Suzuki VX800 1990-1993 Service Manual 03 Engine
CONTENTS
COMPRESSION CHECK
ENGINE COMPONENTS REMOVABLE WITH
THE ENGINE IN PLACE
ENGINE REMOVAL AND REINSTALLATION
ENGINE REMOVAL
ENGINE REINSTA L LA TION
ENGINE DISASSEMBL Y
ENGINE COMPONENTS INSPECTION A ND SERVICING
CYLINDER HEAD COVER
CYLINDER HEAD
CYLINDER
PISTON
PISTON RING
PISTON PIN AND PIN BORE
CONROD
..............................................................
................................................................. .3_31
..............................................................
.................................................. .3_ 1
.................................................. .3_ 2
....................... .3_ 3
.................................................. .3_ 3
...................................... .3_ 4
..................................................
.........................................
.....................................................
........................................................
....................................
.3_ 5
...... 3-20
.3_20
.3_24
.3_30
.3_32
3-33
.3_34
CRANKSHAFT
CLUTCH
GENERATOR
STARTER CLUTCH
OIL PUMP
TRANSMISSION
ENGINE REASSEMBLY
CAMSHAFT TIMING
VALVE ROCKER ARM AND SHAFT
..................................................................
........................................................
.......................................................... .3_41
..................................................
..............................................................
.....................................................
..................................................
................................................
.3_37
3-39
3-4 1
.3_42
.3_42
.3_44
3-57
.......................... .3_50
3-I ENGINE
COMPRESSION CHECK
The compression of a cylinder is good indicator of its internal condition. The decision to overhaul the
cylinders is often based on the results of a compression test. Periodic maintenance records kept at your
dealership should include compression readings for each maintenance service.
COMPRESSION
I
Low compression pressure can indicate any of the following conditions:
Overhaul the engine in the following cases:
*
* Difference in compression pressure between two cylinders is more than 200 kPa (2 kg/cm2, 28 psi).
*
Standard
1300 - 1600 kPa
13 - 16 kg/cm’
184 - 227 psi
Excessively worn cylinder wall
Worn-down piston or piston rings
Piston rings stuck in the grooves
Poor seating of valves
Ruptured or otherwise defective cylinder head gasket
Valve clearance out of adjustment
Starter motor cranks too slowly
Compression pressure in one of the cylinders is less than 1100 kPa (I 1 kg/cm’, 156 psi).
All
compression pressure are below 1300 kPa (13 kg/cm’,
1100 kPa (11 kg/cm2, 156 psi).
Limit
1100 kPa 200 kPa
(Difference in cylinders
184 psi) even when they measure more than
COMPRESSION TEST PROCEDURE
NOTE:
Before testing the compression of the engine, make sure
that the cylinder head bolts and nuts are tightened to speci-
fied torque values.
Warm up the engine before testing.
Remove all the spark plugs.
Fit the compression gauge 0 in one of the plug holes, while
taking care that the connection is tight.
Twist the throttle grip full open.
Crank the engine a few seconds with
the maximum gauge reading as th
cylinder.
Repeat this procedure with the other
09915-64510 : Compression gauge
09918-03810 : Adaptor
the starter,
re compress ion of the
cylinder.
and record
B
!z
2
m
s
ii
d
v)
z
0
$
?
z
4
m
z
engine from the frame. Refer
ENGINE RIGHT SIDE
3-9
See page
Clutch cover . . . . . . . . . . . . . . . . . . . . . . .
3-3
See page
Clutch pressure, drive and
3-3
driven plates . . . . . . . . . . . . . . . . . . . . . 3-9
3-12
3-10
Oil pump driven gear . . . . . . . . . . . . . . . .
3-3
Oil pump drive chain . . . . . . . . . . . . . . . . 3-10 3
3-12
3-10
. . . . . . . . . . . . . . . . . .
Primary drive gear
3-l 7
3-11
Oil pump assembly . . . . . . . . . . . . . . . . . .
3-l 2
3-11 <
Gearshift shaft . . . . . , . . . . . . . . . . . . . . .
The parts listed below can be removed and reinstalled without removing the
to the page listed in this section for removal and reinstallation instructions.
ENGINE CENTER
........................
Radiator
See page
...... 3-3
...........
......................
........................
Exhaust pipe and muffler
Carburetor
Oil filter
3-l 2
3-14
3-3
............
................
...................
Oil sump filter
Oil pressure switch
Starter motor assembly
7-7
3-l 3
....... 3-14
7-7
......... 3-15
3-3
5-7
ENGINE LEFT SIDE
Secondary bevel gear case cover
Secondary bevel gear case ...........
Generator rotor ..................
Gearshift lever ...................
Generator cover ..................
Neutral indicator switch body
Generator stator ..................
Pick-up coil .....................
Secondary driven bevel gear
Water pump assembly ..............
Water pump case .................
3-3 ENGINE
ENGINE REMOVAL AND REINSTALLATION
ENGINE REMOVAL
Bafore taking the engine out of the frame, thoroughly clean the engine with a suitable cleaner. The proce-
dure of engine removal is sequentially explained in the following steps.
1. Remove the oil drain plug to drain out engine oil.
2. Remove the frame head cover and radiator cap.
3. Remove the water drain plug to drain out coolant.
4. Remove the seat.
5. Disconnect the battery 0 and 0 lead wires from the battery terminals, remove the battery.
CAUTION: Be
6. Remove all the frame covers.
7. Turn the fuel cock “OFF” position and remove the fuel tank mounting bolts, remove the fuel tank by
disconnecting the fuel hose.
8. Remove the left and right mufflers.
9. Disconnect the following lead wires.
* Side stand switch
* Generator
* Pick-up coil
10. Remove the secondary bevel gear case cover.
11. Remove the clutch release cam assembly.
12. Remove the radiator by removing the radiator protector, radiator hose clamps and radiator cooling
fan.
13. Remove the left-footrest.
14. Remove the gearshift lever.
15. Remove the water pump case.
16. Loosen the shaft drive boot clamp.
17. Remove the coolant reservoir tank.
18. Disconnect the choke cables and throttle cables.
19. Disconnect the rear carburetor fuel hose.
20. Disconnect the breather hose from the rear cylinder head.
21. Disconnect the fuel pump vacuum hose from the front carburetor intake pipe.
22. Loosen the front and rear carburetor clamps.
23. Remove the rear carburetor air cleaner mounting bolts and slide the air cleaner backward.
24. Remove the front and rear carburetors.
25. Remove the rear brake pedal mounting bolts and rear brake master cylinder mounting bolts, remove
the brake pedal and master cylinder.
26. Support the engine with a proper jack.
27.
Remove the engine mounting bolts, nuts, spacer, brackets and right frame down tube securing bolts.
sure to disconnect the @ lead wire first.
* Starter motor
* Starter relay
* Water temperature gauge * Ground lead
* Cooling fan motor lead
* Neutral indicator
* Oil pressure indicator
_
-
CAUTION: When holding the engine with a jack, place a wooden piece on a jack or oil pan may be
damaged.
28. Dismount the engine by pulling slightly forward and to right-side.
ENGINE 3-4
ENGINE REINSTALLATION
Reinstall the engine in the reverse order of engine removal.
l
Install the brackets, spacer, bolts and nuts properly, as shown in the following illustration.
NOTE:
The engine mounting nuts are self-locking. Once the nut has been removed, it is no longer of any use. Be
sure to use new nuts and tighten them to the specified torque.
1
3-5 ENGINE
l
After remounting the engine, route wiring harness, cables
and hoses properly by referring to the sections, for wire
routing, cable routing and hose routing. (See pages 9-12
through 23.)
l
Adjust the following items to the specification.
