QUICK FACTS:

•  Stock GS1100 gearing is 15/42

•  530 pitch 17/48 or 17/49 gearing with GSXR 180 tire conversion. 48T is 2 mph faster in 5th gear @ 8500rpm than stock

•  42T 630 sprocket larger diameter than 50T 530 sprocket

•  5/8" offset sprocket needed with GSXR 180/55/17 Conversion / stock swing arm

•  Bandit swing arm conversion requires custom offset countershaft sprocket (available on parts site)

•  Early 90s GSXR 750/1100 speedo same gearing as GS and fits katana speedo. Just make sure cable is long enough, use 1100 cable.

•  Check 530 chain width B4 buying - some are wider than your 630 chain.

Katana Gearing

     Changing from stock 630 to 530 is a very good idea. More selection, better chains and a weight savings of up to 8 lbs.
Many think the 530 chains are too weak but a 200hp hayabusa uses a 530 chain. Your katana is safe. I have even used 520 chain sets on 1166cc performance motors. If converting a stock katana, you will need a 6mm spaced front sprocket which you can get from my parts  page; www.parts.suzuki-katana.com. If you buy a sprocket and spacer, the spacer goes on the outside of the sprocket, not behind it.

     It is easier to think of gearing as a factor of tooth number rather than diameter. A 15 tooth GSX1100S front 630 sprocket is the same size as an 18 tooth 530 sprocket. A 630 rear sprocket with 42 teeth has a 250mm diameter. The same size 530 sprocket has 50 teeth. Don't confuse size with tooth number. Where it can become a concern is if the chain is close to the swing arm pivot, so a 15t 530 may not be ideal depending on the swing arm you are using. A good website for gearing is www.gearingcommander.com. I use and sell, 17 tooth front sprockets and 48t rear sprocket on my 180/55-17 wheel equipped katanas for stock gearing. The final gear ratio of an 1100 katana is 2.8, rear sprocket divided by the front (42/15=2.8) 48/17=2.82.

     If you are wanting some more grunt in the bottom end you want to decrease the teeth on the front sprocket or increase the rear. Conversely if you do the opposite your RPMs on the highway will be lower.
     When you got your katana, it probably had a 130/90-17 tire on it. (The stock tire for the 1982 and 1983 gs1100s Katana is 114/88-17 (4.50v 17)) This has already changed your gearing by 3 mph (5 kph) @ 4000 rpm. The 130 tire is larger than the stock one so you may have noticed you are traveling 66 mph (106.5 kph) @ 4000 rpm instead of 62 mph (100 kph) you would have been with the stock tire.

     If you convert to a 1993 GSX-R front end, you don't have to worry about your speedometer. It will read correctly with the GSX-r speedo drive on the wheel. You do have to do is buy a GSX-R speedo cable as your katana cable will not thead into the drive unit at the GSXR front wheel.

Sprocket/Chain

     Many have made the mistake of buying a 530 pitch chain to accommodate the larger wheel thinking that will fix the problem of clearance, only to find out the chain they bought is wider than the stock 630. You have to check the chain pin length before you buy. I have had good success with the EK MVXZ series at 24.60mm wide. If you want to go with a standard chain without O or X rings, they are much narrower.

When you do a 5.5" wheel conversion you will need to buy an offset countershaft sprocket. They are for sale on the Katana parts site linked above. A conversion using a stock GS1100 swing arm requires a 5/8" offset and you can also get the custom offset for the Bandit 1200 swing arm conversion. You will want to buy a 114 link chain with the 530 conversion if you use a 17/48 sprocket set.

For those who just want to change their 630 drive train for a 530, you can also get the countershaft sprocket on the parts site. It has an integral spacer that is needed for the conversion. The spacer side is the outside of the sprocket, NOT! the inside that contacts the motor output bushing. Also for sale is a custom rear 48T hard anodized sprocket. You can buy any tooth count you wish as a special order, but the 17T front and 48T sprockets are standard.
     As you can see in the picture, the 630 and 530 sprockets are the same widths, so naturally the HD 530 Busa chains will be wide like the 630. The GS1100 can run on a 520, as some GSXR 1000 bikes do. I like to use the 530 though.

Note: a 50T rear 530 is just a tad smaller in diameter then the 42T stock 630. Same goes for the front sprockets so don't go too small or risk sawing your swing arm in half. The 530 and 630 sprockets in the pic are the same tooth count.

GEARING (MPH)
4,000 rpm
(MPH)
8,500 rpm
15/42 (114) 62.1 131.9
15/42 (130)64.8137.6
15/42 (180) 61.7 131.2
17/48 (180) 61.2 130.1
17/49 (180) 60.0 127.5

Converstion Parts Here

 Posted on Friday, November 17, 2017
  
    
    
You can buy conversion parts on the Katana Parts site.

