Suzuki Katana 1100 Manuals

Suzuki Katana 1100 Manuals

Manuals and User Guides for Suzuki Katana 1100. We have 1 Suzuki Katana 1100 manual available for free PDF download: Service Manual

Suzuki Katana 1100 Service Manual

Suzuki Katana 1100 Service Manual (231 pages)

Brand: Suzuki | Category: Motorcycle | Size: 10.66 MB

Table of Contents

Group Index
2
General Information Contents
3
View of GSX1100F
4
Serial Number Location
4
Fuel and Oil Recommendation
4
Break-In Procedures
5
Cylinder Identification
5
Brake and Clutch Fluid
5
Front Fork Oil
5
Special Ma Terials
6
Precautions and General Instructions
8
Use of Genuine Suzuki Parts
8
Dimensions and Dry Mass
9
Specifica Tions
9
Table of Contents
11
Periodic Maintenance and Tune-Up Procedures Contents
11
Periodic Maintenance Schedule
12
Periodic Maintenance Chart
12
LUBRICA Tlon POINTS
13
Maintenance and Tune-Up Procedures
14
Battery
14
- Cylinder Head Nuts and Exhaust Pipe Bolts
  15
- Cylinder Head
  15
- Exhaust Pipe
  15
Air Cleaner
15
Valve Clearance
16
Recommended Spark Plug
18
Spark Plugs
18
- Engine Oil and Oil Filter
  19
- Necessary Amount of Engine Oil
  19
- Idle RPM
  20
Fuel Line
20
Carburetor
20
Clutch
20
- Bleeding Air from the Clutch Fluid Circuit
  21
- Drive Chain Checkig
  22
- Drive Chain Adjusting
  22
- Drive Chain Cleaning and Lubricating
  22
- Brake Fluid Level
  23
- Brake Pads
  23
Brakes
23
Tires
25
- Tire Pressure
  26
- Tire Tread Condition
  26
Steering
26
Front Forks
27
Rear Suspension
27
- Chassis Bolts and Nuts
  28
- Engine Contents
  30
- Compression Check
  31
- Compression Test Procedure
  31
- Engine Components Removable with the Engine in Place
  32
- Engine Removal and Reinstallation
  33
- Engine Reinstallation
  38
- Engine Disassembly
  40
- Cylinder Head Servicing
  50
- Engine Components Inspection and Servicing
  50
- Cylinder Head Distortion
  51
- Valve Face Wear
  51
- Valve Head Radial Runout
  51
- Valve Stem Runout
  51
- Valve Guide Servicing
  52
- Valve Stem Wear
  52
- Valve and Seat Condition Valve Seat Width
  53
- Valve Seat Servicing
  53
- Valve Springs
  55
- Valve Stem End Condition
  55
- Reassembly
  56
- Cam Wear
  57
- Camshaft
  57
- Camshaft Journal Wear
  58
- Cam Chain Tensioner
  59
- Cam Sprocket
  59
- Camshaft Runout
  59
- Cam Chain 20-Pitch Length
  60
- Cam Chain Guide
  60
- Cam Chain Idler
  60
- Cylinder Distortion
  60
- Piston Diameter
  61
- Piston Ring-Groove Clearance
  61
- Piston-Cylinder Clearance
  61
- Oversize Oil Ring
  62
- Oversize Piston Ring
  62
- Piston Pin and Pin Bore
  62
- Piston Ring Free End Gap and Piston Ring End Gap
  62
- Conrod Big End Side Clearance
  63
- Conrod Small End I.D.
  63
- Conrod-Crank Pin Bearing Selection
  63
- Bearing Selection Table
  64
- Bearing Assembly
  65
- Crankcase - Crankshaft Bearing Selection
  66
- Crankshaft Thrust Clearance
  68
- Crankshaft Runout
  69
- Clutch Bearing
  70
- Clutch Drive Plates and Driven Plates
  70
- Clutch Spring Free Length
  70
- Clutch Release Cylinder Disassembly
  71
- Clutch Release Cylinder Inspection
  71
- Clutch Release Cylinder Reassembly
  71
- Oil Pump
  71
- Transmission
  72
- Countershaft Disassembly
  73
- Driveshaft Disassembly
  73
- Countershaft and Driveshaft Reassembly
  74
- Engine Reassembly
  77
- Gearshift Fork-Groove Clearance
  77
- Fuel and Lubrication System Contents
  96
- Fuel Cock Removal
  97
- Fuel Tank, Fuel Cock and Fuel Level Gauge
  97
Fuel Gauge Removal
97
Inspection and Cleaning
97
- Carburetor Construction
  98
- I.D. No. Location
  99
- Diaphragm and Piston Operation
  100
- Slow System
  101
- Main System
  102
- Float System
  103
- Starter System
  103
- Fuel System
  104
- Disassembly
  105
- Float Height Adjustment
  105
- Needle Valve Inspection
  105
- Removal
  105
- Reassembly and Remounting
  106
- Balancing Carburetors
  107
- Lubrication System
  109
- Oil Filter
  109
- Oil Pressure
  109
- Oil Sump Filter
  110
- Relief Valve
  110
- Oil Cooler
  111
  - Operating Pressure of Regulators
    111
  - Engine Lubrication System Chart
    112
- Engine Lubrication System
  113
- Cylinder Head Cooling System Chart
  114
