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85-87 750 and 86-88 1100 Parts Interchange Info

133K views 99 replies 45 participants last post by  gotgixers 
#1 · (Edited)
Updated 85-87 750 and 86-88 1100 parts interchange

Well....the interchange we had is lost. Have to start rebuilding what we had so If you have any known swaps for slabsides please post them again here. No questions please....post those as a new thread in the main forum.

THIS IS ONLY FOR KNOWN SWAPS!

The 88/1100 has a 17mm front axle!! It's a typo!!
:cheers
 

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#2 · (Edited)
Re: Gotta start somewhere.....Slabbie parts interchange.

'85,'86'87 750 and '86-'92 1100

Okay,Front brake and Clutch Master cylinders... "01 - '04 Bandit 1200"S" both sides, direct swap,levers and all.

'99 - '07 Busa both sides, direct swap levers and all.

This gives you updated adj. and easily replacable levers at the same time. And they look indentical to original Master Cyl. And are made to work with 6 piston calipers as well. For those of you swapping 6 pots onto your bike.
 
#27 ·
Re: Gotta start somewhere.....Slabbie parts interchange.

'85,'86'87 750 and '86-'92 1100

Okay,Front brake and Clutch Master cylinders... "01 - '04 Bandit 1200"S" both sides, direct swap,levers and all.

'99 - '07 Busa both sides, direct swap levers and all.
Does this include the Clutch Slave? It looks like the Busa's very similar but I don't have access to one to measure or have a clutch slave from it in hand.

Doe the clutch slaves from the Bandit's fit the 86 750?
 
#4 · (Edited)
Re: Gotta start somewhere.....Slabbie parts interchange.

The upper fairing from a '86-'88 1100 is about 1/2" wider at the mirror mounts than a '86,'87 750.

I have had luck interchanging them as long as the correct rear fairing support is used. As the 750 and 1100 supports are physically different from one another. But either one will bolt to either frame.
 
#5 ·
Re: Gotta start somewhere.....Slabbie parts interchange.

The seats and solo fairing are physically interchangable between '86-'87 750's and '86-'88 1100's

You can put a '85 seat set on the '86-'88 slabbie's by taking the rear seat latch and moving it to the front cross member, then removing the old front latch from the latch cable.

So then, you can fit a '86-'88 slabbie seat on a '85 by getting an entire seat latch assy(part that bolts to your left rear peg mount,along with cables and both latches) for a '86-'88 slabbie and installing it on your '85. Long latch on the front cross member, short latch on the rear one. It's that simple.
 
#7 · (Edited)
Re: Gotta start somewhere.....Slabbie parts interchange.

****USD FORK SWAP****

With a set of '91 750 triples you can swap a '01-'03 750, or '01-'04 1k front end onto your slabbie. This type of swap takes considerable mechanical knowledge to finish out all the little details. As the 91-92 triples are approx 7mm wider than the 01-03 triples, so you will need to make wheel and caliper spacers at a minimum. If trying this swap, get a COMPLETE front end. It will make your life much easier.

The 91-92 750 triple will also allow you to swap in the 91-95 750 front forks also.This way will allow you to keep your mech speedo drive.

All GSXR 750 triples from 91-95 will allow you to do these swaps. But 93-95 triples will require steering stop modification also.
 
#14 ·
Re: Gotta start somewhere.....Slabbie parts interchange.

****USD FORK SWAP****

With a set of '91 750 triples you can swap a '01-'03 750, or '01-'04 1k front end onto your slabbie. This type of swap takes considerable mechanical knowledge to finish out all the little details. As the 91-92 triples are approx 7mm wider than the 01-03 triples, so you will need to make wheel and caliper spacers at a minimum. If trying this swap, get a COMPLETE front end. It will make your life much easier.

The 91-92 750 triple will also allow you to swap in the 91-95 750 front forks also.This way will allow you to keep your mech speedo drive.

All GSXR 750 triples from 91-95 will allow you to do these swaps. But 93-95 triples will require steering stop modification also.
So, I can use a complete fork from a '92 750 gixxer on my '88 1100 gixxer ? Just swap it ... right ?
That's what I am about to do, but I have to be sure. The length and thickness of the Steering Stern should be the same. Right ?
 
#8 ·
Re: Gotta start somewhere.....Slabbie parts interchange.

The mid panels will physically interchange between the 750 and 1100 with one modification.You will have to drill a new hole for the bolt that goes into the side of the head. The hole for the bolt that mounts to the head is in a slightly different location between the two due to differing cylinder heights.
 
#9 · (Edited)
Re: Gotgixxers 85-87 750 and 86-88 1100 parts interchange.

OK some basic stuff to most of us but here are a few basics. The information pertains to US models and other countries will have some different combinations so always double and tripple check. This is a starting point.

