mounting bolt 204
• Removal and disassembly 204
• Support the motorcycle by u ing jack with 204
• Wooden block 204
• Chassis 640 207
• Inspection 207
• Reassembly and remounting 208
• 43 chassis 210
• Removal 210
• Tire and wheel 210
• Chassis 6 44 211
• 45 chassis 212
• Inspection 212
• Repair 212
• Chassis 646 213
• Tire mounting 214
• Rfar suspension 216
• Swingarm 216
• Chassis 6 50 217
• Shock absorber and cushion lever 217
• 51 chassis 218
• Removal and disassembly 218
• Chassis 652 219
• Inspection 221
• Point i 223
• Reassembly and remounting 224
• 59 chassis 226
• After installing the rear swingarm shock absorber 226
• Brake and rear wheel the following adjustments are required before driving motorcycle drive chain rear brake 226
• Chassis bolts ana nuts 226
• Final inspection and adjustment 226
• Install the rear shock absorber lower mounting 226
• Rea suspension s adjustable according to the rider s requirements the high speed capability of th motorcycle makes proper suspension setting and balance very important use the following table to adjust the rear suspen sion 226
• Rear suspension setting 226
• Shock absorber 226
• Tire pressure 226
• Çhten the nuts to the specified torque 226
• Chassis 660 227
• 6i chassis 228
• Clutch master cylinder 228
• Removal and disassembly 228
• Inspection 230
• Reassembly and remounting 230
• Servicing information 232
• 1 servicing information 233
• Engine 233
• Troubleshooting 233
• I туда 234
• Servicing information 7 2 234
• Carburetor 235
• Compi nt 235
• Detrae beery t k4 vmoay 235
• Lack power 235
• Medium orh h wd иоиые 235
• Or tow tpmd troubw 235
• S wo mlx v qv ___ ___remedy 235
• Trouble meh ttaron 235
• W servicing aforuat1c 235
• Ел м overhaan 235
• Cheriton and fuel 236
• Complaint 236
• Electrical 236
• Remedy 236
• Servicing information m 236
• 5 servicing information 237
• Battery 237
• Battery run down quickly 237
• Bettcry charges too rap fly i 237
• Complaint symptom and potubu causes remedy 237
• I battery sulf at on 237
• Start button t not effective 237
• Sulfation acid white powdery mbstanca o pots on surfaces of cell putei 237
• Symptom probable cause remedy 237
• __ _______ reversed battery pour y 237
• Chassis 238
• Compum i 238
• Servicing information 74 238
• Symptom and powble caut remedy 238
• 7 servicing information 239
• Brake squaak ng 239
• Brakes 239
• C i w brake lerer stroke 239
• Compia nl symptom and possible causes 239
• Inwhofm brake id 239
• Leakage of brake fluid 239
• Servicing information 7 8 240
• Servicing information 7 10 242
• Wire color 242
• 11 servicing information 243
• Headlight 244
• Neas relay 244
• Servicing information 7 12 244
• Wire cable and hose routing 244
• Noilvnhodni 9н1э1лнэ eu 245
• Fuel tank water drain hose routing 247
• Servicing information m6 247
• Rear brake hose routing 249
• Servicing information 18 249
• Clutch hose routing 250
• Servicing information 250
• Item part no part name 251
• Special tools 251
• Servicing information 252
• Engine 255
• Servicing information 7 24 255
• Tightening torque 255
• 25 servicing information 256
• Chassis 256
• Servicing information 26 257
• Tightening torque chart 257
• 27 servicing information 258
• Camshaft cylinder head 258
• Service data 258
• Vai vf guide 258
• Cylinder piston piston ring 259
• Servicing information 7 28 259
• 29 servicing information 260
• Clutch ___________________ 260
• Conrod crankshaft 260
• Oil pump___________ ______ 260
• Carburetor 261
• Transmission drive chain 261
• 31 servicing information 262
• Electrical 262
• Brake wheel ______________________________________ unit mm m 263
• Servicing information 7 32 263
• Wattage ___________________________________ 263
• Fuel oil 264
• Tire pressure 264
• Servicing information 7 34 265
• Appendix information of the 86 model 266
• Early late 267
• Exhaust valve guide 267
• Intake valve guide 267
• Parts supply data 267
• Additional information to steering damper inspection 268
• Steering damper 268
• 3 appendix information of the 86 model 269
• Ignition coil inspection 269
• Jumper wire 269
• Piston ring 270
• Gsx r1100h c87 m0del 271
• Capacities 272
• Dimensions and dry mass 272
• Electrical 272
• Specifications 272
• Transmission 272
• Camshaft cylinder head 273
• I__________ j 273
• Service data 273
• Vai vf 4 ql uhf 273
• Conrod crankshaft 275
• Oil pump 275
• Carburetor _______ 276
• Drive chain 276
• Standard 276
• __________ item 276
• Electrical______________________________________________ 277
• Brake wheel _____ __________________________________________ 278
• Unit mm in 278
• Wattage ____ 278
• Suspension________________ 279
• Tire pressure 279
• 9 gsxr1 looh hp mode li 280
• Standard 280
• Engine 281
• Tightening torque 281
• Chassis 282
• Combination meter only for e28 283
• Electrical system 283
• Ignition coil 284
• Side stand ignition interlock system only for e 28 284
• Sidestand relay on 284
• The circuit consists ol relay lamp diode and switches and decides to live the ignition coil depending on the position of the transmission and side stand with the neutral and side stand switches working mutually the ignition coil lives only in two situations as follows 1 transmission neutral on side stand down off 284
• The current flow a turns on the relay and the ignition coil lives even the side stand is kept down this is for warming up the engine 284
• The s e s 284
• Thi idestand ionition interlock system has been newly attached to prevent starting the motorcycle with 284
• Gsxr1i00h 87 model 286
• Chassis 287
• Front fork 287
• Rear suspension 287
• Gsxr1100 288
• Kcoikaznae2e 288
• Xxju aaicib nb 288
• О сп 289
• 19 gsx r110oh 87 m0 el 290
• M ù oo 290
• Gsx r1100h 87 model 9 20 291
• 21 gsx r1100h 87 model 292
• Csx rh00hc87 model 293
• Suzuki motor co ltd 294

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W lXE 38 ENGINE REINSTALLATION NOTE h h eVe W 01 Install the brackets huUlw gn J nuts properly a shown in lhc fo owj m lion LENGTH 180 mm 7 1 n TIGHTENING TORQUE 255 mm H0 0 in 55 mm 2 2 in 55 mm 2 2 in OTHER BOLTS SPACER LF GTH 59 mm 2 3 m _ 46mm J1 8m 27 mm 1 1 in 70 88 N m 70 88kgm 50 5 63 6 ibtt 5O 6ONm 50 6 0kgm 36 0 43 5 tbit 25 38 N m 2 5 3 8 kym 18 0 27 5 lt ft o L m un n X u B I Io UM and ghlan them to the spoc f ed torque