- Cylinder Head Cooling System
  115
- Emission Control Information Contents
  116
- Emission Control Carburetor Components
  117
- Evaporative Emission Control System
  118
Canister Hose Routing
119
- Air Suction System
  120
- Air Suction Hose Routing
  121
  - Electrical System Contents
    122
  - Charging System
    123
  - Description (Generator with IC Regulator)
    123
  - Charging Output Check
    124
  - Generator Removal and Disassembly
    124
  - Rotor Bearing Inspection
    125
  - Stator Coil Continuity Check
    125
  - Carbon Brush
    126
  - Rectifier
    126
  - Rotor Coil Continuity Check
    126
  - Slip Ring
    126
  - Generator Driven Gear Damper
    127
  - IC Regulator
    127
  - Reassembly Information
    129
  - Ignition System Description
    130
  - Ignition Coil Inspection (with Electro Tester)
    131
  - Ignition Coil Inspection (with Pocket Tester)
    131
  - Signal Generator Inspection (with Pocket Tester)
    131
  - Ignitor Unit
    132
  - Spark Plug
    132
  - Starter Motor Removal and Disassembly
    133
  - Starter System Description
    133
  - Commutator
    134
  - Starter Motor Inspection
    134
  - Armature Coil
    135
  - O-Ring
    135
  - Oil Seal
    135
  - Starter Motor Reassembly
    135
  - Housing End (Gear-Side)
    136
  - Starter Relay Inspection
    136
  - Combination Meter Removal and Disassembly
    137
  - Combination Meter Inspection
    138
  - Fuel Gauge Sending Unit Inspection
    139
  - Fuel Level Meter/Gauge
    139
  - Fuel Meter Inspection
    139
  - Battery Replacement
    140
  - Digital Clock
    140
  - Headlight
    140
  - Lamps
    140
  - Tail/Brake Light
    141
  - Turn Signal Light
    141
  - Switches
    142
  - Wire Color
    143
  - Side-Stand Relay
    144
  - Wind-Shield Motor Relay
    144
  - Battery Servicing
    145
  - Battery Specifications
    145
  - Initial Charging
    145
  - Rechrging Operation Based on S.G. Reading
    146
  - Service Life
    146
  - Chassis Contents
    147
- Fairing
  148
  - Fairing Removal
    148
  - Fairing Reinstallation
    149
  - Wind-Shield Removal and Disassembly
    150
  - Wind-Shield Reassembly and Remounting
    152
  - Wiring Diagram
    152
- Front Wheel
  153
- Front Brake
  157
  - Caliper Removal and Disassembly
    158
  - Caliper Inspection
    159
  - Caliper Reassembly and Remounting
    159
  - Disc Inspection
    160
  - Disc Servicing
    160
  - Master Cylinder Removal and Disassembly
    160
  - Master Cylinder Inspection
    161
  - Master Cylinder Reassembly and Remounting
    162
- Front Fork
  163
- Steering
  169
  - Steering Removal and Disassembly
    170
  - Steering Inspection
    171
  - Steering Reassembly and Remounting
    171
- Rear Brake
  173
- Cliper Removal and Disassembly
  174
- Rear Wheel
  178
- Rear Wheel Removal
  178
- Rear Wheel Inspection and Disassembly
  179
- Wheel and Sprocket Drum Bearings
  179
- Sprocket Drum Bearing and Sprocket Reassembly and Remounting
  182
- Tire and Wheel Removal
  183
- Valve Inspection
  185
- Tire Inspection
  185
- Wheel Inspection
  185
- Valve Installation
  186
- Tire Mounting
  186
- Swingarm
  188
REAR Suspension
188
- Shock Absorber and Cushion Lever
  189
- Rear Suspension Removal
  190
- Cushion Lever/Rod Inspection and Disassembly
  191
- Shock Absorber Inspection and Disassembly
  191
- Swingarm Inspection and Disassembly
  192
- Cushion Lever/Rod Reassembly and Remounting
  193
- Swingarm Reassembly and Remounting
  193
- Reassembling Information
  194
- Final Inspection and Adjustment
  195
- Rear Suspension Setting
  195
- Setting Table
  195
- Clutch Master Cylinder
  196
- Troubleshooting
  198
- Wiring Diagram (California Model Only)
  206
- Wire, Cable and Hose Routing
  207
  - Front Brake Hose Routing
    209
  - Rear Brake Hose Routing
    210
  - Clutch Hose Routing
    211
  - Fuel Hose/Vacuum Hose Routing
    212
  - Fuel Tank Hose Routing
    213
  - Other Hoses Routing
    214
  - Battery Breather Hose Routing
    215
- Special Tools
  216
Tightening Torque
219
- Tightening Torque Chart
  221
- Service Data
  222

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