GS1100 Oil

Oil Pump Gearing

     All GS1100 engines are equipped with a high-volume, low-pressure oil pump. Normal oil pressure is > 0.1 kg/cm2 (1.42 psi) and < 0.5kg/cm2 (7.11 psi) at 3,000rpm. You can use 4v 750 oil pump gears to increase pressure. GS1150/1100 gears are 34/33 ratio. Pump turns 1.03 x for each clutch rotation. GS/GSX 750 gears are 38/29 ratio. Pump turns 1.31 x for each clutch rotation.
Top End Oiling Kit

     Very controversial. I use them. I have tested the ones on my bikes and there is no pressure loss when using them. There are some who believe they are a detriment to the motor. Interesting to note, road racing teams never used them but drag racers do. I melted a camshaft and head one summer from insufficient oil. So I bought one. They are also needed if you go to heavy duty studs as they are larger diameter restricting oil from getting to the top end. Its your call.

     I have read debates on the effects of top end oiling kits and oil coolers on gs1100 engine oil pressure. Because the pressure is so low on these roller crank engines there are some who believe that pressure drops when these extras are installed. I have measured pressures with and without the cooler and top end oiler and found no differences in pressure readings. I took readings from the oil sensor location as well as the right hand access port at the base of cylinder 4
gs1100 oil pressure

Oil Pressure

     Oil pressure in the GS1100 is very low. Have a look at the excerpt from the GS service manual. At idle the pressure is so low at times the oil light can flicker as the sensor degrades.

Many including me, swap out the oil pump gears for a set of high volume or 750cc gears which are the same thing.

Katana Oil Cooler

     When adding an oil cooler to your GS1100e or GS1100s Katana, you have to purchase a GS1150ef oil filter cover for it to work correctly. The  1984-85 GS1150ef came with an oil cooler stock and has a restrictor in the plate to send the oil up to the cooler (see pic)

     If you for any reason remove the cooler, remember to change the filter cover back or you will be riding a boat anchor in short order. If you look on my custom pages, I like to us an Earl's "wide 10 row" cooler which fits the Katana very nicely. I also prefer to use the oil galleries on either side of the filter to supply the cooler and return to the engine.

GS1150 Oil Filter Cover

GS1100s Engine

     The katana has some differences from the gs1100e 4v motor. Piston rods are stronger and the cranks are different. The katana uses a smaller stator as mentioned above and the taper is smaller so you cannot use a larger rotor. The '82 crank is not welded, the '83 is partially welded. Thank you to a website subscriber for the chart to the right on crank taper compatibility

Carburetors

     The 750cc Katana carbs are the same size (34mm) as the 1100 Katana, they are only jetted differently. I think 34mm Mikuni flat slide carbs are plenty for the street and better street performance than the 36mm. 38mm and 40mm are not a good option for an 1100cc or 1166cc street bike.

Engine Covers

     A GS1100e stator and stator cover will not fit a GS1100s Katana. The Katana uses a smaller stator (118mm), the same size as the one that is in the 750 Katana. The 1100e has a 130mm rotor. Though the 750 Katana stator can be used in a pinch, the orientation of the phase wires put them at 6 O'clock, where as the 1100 Katana is 3 O'clock, making the wires too short to reach the wiring harness.

Katana Stator

katana Stator
1100e Stator
33 smoothbore

33 Smoothbore
katana carburetor tuning

RS Tuning
dynojet

Trouble Shooting
mikuni flat slide

Flatslides
Ignition
  
  See the wiring page
Welcome to the Katana technical pages. This site is the result of my years of experience upgrading 1982 and 1983 GS750 / 1100 Katanas with wheels, suspension and brakes to more modern versions. The site also has other information of interest to both Katana and other GS owners.

There is a time and financial cost maintaining this site, and answering your many email questions. Would you consider selecting one of the options below to help offset my time and costs? I guarantee you, after years of searching forums, wasting money buying parts that don't fit and don't work, the information here will save you significant money, time and frustration, because everything on this site has been tested on my own bikes.

Have a look at the information, and if you truly feel you have not got at least a dollars worth of entertainment, inspiration or information, then I thank you for visiting and I hope you liked the bikes, and will come back.
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WARNING Posted on Friday, November 17, 2017
   Information on this site is my personal experiences and experiments with modifications. I am not a licensed mechanic. Any changes to handling, braking or anything else described on this site are for entertainment purposes only. I do not recommend that anyone make changes to their motorcycle without checking with a licensed professional.


 
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