Suzuki Burgman 400 - Service manual > Final Gear Disassembly and Assembly

Refer to "Final Gear Assembly Removal and Installation".

Disassembly

Final gear cover

1) Remove the drive shaft (1) and O-ring (2) from the final gear cover (3).

2) Remove the oil seal (4) using the special tool.

Special tool (A): 09913-50121 (Oil seal remover)

3) Remove the bearing (5) and (6) using the special tool.

Special tool (B): 09921-20240 (Bearing remover set)

4) Remove the bearing (7) using the special tool.

Special tool (C): 09913-70210 (Bearing installer set)

5) Remove the magnet (8).

Idle gear / Idle shaft

1) Remove the washers (1), snap ring (2) and idle gear (3).

2) Remove the snap ring (4) and idle shaft (5).

Final driven gear / Rear axle shaft

1) Remove the snap ring (1) and final driven gear (2).

2) Remove the snap ring (3) from the rear axle shaft (4).

Final gear case

1) Remove the bearing retainer (1).

2) Remove the bearing (2) using the special tool.

Special tool (A): 09913-75830 (Bearing installer)

3) Remove the oil seal (3) using the special tool.

Special tool (B): 09913-50121 (Oil seal remover)

4) Remove the bearings (4) and (5) using the special tool.

Special tool : 09921-20240 (Bearing remover set)

Assembly

Assemble the final gear assembly in the reverse order of disassembly. Pay attention to the following points:

Final gear case

• Install the bearings (1) and (2) using the special tool.

! CAUTION

• Replace the bearings with the new ones.
• Install the bearing so that its stamped mark faces outside.

Special tool : 09913-70210 (Bearing installer set)

• Install the oil seal (3) and bearings (4) using the special tool.

! CAUTION

• Replace the O-ring with a new one.
• Replace the bearings with the new ones.
• Install the bearing so that its stamped mark faces outside.

Special tool (A): 09913-70210 (Bearing installer set)

• Apply the grease to the oil seal lip.

: Grease 99000-25010 (SUZUKI SUPER GREASE A or equivalent)

• Install the bearing retainer (5).

Final gear cover

• Install the bearings (1), (2) and (3) using the special tool.

! CAUTION

• Replace the bearing with a new one.
• Install the bearing so that its stamped mark faces outside.

Special tool (A): 09913-70210 (Bearing installer set)

• Install the oil seal (4) using the special tool.

! CAUTION Replace the oil seal with a new one.

Special tool (A): 09913-70210 (Bearing installer set)

• Apply the supper grease to the oil seal lip.

: Grease 99000-25010 (SUZUKI SUPER GREASE A or equivalent)

• Tighten the oil level bolt (5), oil filler bolt (6) and final gear cover bolts (7) to the specified torque.

! CAUTION

• Replace the gasket washer with a new one.
• Apply engine oil to each gear and bearing.
• Tighten the final gear cover bolts diagonally.

Tightening torque
Oil level bolt (a): 16 N*m (1.6 kgf-m, 11.5 lb-ft)
Oil filler bolt (b): 23 N*m (2.3 kgf-m, 16.5 lb-ft)
Final gear cover bolt (c): 22 N*m (2.2 kgf-m, 16.0 lb-ft)

Final Drive Gear Bearing Inspection

Refer to "Final Gear Disassembly and Assembly".

Inspect the following items.

Final gear case side

Inspect the play of the bearings by hand while they are in the case. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. Refer to "Final Gear Assembly Removal and Installation".

Final gear cover side

Inspect the play of the bearings by hand while they are in the cover. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. Refer to "Final Gear Assembly Removal and Installation".

Specifications

Tightening Torque Specifications

NOTE The specified tightening torque is also described in the following.

Reference: For the tightening torque of fastener not specified in this section, refer to "Tightening Torque Specifications".

Special Tools and Equipment

Recommended Service Material

NOTE Required service material is also described in the following.

Special Tool

09913-50121 Oil seal remover

09913-75830 Bearing installer

09913-70210 Bearing installer set

09921-20240 Bearing remover set

See also: