This Hyanes DIY repair manual covers Suzuki GSX/GS1000, 1100, and 1150 4-valve Fours motorcycles, including:
- Suzuki GSX1000 Katana, GS1000 Katana, GS1000S, U.K. 1981-1985, U.S. 1981-1982
- Suzuki GSX1100S, GS1100S, U.K. 1981-1985, U.S. 1982-1983
- Suzuki GSX1100E, GS1100E, U.K. 1979-1984, U.S. 1980-1983
- Suzuki GSX1100ES, GS1100ES, U.K. 1983-1985, U.S. 1983
- Suzuki GSX1100E, U.K. 1985-1988
- Suzuki GSX1100EF, U.K. 1984-1988
- Suzuki GS1150E, U.S. 1984-1986
- Suzuki GS1150ES, U.S. 1984-1985
- Suzuki GS1100L, U.S. 1980
Note: This manual DOES NOT cover Suzuki GSXR1100 or GSX1100F models.
Book Excerpt: 1979-1988 Suzuki Katana GSX1000, GSX1100, GS1000, GS1100, GS1150 Repair Manual
ENGINE, CLUTCH AND TRANSMISSION
ENGINE REASSEMBLY; REFITTING THE UPPER CRANKCASE COMPONENTS
FRAME AND FORKS
- Check that the small oil feed jet in the right-hand main bearing recess is unobstructed; the supply of oil to the bearing is dependent on this, so do not overlook it. Fit the main bearing location pins, if removed, and fit the half-ring to the right-hand main bearing recess.
- Place the cam chain around the crankshaft sprocket and fit a new oil seal to its right-hand end. Lower the crankshaft into position, feeding the cam chain through the opening in the crankcase.
- Arrange the right-hand main bearing so that it locates over the half-ring and rotate it until the small locating pin sits in the cutout to the rear of the bearing recess, parallel to the gasket face.
- Position the remaining bearings so that they engage their respective location pins. Each bearing has a small punch mark diametrically opposite the location hole as an aid to alignment. When all the bearings are aligned, the crankshaft will drop into place.
- Fit the five half rings to their respective grooves in the gearbox shaft bearing recesses. Fit the gearbox shafts, noting that all but the output shaft right-hand bearing have small location pins which must align with the cutouts provided.
Note also that the input shaft left-hand bearing must be preceded by the two wave washers removed during dismantling. Finally, fit a new O-ring to the oil feed passage between the crankshaft and gearbox shafts.
REAR SUSPENSION UNITS: EXAMINATION AND ADJUSTMENT
STANDS: EXAMINATION AND MAINTENANCE
- The rear suspension units are of the oil-damped coil spring type, featuring 4-way adjustable damper settings and 5 spring preload settings.
The settings are largely up to the rider, the standard setting for most models being spring preload '3' and damper setting '2'.
In the case of the Katana machines a more extensive range of settings will be found in figure 4.12 of this Chapter.
- Spring preload is altered by turning the stepped collar at the lower end of each unit, using a C-spanner or a round bar in the recesses provided for this purpose.
Damping adjustment is effected by turning the knurled wheel set in the top mount. For obvious reasons, ensure that the settings are the same on each unit.
- The suspension units are of sealed construction, and in the event of failure of the damper insert it will be necessary to renew the units as a pair.
Many dealers will be able to offer alternative replacement units from a wide choice of suppliers, and in many cases these can prove a useful way of altering the suspension characteristics.
It is important to purchase units matched to the particular model; the dealer should be able to provide advice on choosing a suitable type.
- The centerstand is retained by two pivot bolts to lugs on the underside of the frame, each being secured by an R-pin passed through its end. A sleeve is fitted between each bolt and the stand pivots.
It is good practice to remove the stand from time to time so that the pivots can be cleaned and greased. Examine the stand for damage or cracking, and have any such damage repaired by welding before it causes the stand to collapse.
Subject: 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988 Suzuki Katana GSX1000, GSX1100, GS1000, GS1100, GS1150 service, maintenance, repair. ISBN-10: 185010574X | ISBN-13: 9781850105749 | Haynes 737