Suzuki Burgman 400 - Service manual > Camshaft

Camshaft Inspection

Refer to "Engine Top Side Disassembly".

Refer to "Engine Top Side Assembly".

Camshaft Identification

The exhaust camshaft has embossed letters "EX" and automatic decomp. (1).

The intake camshaft has embossed letters "IN".

Cam Wear

Check the camshaft for wear or damage.

Measure the cam height "a" with a micrometer.

Replace a camshaft if the cams are worn to the service limit.

Special tool : 09900-20202 (Micrometer (1/100 mm, 25 - 50 mm) )

Cam height "a"
Service limit: (IN) 36.31 mm (1.430 in)
Service limit: (EX) 35.64 mm (1.403 in)

Camshaft Runout

Measure the runout using the dial gauge. Replace the camshaft if the runout exceeds the limit.

Special tool
(A): 09900-20606 (Dial gauge (1/100 mm) )
(B): 09900-20701 (Magnetic stand)
(C): 09900-21303 (V-block (75 mm) )

Camshaft runout (IN & EX)
Service limit: 0.10 mm (0.004 in)

Camshaft Journal Wear

Inspect the camshaft journal wear in the following procedures:

1) Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place.

2) Use the plastigauge to read the clearance at the widest portion, which is specified as follows.

Special tool (A): 09900-22301 (Plastigauge (0.025 - 0.076 mm) )

3) Install the camshaft journal holder. Refer to "Engine Top Side Assembly ".

NOTE Do not rotate the camshafts with the plastigauge in place.

Tightening torque
Camshaft journal holder bolt: 10 N*m (1.0 kgf-m, 7.0 lb-ft)

4) Remove the camshaft journal holder and measure the width of the compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge.

Camshaft journal oil clearance (IN & EX)
Service limit: 0.15 mm (0.0059 in)

5) If the camshaft journal oil clearance exceeds the limit, measure the inside diameter of the camshaft journal holder and the outside diameter of the camshaft journal. Replace the camshaft or the cylinder head depending upon which one exceeds the specification.

Special tool
(B): 09900-20602 (Dial gauge (1/1000 mm, 1 mm) )
(C): 09900-22403 (Small bore gauge (18 - 35 mm) )

Camshaft journal holder I.D. (IN & EX)
Standard: 22.012 - 22.025 mm (0.8666 - 0.8671 in)

Special tool
(D): 09900-20205 (Micrometer (0 - 25 mm) )

Camshaft journal O.D. (IN & EX)
Standard: 21.972 - 21.993 mm (0.8650 - 0.8659 in)

Automatic Decomp.

Check that automatic decomp. cam (1) moves smoothly and pin (2) rotates together. If any abnormal condition are found, replace the camshaft.

Cam Chain Tension Adjuster Inspection

The cam chain tension adjuster is maintained at the proper tension by an automatically adjusted.

1) Remove the cam chain tension adjuster. Refer to "Engine Top Side Disassembly".

2) Unlock the ratchet mechanism (1) and move the push rod (2) in place to see if it slides smoothly. If it does not slide smoothly or the ratchet mechanism is worn or damaged, replace the cam chain tension adjuster with a new one.

3) Install the cam chain tension adjuster. Refer to "Engine Top Side Assembly".

Cam Chain Guide Inspection

Inspect the cam chain guide in the following procedures: 1) Remove the cam chain guides. Refer to "Engine Top Side Assembly".

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

3) Install the cam chain guides. Refer to "Engine Top Side Assembly".

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