Needing "New" Engine - Motorcycle-Journal Forums

pflickner · 06-16-2006, 12:46 PM

I have a 1996 Suzuki Intruder VS 800 that's in need of an engine. I found a 2003, but I can't find any specs on either engine to know if it's a match, if they made the engines the same way until whatever year (or are still making them the same way). I can't seem to get a straight answer from anyone, so I'm hoping someone here can help. Thanks.

Pat

Atlas68 · 06-16-2006, 12:54 PM

Can't help with your question, but thought I'd welcome you all the same. Someone will be here shortly to assist you...coffee ??...newspaper ??

italian biker · 06-16-2006, 01:04 PM

I had a 1993 intruder and the chiltons manual I had, I believe, covered up to 2003. The 800 cc model did not change very much over the years until they became the boulevard. I believe that the engine should fit the frame, but can't say for sure. One thing you can do is check part numbers for difference in the major parts that you need to transfer the engine. Like motormounts, carbs, wire harness. The frame itself, the shaft drive, etc...

viper94bite · 06-16-2006, 01:08 PM

i don't see why it wouldn't I think even now the only change is the name.

DrBob · 06-16-2006, 05:55 PM

The Intruder 800 motor is interchangable from 1993 all the way up to the 2007 S50. The motor from a Suzuki VX800 is identical also, except it has a different fuel pump than the one in the Intruder.

There are some slight differences in the bike's eletrical and ignition systems from year to year, so there are actually three ignition module/ brain boxes used over the years. The best way to make sure your new motor runs right in you old frame is to use the ignition control module from the bike you are getting the motor from.

As for the motor itself, the cylinder heads from the early 800s are bare aluminum, while the newer ones are painted black. The post-2004 ones have little tabs on the casting to allow the mounting of the fake air cleaner tool box on the S50. But other than these visual differences the motors are identical. Several folks I know have swapped engines without any bother.

bostonjim · 06-16-2006, 07:20 PM

Not to steal a thread but I noticed that Dbob mentioned the VX 800. I had one of those and I absoultly loved it. I gave it to a friend of mine and he is currently rebuilding it. I can't wait for it to be finished so I can take it for another blast. What a great bike that was.
Jim

06-16-2006, 12:46 PM	#1 (permalink)
pflickner Newbie Joined: Jun 2006 Posts: 1	Needing "New" Engine I have a 1996 Suzuki Intruder VS 800 that's in need of an engine. I found a 2003, but I can't find any specs on either engine to know if it's a match, if they made the engines the same way until whatever year (or are still making them the same way). I can't seem to get a straight answer from anyone, so I'm hoping someone here can help. Thanks. Pat

06-16-2006, 12:54 PM	#2 (permalink)
Atlas68 Sit speling cheker Joined: Jan 2006 Bike: 2006 Blue M50 SOLD '05 Anniversary Edition VMax #1878 Location: Vancouver B.C. Canada Posts: 1,728	Can't help with your question, but thought I'd welcome you all the same. Someone will be here shortly to assist you...coffee ??...newspaper ?? __________________ Rudeness is a weak man's imitation of strength. SuperTrapp Exhaust

06-16-2006, 01:04 PM	#3 (permalink)
italian biker Kickstand Operator Joined: Mar 2006 Bike: 2006 M50, Blue Location: Toledo Posts: 264	I had a 1993 intruder and the chiltons manual I had, I believe, covered up to 2003. The 800 cc model did not change very much over the years until they became the boulevard. I believe that the engine should fit the frame, but can't say for sure. One thing you can do is check part numbers for difference in the major parts that you need to transfer the engine. Like motormounts, carbs, wire harness. The frame itself, the shaft drive, etc... __________________ 2006 M50, blue, Power Commander III, Kury Hyper Charger, Roadhouse Classic 2:1 exhaust. Kury ISO Grips with matching throttle boss on both grips, Kury Dually ISO rider pegs. Memphis Shades Alley Cat(gradient black), Cobra Sissybar, Cobra luggage rack, saddle bags are from a small company in Newark, Ohio

06-16-2006, 01:08 PM	#4 (permalink)
viper94bite Sit speling cheker Joined: Jan 2005 Bike: 2008 Yamaha FZ6 Location: omaha, ne Posts: 1,792	i don't see why it wouldn't I think even now the only change is the name. __________________ *yippee*

06-16-2006, 05:55 PM	#5 (permalink)
DrBob In The Zone Joined: May 2004 Bike: several Location: Decatur, GA Posts: 2,765	The Intruder 800 motor is interchangable from 1993 all the way up to the 2007 S50. The motor from a Suzuki VX800 is identical also, except it has a different fuel pump than the one in the Intruder. There are some slight differences in the bike's eletrical and ignition systems from year to year, so there are actually three ignition module/ brain boxes used over the years. The best way to make sure your new motor runs right in you old frame is to use the ignition control module from the bike you are getting the motor from. As for the motor itself, the cylinder heads from the early 800s are bare aluminum, while the newer ones are painted black. The post-2004 ones have little tabs on the casting to allow the mounting of the fake air cleaner tool box on the S50. But other than these visual differences the motors are identical. Several folks I know have swapped engines without any bother. __________________ Dream like you'll live forever, live like you'll die tomorrow. You MUST obey the pug dog!

06-16-2006, 07:20 PM	#6 (permalink)
bostonjim In Training Joined: May 2006 Bike: Suzuki S83 Location: just south of boston ma. Posts: 148	Not to steal a thread but I noticed that Dbob mentioned the VX 800. I had one of those and I absoultly loved it. I gave it to a friend of mine and he is currently rebuilding it. I can't wait for it to be finished so I can take it for another blast. What a great bike that was. Jim __________________ Some days it's not worth chewing through the restraints!!!

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