Suzuki Burgman 400 - Service manual > Cylinder

• Install the dowel pins (1) and a new gasket (2) to the crankcase.
• Coat the cylinder wall and piston surface with engine oil.

! CAUTION Replace the gasket with a new one.

• Install the cylinder.

Cam Chain Guide

• Install the cam chain guide No. 1 (1).

! CAUTION When installing the cam chain guide No. 1, check that the chain is properly engaged with the crankshaft sprocket.

Cylinder Head

• Place the dowel pins and a new gasket (1) on the cylinder.

! CAUTION Replace the gasket with a new one.

• Install the cylinder head.

NOTE When installing the cylinder head, keep the cam chain taut.

Cylinder head bolt

Tighten the cylinder head bolts "A" (L190) and "B" (L130) in the following procedures:

1) Apply engine oil to the bolt threads and both sides of washers.

2) Tighten the bolts 1 and 2 diagonally and evenly to the specified torque.

Tightening torque
  Cylinder head bolt (L190) (Initial) (a): 25 N*m (2.5 kgf-m, 18.0 lb-ft)
  Cylinder head bolt (L130) (b): 25 N*m (2.5 kgf-m, 18.0 lb-ft)

3) Additionally tighten the bolts "A" to the specified torque.

Tightening torque
  Cylinder head bolt (L190) (Final) (a): 42 N*m (4.2 kgf-m, 30.5 lb-ft)

Water hose

• Install the water by-pass hose (1).

Camshaft

• Turn the crankshaft to bring the piston to the TDC.

  (Refer to "Valve Clearance Inspection and Adjustment".

! CAUTION

• Keep the cam chain taut when turning the crankshaft, or the chain will be caught between crankcase and cam drive sprocket.
• To adjust the camshaft timing correctly, be sure to align the line "A" with slit "B" and hold this position during installing the camshafts.

• Coat the journals, cam surfaces and camshaft journal holder with molybdenum oil.

  M/O: Molybdenum oil (Molybdenum oil solution)

• The exhaust camshaft and intake camshaft are distinguished by the embossed letters "EX" or "IN".

• The exhaust camshaft sprocket has an arrow marked "1". Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head.
• Engage the cam chain with the exhaust camshaft sprocket.
• The other arrow marked "2" should now be pointing upward. Starting from the roller pin that is directly above the arrow marked "2", count out 15 roller pins (from the exhaust camshaft side going towards the intake camshaft side).
• Engage the 15th roller pin on the cam chain with the arrow marked "3" on the intake sprocket.

NOTE The cam chain should now be on all three sprockets. Be careful not to move the crankshaft until the camshaft journal holder and cam chain tension adjuster are secured.

• Install the dowel pins.

• Install the camshaft journal holder (1) and cam chain guide No. 2 (2).
• Tighten the camshaft journal holder bolts in the ascending order of numbers to the specified torque.

Tightening torque
Camshaft journal holder bolt: 10 N*m (1.0 kgf-m, 0.7 lb-ft)

Cam Chain Tension Adjuster

• With the spring holder bolt and spring removed from the cam chain tension adjuster, release locking of the ratchet mechanism (1) and push the push rod all the way in.

• Fit a new gasket (2) on the cylinder head.

• Position the cam chain tension adjuster so the UP mark "A" points upward.
• Tighten the cam chain tension adjuster bolts to the specified torque.

! CAUTION Replace the gasket with a new one.

Tightening torque
Cam chain tension adjuster bolt: 10 N*m (1.0 kgf-m, 7.0 lb-ft)

• Install the gasket washer (3), spring (4) and spring holder bolt (5).

! CAUTION Replace the gasket washer with a new one.

• Tighten the spring holder bolt to the specified torque.

Tightening torque
Spring holder bolt: 23 N*m (2.3 kgf-m, 16.5 lb-ft)

CAUTION

• When the cam chain tension adjuster has been installed, check for cam chain tension to determine if the tension adjuster is functioning properly.
• Turn the crankshaft and check that all the moving parts work properly.

 

• Inspect the valve clearance. Refer to "Valve Clearance Inspection and Adjustment".

Cylinder Head Cover

• Install the gaskets (1) and (2) to the cylinder head cover.

! CAUTION Replace the gaskets with the new ones.

• Apply bond to the cam end cap.

: Sealant 99000-31140 (SUZUKI Bond 1207B or equivalent)

• Replace the gaskets with new ones and apply engine oil to both sides of them.
• Tighten the bolts to the specified torque.

Tightening torque
Cylinder head cover bolt (a): 14 N*m (1.4 kgf-m, 10.0 lb-ft)

• Install the spark plug.

Tightening torque
Spark plug: 11 N*m (1.1 kgf-m, 8.0 lb-ft)

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