Suzuki Burgman 400 - Service manual > Cam Chain Tensioner

Cam Chain Tensioner Inspection

Inspect the cam chain tensioner in the following procedures:

1) Remove the cam chain tensioner. Refer to "Engine Bottom Side Disassembly".

2) Inspect the contacting surface of the cam chain tensioner. If it is worn or damaged, replace the cam chain tensioner with a new one.

3) Install the cam chain tensioner. Refer to "Engine Bottom Side Assembly".

Conrod and Crankshaft Inspection

Refer to "Engine Bottom Side Disassembly".

Refer to "Engine Bottom Side Assembly".

Conrod Small End I.D.

Measure the conrod small end inside diameter using the small bore gauge.

If the conrod small end inside diameter exceeds the service limit, replace the conrod.

Conrod small end I.D.
Service limit: 20.040 mm (0.789 in)

Special tool (A): 09900-20605 (Dial calipers (1/100 mm, 10 - 34 mm) )

Conrod Big End Side Clearance

Inspect the conrod side clearance using the thickness gauge.

If the clearance exceeds the limit, inspect the conrod big end width and crank pin width.

If the width exceed the limit, replace conrod or crankshaft.

Conrod big end side clearance
Limit: 1.00 mm (0.04 in)

Special tool (A): 09900-20803 (Thickness gauge)

Conrod big end width
Standard: 21.95 - 22.00 mm (0.864 - 0.866 in)

Conrod Deflection

Move the small end sideways while holding the big end immovable in thrust direction.

Measure the amount of deflection.

Turn the conrod and see if it moves smoothly without play and noise.

This method can check the extent of wear on the parts of the conrod's big end.

Conrod deflection
Service limit: 3.0 mm (0.12 in)

Special tool
(A): 09900-20607 (Dial gauge (1/100 mm, 10 mm) )
(B): 09900-20701 (Magnetic stand)
(C): 09900-21304 (V-block (100 mm) )

Crankshaft Runout

With the right and left crank journals supported with V-block, turn the crankshaft slowly. At this time, measure the crankshaft end runout using a dial gauge. If the runout exceeds the service limit, replace the crankshaft.

Crankshaft runout
Service limit: 0.08 mm (0.003 in)

Special tool
(A): 09900-20607 (Dial gauge (1/100 mm, 10 mm) )
: 09900-20701 (Magnetic stand)
: 09900-21304 (V-block (100 mm) )

NOTE Set the V-block so that the crankshaft becomes horizontal.

See also:

 Suzuki Burgman 400 - Service manual > Generator Rotor

Degrease the tapered portion "A" of generator rotor and also the crankshaft "B". Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely off oily or greasy matter and make these surfaces completely dry. Install the generator rotor (1).