Suzuki Intruder VZ1500, Service Manual

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1D-55 Engine Mechanical:
Piston and Piston Ring Inspection
B940H21406031
Refer to “Piston Ring Removal and Installation
(Page 1D-53)”.
Piston Diameter
Measure the piston diameter using the micrometer at
15mm (0.6 in) “a” from the skirt end. If the piston
diameter is less than the service limit, replace the piston.
Special tool
(A): 09900–20204 (Micrometer (75 – 100 mm))
Piston diameter
Service limit: 95.880 mm (3.7748 in)
Piston-to-cylinder Clearance
Subtract the piston diameter from the cylinder bore
diameter. If the piston-to-cylinder clearance exceeds the
service limit, replace both the cylinder and the piston.
Piston-to-cylinder clearance
Service limit: 0.120 mm (0.0047 in)
Piston Ring-to-groove Clearance
Measure the side clearances of the 1st and 2nd piston
rings using the thickness gauge. If any of the clearances
exceed the limit, replace both the piston and piston
rings.
Special tool
(A): 09900–20803 (Thickness gauge)
(B): 09900–20205 (Micrometer (0 – 25 mm))
Piston ring-to-groove clearance
Service limit: (1st): 0.180 mm (0.0071 in)
Service limit: (2nd): 0.150 mm (0.0059 in)
Piston ring groove width
Standard: (1st): 1.21 – 1.23 mm (0.0476 – 0.0484 in)
Standard: (2nd): 1.01 – 1.03 mm (0.0398 – 0.0406 in)
Standard: (Oil): 2.51 – 2.53 mm (0.0988 – 0.0996 in)
Piston ring thickness
Standard: (1st): 1.17 – 1.19 mm (0.046 – 0.047 in)
Standard: (2nd): 0.97 – 0.99 mm (0.038 – 0.039 in)
“ a ”
I940H1140168-03
(A)
I940H1140169-01
(A)
I649G1140263-03
(B)
I649G1140264-03