1986 Suzuki GSXR 1100 Service Manual

The 1986 Suzuki GSXR 1100 is a high-performance sport motorcycle featuring a 1074cc liquid-cooled four-cylinder engine, dual overhead camshafts, 16-valve configuration, 6-speed transmission, aluminum frame, adjustable suspension, dual front disc brakes, and advanced aerodynamics. Below are comprehensive sections covering maintenance procedures, specifications, troubleshooting, and repair guidelines.

General Information

Key components: 1074cc inline-four engine, aluminum twin-spar frame, telescopic front forks, Uni-Trak rear suspension, dual 310mm front disc brakes.

Specifications

• Displacement: 1074cc
• Power Output: 130 hp @ 9,500 rpm
• Torque: 85 lb-ft @ 8,500 rpm
• Fuel Capacity: 5.5 gallons (21 liters)
• Oil Capacity: 3.7 liters (with filter change)
• Front Tire: 120/80V16
• Rear Tire: 150/80V16
• Dry Weight: 218 kg (481 lbs)
• Seat Height: 785 mm (30.9 inches)
• Wheelbase: 1,490 mm (58.7 inches)

Periodic Maintenance

Regular maintenance intervals and procedures for optimal performance.

1. Oil Change: Every 3,000 miles - Use 10W-40 motorcycle oil
2. Oil Filter: Replace with every oil change
3. Air Filter: Clean every 6,000 miles, replace every 12,000 miles
4. Spark Plugs: Replace every 7,500 miles (NGK DR8ES-L)
5. Valve Clearance: Check every 15,000 miles
6. Chain Adjustment: Every 500 miles - 20-30mm free play
7. Brake Fluid: Replace every 2 years (DOT 4)
8. Coolant: Replace every 2 years

WARNING! Always use genuine Suzuki parts. Wear protective equipment during maintenance.

Engine Service

Comprehensive engine maintenance and repair procedures.

1. Cylinder Head Removal: Drain coolant, remove camshafts, unbolt head
2. Valve Adjustment: Intake: 0.10-0.20mm, Exhaust: 0.15-0.25mm
3. Camshaft Timing: Align timing marks at TDC compression stroke
4. Piston Replacement: Remove cylinders, check ring end gaps
5. Clutch Service: Adjust cable free play to 2-3mm
6. Oil Pump: Check for wear, replace if clearance exceeds 0.20mm

CAUTION! Use torque wrench for all critical fasteners. Follow specified torque values.

Fuel System

Mikuni BST34SS carburetor service and adjustment.

1. Carburetor Synchronization: Use vacuum gauges for balance
2. Float Level: 21.5mm ± 1.0mm
3. Pilot Screw: 2 turns out from lightly seated
4. Main Jet: #115 (standard)
5. Pilot Jet: #42.5 (standard)
6. Fuel Filter: Replace every 12,000 miles

Tip: Always clean fuel tank before carburetor service to prevent contamination.

Electrical System

Electrical component testing and replacement procedures.

Chassis & Suspension

Frame, suspension, and steering maintenance.

1. Front Fork Oil: 487ml per leg (10W)
2. Fork Spring: Free length 515mm (replace if <505mm)
3. Steering Head Bearings: Adjust to eliminate play
4. Rear Shock: Preload: 5 positions, Rebound: 4 positions
5. Swingarm Pivot: Torque to 65 Nm
6. Wheel Alignment: Check chain adjuster marks

Brake System

Brake system service and maintenance procedures.

1. Front Brake Pads: Replace when worn to 1.0mm thickness
2. Brake Disc: Minimum thickness 4.5mm
3. Brake Fluid: DOT 4, bleed every 2 years
4. Master Cylinder: Check for leaks, rebuild if necessary
5. Caliper Service: Clean pistons, replace seals annually
6. Brake Lines: Inspect for cracks, replace if damaged

WARNING! Test brakes at low speed after service. Never reuse brake fluid.

Troubleshooting

Wiring Diagrams

Complete electrical schematics for the 1986 GSXR 1100. Diagrams include color codes, connector locations, and component identification for all electrical systems including ignition, charging, lighting, and instrumentation.

Note: Refer to specific wiring diagram pages for detailed circuit tracing and troubleshooting guidance.