85-86 750's and 86 1100's have 15mm front axel's
87 750 & 1100 have 17mm front axel's
88 1100 has 20mm front axel as does 88-94 750 & 89-94 1100
so for rim upgrades on the front the 88 1100 front end is easiest to retain the 41mm fork tubes with 17" rims or Slingshot front end (43mm tubse) or 91-92 USD (up side down) forks allow the 17" front rim. The 750 USD's are 50mm tubes and the 1100 USD's are 52mm tubes.

85,86,87 Engine Ignition and Starter clutch covers interchange with the 86,87,88 1052 motor as well as the 88 89 slingshot motors and the 90 91 92 GSXR 750 motors. These covers are the same for the Kat 750 motors and bandit 600 motors
85-92 GSXR 750
86-88 GSXR 1100
96-04 GSF 600 Bandit
89-06 GSX 750 Katana
88-06 GSX 600 Katana

The 1127 Ignition and starter clutch covers interchange with the bandit 12 motors and the Kat 1127 motors.
Bandit 1200 96-06
Kat 1100 88-93
GSXR 1127 89-92

Rear Sprocket 6 bolt are 92-95 GSXR 750 & 89-98 GSXR 1100
Rear Sprocket 5 Bolt are 85-89 GSXR 750 &
86-88 GSXR 1100
92-93 GSXR 600 WC
89-95 GSXF 600
89-95 GSXF 750
94-95 RF 600

Rear Brake rotors interchange for
220mm rotor 85,86,87 GSXR 750
.................86,87,88 GSXR 1100
220mm rotor but thinner 97-07 GSXR 600
..................................96-07 GSXR 750
..................................01-07 GSXR 1000
..................................03-07 SV 650 & 1000
..................................98-03 TL & TLR 1000

240mm rotor 88-94 GSXR 750
..................89-94 GSXR 1100
If you want to run a different diameter rear rotor you need to use corresponding rear brake hanger.
 
#11 · (Edited)
Re: Updated 85-87 750 and 86-88 1100 parts interchange

Starter clutches, although slightly different, interchange between the 1052 and the 749cc motors. To use the 750 starter clutch in a 1052 motor, use the 750 starter clutch, the 750 intermediate gear and the 750 starter motor as the 1100 items have different numbers of teeth, looks like 1 tooth different on all components.
 
#12 ·
Re: 85-87 750 and 86-88 1100 parts interchange ~ Flatslide Drain hoses

Anyone who has the flatslides on their slabby knows about the dripping of the float bowl drains.

According to our local Suzuki shops, the hoses that redirect the drains have been discontinued however, I found a guy who knew what he was doing and he gave me a part number for a hose that fits.

Suzuki Part Number 09351-30503-600

It's about 15" in length so plenty of extra length.
 
#13 ·
Known Swap for those wanting original Mikuni BST31 carbs is:
1987 and 1988 Katana 600 carbs are the same. What is nice is that if you want to use your stock air box, these carbs are 50mm in back and 31 up front same as original GSXR 750. When looking at Katana carbs, if the vacuum slide lids have 4 screws you are good to go. The vacuum slides are slightly smaller and are not interchangeable. You may be able to remove the side guides for the slides and swap them or use them as is. You will have to drill the main air jets in the back out to 1.7mm as they are smaller. Obviously change the Main jets, needles, and the pilot jet should be the same 32.5. I'm not sure but the 1100 Kats of the same year may also be the same.
 
#17 ·
Awesome sounding build.

On my 85 GSXR750 I stopped at 5.5 with a factory swinger with an adjusted/bent brake arm. It allows me to put on a fat 180/55. Why don't you start a new post and ask for advice on swing arms for 1st generation 1100's. You'll get more results that way than posting in the interchange.
 
#19 ·
Re: USD conversion

This is from Awasson and I thought it would make sense to have it in here.

I swapped my 85 750 over to 94 GSXR 750 USD and 17" rims over a 2-day period and it was quite simple. The front end is quite easy because the steering head, bearings, etc... are the same diameter. It almost drops in without issue however there are some things to watch for:
The steering lock will no longer work because there's no easy way to transfer the lock over from the OEM bottom triple to the new one. A disk lock is a good solution.
You have to remove the steering stops (horns) from the USD bottom triple because they will scrape and bind against the frame.
You have to remove the 2 mounting points for the ignition switch on the USD upper triple and drill/tap new holes so that your ignition switch will fit.
You will end up with less lock to lock steering movement with the USD setup because they are much beefier than the OEM forks. When you do the swap re-route the electrical and speedo cable around the cockpit so that it is well clrear of the fork left/right movement and it should be ok.
You may find that you need to lower the clipons on the USD front end to account for the openings in the upper fairing. It will likely be pretty minor though.

