Suzuki Intruder VZ800 User Manual

ENGINE 3-41
PISTON
PISTON DIAMETER
Using a micrometer, measure the piston outside diameter at the
place shown in Fig. If the measurement is less than the limit,
replace the piston.
 Piston diameter
Service Limit: 82.880 mm (3.2630 in)
 09900-20204: Micrometer (75 – 100 mm)
PISTON-TO-CYLINDER CLEARANCE
As a result of the aforesaid measurement, if the piston to cylin-
der clearance exceeds the following limit, overhaul the cylinder
and use an oversize piston, or replace both cylinder and piston.
 Piston to cylinder clearance
Service Limit: 0.120 mm (0.0047 in)
Piston oversize: 0.5, 1.0 mm
PISTON RING TO GROOVE CLEARANCE
Using a thickness gauge, measure the side clearances of the
1st and 2nd rings. If any of the clearances exceeds the limit,
replace both piston and piston rings.
 Piston ring-groove clearance
Service Limit (1st) : 0.180 mm (0.007 in)
(2nd): 0.150 mm (0.006 in)
 Piston ring groove width
Standard (1st) : 1.01 – 1.03 mm (0.0398 – 0.0406 in)
(2nd): 1.21 – 1.23 mm (0.0476 – 0.0484 in)
(Oil) : 2.51 – 2.53 mm (0.0988 – 0.0996 in)
 Piston ring thickness
Standard (1st) : 0.970 – 0.990 mm (0.0382 – 0.0390 in)
(2nd): 1.170 – 1.190 mm (0.0461 – 0.0469 in)
 09900-20803: Thickness gauge
09900-20205: Micrometer (0 – 25 mm)
15 mm (0.6 in)
SAMPLE

Suzuki Intruder VZ800 Specifications

General

Engine Type	4-stroke, liquid-cooled, DOHC, 45-degree V-twin
Displacement	805 cc
Bore x Stroke	83.0 mm x 74.4 mm
Compression Ratio	9.4:1
Fuel System	Fuel injection
Ignition	Electronic ignition (transistorized)
Transmission	5-speed constant mesh
Final Drive	Shaft drive
Front Suspension	Telescopic, coil spring, oil damped
Rear Suspension	Link type, coil spring, oil damped
Rear Brake	Drum brake
Seat Height	700 mm (27.6 in)
Front Brake	Disc brake
Rear Tire	170/80-15M/C 77H, tube type
Fuel Tank Capacity	15.5 L (4.1 US gallons)