The 1986-1996 Suzuki Katana 600, GSXR750, GSXR1100 sportbike repair manual by Clymer, covers the following models:

• Suzuki GSX600F Katana, 1988-1996
• Suzuki GSXR750, 1986-1987
• Suzuki GSXR750R Limited Edition, 1986
• Suzuki GSXR1100, 1986-1987

Book Excerpt: 1986-1987 Suzuki Katana 600 1988-1996, GSXR750, GSXR750R, GSXR1100 Repair Manual TRANSMISSION AND GEARSHIFT MECHANISMS

This chapter provides complete service procedures for the transmission and the external and the internal shift mechanism. EXTERNAL GEARSHIFT MECHANISM The external gearshift mechanism is located on the same side of the crankcase as the clutch assembly. To remove the internal shift mechanism (shift drum and shift forks), it is necessary to remove the engine and split the crankcase. This procedure is covered in Chapter Four. The gearshift lever is subject to a lot of abuse. If the bike has been in a hard spill, the gearshift lever may have been hit and the gearshift shaft bent. It is very hard to straighten the shaft without subjecting the crankcase halves to abnormal stress where the shaft enters the crankcase. If the shaft is bent enough to prevent it from being withdrawn from the crankcase, there is little recourse but to cut the shaft off with a hacksaw very close to the crankcase. It is much cheaper in the long run to replace the shaft than risk damaging a very expensive crankcase assembly.

ENGINE

OIL PAN AND OIL PRESSURE REGULATOR REMOVAL/INSTALLATION NOTE: This procedure is shown with the engine removed from the frame for clarity. The oil pan can be removed with the engine installed in the frame.

1. Remove the union bolts and sealing washers securing the lower portion of the oil lines to the oil pan. Refer to Figure 186 for the right-hand side and Figure 187 for the left-hand side.
2. Remove the bolts securing the oil pan (Figure 190) to the lower crankcase.
3. Remove the oil pan and gasket. Discard the gasket as a new one must be installed.
4. Remove the shim (Figure 191) and O-ring seal (Figure 192) from the crankcase.
5. Install a new pan gasket (Figure 193).
6. Apply a light coat of cold grease to the O-ring seal (Figure 192) and install it in the receptacle in the crankcase.
7. Apply a light coat of cold grease to the shim and install it on top of the O-ring seal (Figure 191).
8. Install the oil pan and bolts. Be sure to install the copper washer under the one pan bolt (W, Figure 190). Tighten the bolts to the torque specification listed in Table 3.
9. Clean off all road dirt and oil residue from the oil line mating surfaces on the oil pan.
10. Be sure to place a new sealing washer on each side of the oil line fittings.
11. Install the union bolts and tighten to the torque specification listed in Table 3.

INSPECTION AND CLEANING

1. Unscrew the oil gallery plug bolts and gaskets from the oil pan. Refer to Figure 194 and Figure 195.
2. Unscrew the oil pressure regulator and washer (Figure 196) from the oil pan.
3. Unscrew the oil gallery plug bolt, gasket, spring and plunger from the oil pan.
4. Wash the oil pan in solvent. Clean out all of the oil galleries located behind the plug bolts.
5. Thoroughly dry with compressed air. Be sure to remove all solvent residue and any oil sludge loosened by the solvent. Any pieces of sludge left in any oil gallery may clog the gallery and any oil control orifices in the lubrication system.
6. Install the oil gallery plug bolt and gaskets into the oil pan. Tighten the plug bolts securely.

Subject: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 Suzuki GSX600F Katana, GSXR750, GSXR750R Limited Edition, GSXR1100 service, maintenance, repair info. ISBN-10: 0892877723 | ISBN-13: 9780892877720 | Clymer M383-3