Doing the rear wheel is easier. I used the 94 axle, spacer, cush-drive, sprocket and rear disc and it pretty much just bolted right on. I used the OEM rear caliper with the 94 disc and the only thing I had to deal with was adding more curve to the brake torque arm so that it didn't rub against the much wider rear tire.

It's an amazing upgrade
 
#22 ·
The 88 1100 has a 17mm front axle not the 20mm noted above. I have an 88 front end and I measured it, also checked Suzuki parts fiche that shows the axle and bearings as 17mm. Front end axle went to 20mm when wheels went to 17". This was corrected in an after note above but has since been repeated incorrectly.
 
#23 · (Edited)
Pegs - 1100/750(xc LTD) interchange but 1100 have rubber insert, small front/large rear. 750's have no rubber either one.
Peg brackets - 1100/750(xc LTD) interchange front & rear. Rears are big & ugly & never break.
Upper Cowl big bracket - 1100/750 interchange but 1100's have a NEAS relay mount on right lower tube. NEAS relay is same as headlight relay.
Upper Cowl T bracket - 1100/750 interchange.
Instruments - 750/1100 interchange but 1100 has lower redline & higher speed; some warning panels are missing sidestand light (85 750??).
Mid cowl - 1100 & 86-87 750 interchange xc LTD but 750 rear bolthole is about 1" lower due to shorter cylinder. Can bodge it. 85 750 has different vents. 1100/750 use same head/cowl isolator bolt thru slingshots.
Lower cowl - 1100 & 86-87 750 interchange. 85 750 does not curve forward at front bottom.
Side panels - 1100/750 same xc LTD.
Tail sections - 1100/750 same xc LTD has protruding taillight lens. Tail light ass'y is now NLS.
Rear Inner Fender - 1100/750 are same both front & rear sections. Beware of butchered cutoff rear license plate section in used units. Rubber flap extension to front section protecting shock is NLS.
Fuel tank - 1100 & 750 are same but California versions are different - smaller and complex vents. Cannot fix dents from inside due to baffles so need to clean out, tack weld bungs and pull out. New tank is NLS.
Fuel tank breather plug - 1100/750 identical, screws out(special wrench), has gasket. California version differs again.
Fuel tank cap - 1100/750 identical.
Forks - 1100/750 appear to be same 41mm conventional xc 1100 has NEAS and 750 has PDF. Springs probably differ.
Shock - 1100/750 not same, neither is cushion link.
Swingarm - 1100/750 not same, 1100 has lower box-section bracing at front & is longer.
Clipons - 1100 bars are internally weighted & attached to fork mount with 2 bolts; 750 are lighter & fixed to fork mount.
Sidestand - 1100/750 are same dimensions but sidestand lever & sidestand switch tab are in different locations.
Fusebox - 1100/750 identical.
Circuit Breaker (under batterybox) - 1100/750 identical.
Starter solenoid (front of batterybox) - 1100/750 identical.
CDI ignition Igniter - 1100/750 will interchange but 1100 (ends in L) has lower rpm limiter than 750(ends in H) & do not know if identical timing curve.
Exhaust - OEM not same as 1100 engine is taller, but 1100/750 aftermarket may interchange - try it before buy it. Reported that appropriate size Slingshot & Bandit exhausts may be modified to fit.
 
#25 ·
Rear sprocket carrier - 86/87 1100 does not swap with 88 1100; 86/87 wheel has smaller ~42/52mm id/od raised flange outside of bearing than 88 1100's ~46/56 mm raised flange so even though both use 20mm id bearings, 5 cushions & 5 sprocket bolts they do not interchange as flanges do not match carrier's groove. Do not know where else the 88 1100 wheel&carrier is used.
 
#26 ·
Re: Gotgixxers 85-87 750 and 86-88 1100 parts interchange.

hi there new on here from cheshire. sold my green one and now have a 1100 gsxr which im gonna streetfighter. do you know if there is any difference in length between a
Suzuki GSXR 750 WP J Reg Swing Arm to that of a standard 1100 swing arm.
thank you
Gaz
 
#31 ·
Fuel Tank - Canadian/Continental Europe flat-top is about 19liters & has curved knee indent profile; England/Australia/US non-CA humpback is about 21 liters & has straight knee indent profile, not sure about CA humpback capacity. Also not exactly sure which markets got which tank.
- the '86 1100 stripe decals are different for the tanks with the flat-top requiring 2" longer top stripes (both sides) with about a 15degree wider included angle between the two stripe wings. RD Decals' stripes only fit the humpback but I'm working with Mark to make flat-top stripes as well. *Note that RD will provide a longer right top stripe on request that fits closer to the breather hump than does the oem stripe.
 
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