Suzuki Burgman 400 - Service manual > Final Gear Assembly Removal and Installation

Removal

1) Remove the drive V-belt. Refer to "Drive V-belt Removal and Installation".

2) Remove the oil level bolt (1).

3) Remove the oil drain bolt (2) and drain oil.

4) Remove the final gear cover bolts.

5) Remove the rear wheel. Refer to "Rear Wheel Assembly Removal and Installation".

6) Remove the final gear cover (3) along with the drive shaft (4).

7) Remove the dowel pins (5) and washer (6).

8) Remove the final driven gear (7) and rear axle shaft (8).

9) Remove the idle shaft (9).

10) Remove the washer (10).

Installation

Install the final gear assembly in the reverse order of removal. Pay attention to the following points:

! CAUTION Apply engine oil to each gears and shaft part.

• Install the dowel pin to the case side.
• Install the final gear cover and drive shaft.

! CAUTION

• Replace the O-ring with a new one.
• Care should be used not to allow the O-ring to be come off when installing the transmission cover.

• Tighten the final gear cover bolt (1) to the specified torque.

! CAUTION Tighten the final gear cover bolts diagonally and evenly.

Tightening torque
Final gear cover bolt (a): 22 N*m (2.2 kgf-m, 16.0 lb-ft)

Tighten the oil drain plug (2) to the specified torque and after filling oil through the level hole, also tighten the level bolt (3) to the specified torque.

! CAUTION Replace the gasket washer with a new one.

Tightening torque
Oil drain plug (b): 12 N*m (1.2 kgf-m, 8.5 lb-ft)
Oil level bolt (c): 16 N*m (1.6 kgf-m, 11.5 lb-ft)

Final gear capacity (when replacing)
190 ml

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