Engine Bottom Side Disassembly - Suzuki Intruder VZ1500 Service Manual

Piston Ring Free End Gap and Piston Ring End Gap
Measure the piston ring free end gap using vernier
calipers. Next, fit the piston ring squarely into the
cylinder and measure the piston ring end gap using the
thickness gauge. If any of the measurements exceed the
service limit, replace the piston ring with a new one.
Special tool
(A): 09900–20101 (Vernier calipers (1/15 mm,
150 mm))
Piston ring free end gap
Service limit: (1st): 8.8 mm (0.35 in)
Service limit: (2nd): 8.8 mm (0.35 in)
Special tool
(B): 09900–20803 (Thickness gauge)
Piston ring end gap
Service limit: (1st): 0.50 mm (0.020 in)
Service limit: (2nd): 0.50 mm (0.020 in)
Piston Pin / Pin Bore
Measure the piston pin bore inside diameter using the
small bore gauge. If measurement is out of specification,
replace the piston.
Special tool
(A): 09900–20602 (Dial gauge (1/1000 mm, 1
mm))
(B): 09900–22403 (Small bore gauge (18 – 35
mm))
Piston pin bore I.D.
Service limit: 22.030 mm (0.8673 in)
(A)
I649G1140265-03
(B)
I940H1140170-01
(B)
Measure the piston pin outside diameter at three
positions using the micrometer. If any of the
measurements are out of specification, replace the
piston pin.
Special tool
(C): 09900–20205 (Micrometer (0 – 25 mm))
Piston pin O.D.
Service limit: 21.980 mm (0.8654 in)

Engine Bottom Side Disassembly

Refer to "Engine Assembly Removal (Page 1D-20)".
Refer to "Engine Top Side Disassembly (Page 1D-27)".
NOTE
The crankcase must be separated to service
the crankshaft and conrod.
Starter Motor
Remove the starter motor (1).
Engine Mechanical: 1D-56
(A)
I649G1140267-03
(C)
I649G1140268-03
B940H21406032
1
I940H1140171-01