*
Filling coolant
*
Clutch cable play
*
Throttle cable play . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
*
Idling adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
*
Balancing carburetors
*
Rear brake pedal height
0
Pour 3.3 L (3.5/2.9 US/Imp qt) of engine oil SAE lOW/40
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
. . . . . , . . . . . . . . . . . . . . . . . . . . . . .2-10
, . . . . . . . . . . . . . . . . . . . . . . . . .6-15
. . . . . . . . . . . . . . . . . . . . . . . .2-l
graded SE or SF into the engine after overhauling engine.
l
Start up the engine and allow it run for several minutes at
idle speed. About several minutes after stopping engine,
check that the oil level remains between the marks of oil
level inspection window.
Change
Filter change
Overhau I
I
I
2400 ml (2.5/2.1 US/Imp qt)
2800 ml (3.0/2.5 US/Imp qt)
3300 ml (3.V2.9 US/Imp qt)
Page
2
-
-
1
ENGINE DISASSEMBLY
CAUTION:
Be sure to identify each removed part such as intake pipe,
camshaft, piston, conrod etc. as to its location and lay the
parts out in groups so that each will be restored to the original
location during assembly.
l
Remove the valve
inspection caps.
ENGINE 3-6
l
Remove the cylinder head covers.
NOTE:
When removing the cylinder head covers, the piston must be
at top dead center on the compression stroke.
No. 2 (FRONT)
No. 1 (REAR)
l
Flatten the lock washers and remove the camshaft sprocket
bolts.
l
Remove the camshafts and sprockets.
l
Remove the front intake pipe.
l
Loosen the water hose clamp screws.
l
Remove the water pipe/water hose by removing the water
pipe bolts and loosening the water hose clamp screw.
l
Remove the cylinder head bolts.
l
Remove the front and rear cylinder heads along with the
respective cylinders.
Remove the cylinder head nuts and bolts.
ENGINE 3-8
After releasing the ratchet, push the chain tensioner rod and
insert a screwdriver between ratchet and chain tensioner
body.
Separate the respective cylinder heads and cylinders.
l
Check the “F” and “R” piston marks.
Place a clean rag over the cylinder base to prevent piston pin
circlips from dropping into crankcase. Remove the piston
pin circlips with long-nose pliers.
Drive out the piston pins by using proper drift.
3-9 ENGINE
l
After removing the clutch cover bolts, remove the clutch
cover by tapping with a plastic hammer.
l
Remove the clutch spring mounting bolts diagonally.
l
Remove the pressure plate.
l
Remove the clutch push piece, thrust washer, bearing and
push rod.
l
Remove the clutch drive and driven plates.
l
Remove the clutch sleeve hub nut by using the special tool.
09920-50710 :
l
Remove the back torque limiter (c along with the clutch
Clutch sleeve hub holder
sleeve hub 0.
l
Remove the thrust washer.
l
Remove the oil pump driven gear circlip.
09900-06107 : Snap ring pliers
ENGINE 3-10
l
Remove the primary driven gear assembly, oil pump drive
chain and oil pump driven gear.
l
Remove the thrust washer and spacer.
l
Remove the primary drive gear bolt while holding the
primary drive gear with the special tool and remove the
primary drive gear.
09930-40113
CAUTION
:
Rotor holder
:
This bolt has left-hand thread. Turning it counter-clockwise
it may cause damage.
l
Remove the cam chain guide and cam chain.
l
Remove the camshaft drive sprocket and thrust washer.
l
Remove the oil pump by removing the bolts.
l
Remove the gearshift shaft 0.
l
Remove the paw1 lifter and cam guide by removing the nuts
@ and screws 0.
-
-
09900-09003
l
Remove the gearshift cam driven gear retaining bolt @.
l
Remove the gearshift cam driven gear 0.
:
Impact driver set
NOTE:
When removing the gearshift cam driven gear, do not lose
gearshift pawl
l
Unhook the gearshift cam stopper spring 0, gearshift cam
@ ,
pin @ and spring 0.
stopper plate @ and washer 8.
l
Remove the oil sump filter cap and oil sump filter.
l
Remove the oil filter by using the special tool.
09915-40611 : Oil filter wrench
ENGINE 3-12
l
Remove the starter motor cover.
l
Remove the starter motor.
l
Remove the generator cover.
3-13 ENGINE
l
Remove the starter driven gear and its idle gear.
l
Loosen the rotor bolt.
NOTE:
When removing the rotor, do not remove the rotor bolt after
loosening the bolt. The rotor bolt is used in conjunction with
the rotor remover.
l
Remove the rotor by using the special tool.
(For U.S.A. models)
09930-30720
:
Rotor remover
(For the other models)
09930-34970
l
Remove the key (iJ.
l
Remove the starter driven gear.
l
Remove the cam chain guide and cam chain.
:
Rotor remover
l
Remove the neutral switch assembly.
NOTE:
Do not lose the neutral switch contact and its spring.
l
Disconnect the oil pressure switch lead wire.
ENGINE 3-14
Install the universal joint into the secondary driven
gear.
Remove the driveshaft bolt @ and secondary drive
gear shaft nut @ while holding the universal joint.
CAUTION:
Driveshaft bolt 0
l
Remove the secondary driven bevel gear housing bolts and
has left-hand thread.
secondary bevel gear case bolts.
bevel
bevel
l
Remove the secondary driven bevel gear assembly and
bearing.
l
Remove the crankcase securing bolts.
l
Separate the crankcase into 2 parts, right and left with a
crankcase separating tool.
09920-13120 : Crankcase separating tool
NOTE:
Fit the crankcase separating tool, so that the tool plate is
parallel with the end face of the crankcase. The crankshaft and
transmission components must remain in the left crankcase
half
Remove the gearshift fork shafts and gearshift forks.
Remove the gearshift cam.
Remove the driveshaft assembly, countershaft assembly and
secondary reduction gear.
Remove the crankshaft.
l
Loosen the secondary drive bevel gear housing bolts and
remove the secondary drive bevel gear assembly.
TRANSMISSION
DISASSEMBLY
l
Disassemble the transmission gears as shown in the illustration.
ENGINE 3-16
Reduction drive gear
Low driven gear
4th driven gear
3rd driven gear
Driveshaft
Top driven gear
2nd driven gear
CountershaftlLow
drive gear
4th drive gear
3rd drive gear
(@ Top drive gear
@ 2nd drive gear
LUBRICATION RELATED PARTS
l
Remove the oil pipe and O-rings.
CAUTION:
The removed O-ring should be replaced with a new one.
l
Remove the oil pressure regulator.
l
Remove the oil pressure switch.
NOTE:
When reinstalling the oil pressure switch, apply the SUZUKI
BOND NO. 1207B/NO. 1215 to thread
part.
(For U.S.A. model)
99104-31140 : SUZUKI BOND NO. 1207B
(For the other models)
99000-31110 : SUZUKI BOND NO. 1215
l
Check the oil jet fitted on the crankcase for clogging.
NOTE:
When installing the oil jet, apply the motor oil to the oil jet
O-ring.
CRANKCASE BEARING OIL AND SEAL
l
Remove the bearing retainer screws.
NOTE:
When reinstalling the bearing retainers, apply THREAD LOCK
SUPER “1303”/“1324” to bearing retainer bolts or screws.
(For U.S.A. model)
99000-32030 : TH READ
(For the other models)
99000-32120 : THREAD
l
Remove the bearings and oil seal by using the special tools.
09914-79610 : Bearing remover
09923-73210
:
Bearing remover
09930-30102 : Sliding shaft
LOCK SUPER “1303”
LOCK SUPER “1324”
ENGINE 3-18
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