Suzuki Burgman 400 - Service manual > Cylinder Head

Cylinder Head Disassembly and Reassembly

Disassembly

! CAUTION Identify the position of each removed part.

1) Remove the tappet (1) and shim (2) by fingers or magnetic hand.

! CAUTION Identify the position of each removed part.

2) Install the protector (3) between the valve spring and cylinder head.

3) Using the special tools, compress the valve spring and remove the two cotter halves from the valve stem.

Special tool
(A): 09916-14510 (Valve spring compressor)
(B): 09916-14530 (Valve spring compressor attachment)
(C): 09919-28610 (Sleeve protector) : 09916-84511 (Tweezers)

! CAUTION To prevent damage of the tappet sliding surface with the special tool, use the protector.

4) Remove the valve spring retainer (4) and valve spring (5).

5) Pull out the valve (6) from the combustion chamber side.

6) Remove the oil seal (7) and spring seat (8).

! CAUTION Do not reuse the removed oil seal.

7) Remove the other valves in the same manner as described previously.

8) Remove the thermostat case (9).

9) Remove the thermostat (10).

10) Remove the intake pipe (11).

11) Remove the ECT sensor (12).

12) Remove the oil jet (for cam chain tension adjuster) (13).

13) Remove the oil gallery plug (cylinder head) (14).

Assembly

Assembly is in the reverse order of disassembly. Pay attention to the following points:

• Tighten the oil gallery plug (cylinder head) (1) to the specified torque.

Tightening torque
Oil gallery plug (cylinder head): 10 N*m (1.0 kgf-m, 7.0 lb-ft)

! CAUTION Replace the gasket with a new one.

• Apply engine oil to O-ring and install the oil jet.
• Apply engine coolant to O-ring and install the ECT sensor.

! CAUTION Replace each O-ring with a new one.

Tightening torque
ECT sensor: 12 N*m (1.2 kgf-m, 8.5 lb-ft)

• Make sure that the scooped part "A" faces downward.
• Apply grease to O-ring and thread lock to the intake pipe bolts.

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

: Thread lock cement 99000-32050 (THREAD LOCK CEMENT 1342 or equivalent)

• Tighten the intake pipe bolts to the specified torque.

! CAUTION Replace the O-ring with a new one.

Tightening torque
Intake pipe bolt (a): 10 N*m (1.0 kgf-m, 7.0 lb-ft)

• Install the thermostat. Refer to "Thermostat Removal and Installation".
• Install the valve spring seat.
• Apply MOLYBDENUM OIL SOLUTION to the oil seal (2), and press-fit it into position.

M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION)

! CAUTION Do not reuse the removed oil seal.

• Insert the valve, with its stem coated with MOLYBDENUM OIL SOLUTION all around and along the full stem length without any break.

! CAUTION When inserting the valve, take care not to damage the lip of the oil seal.

M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION)

• Install the valve spring with the small-pitch portion "B" facing cylinder head.

3. Large-pitch portion
4. UPWARD
5. Paint

• Put on the valve spring retainer (3), and using the special tools, press down the spring, fit the cotter halves to the stem end, and release the lifter to allow the cotter halves to wedge in between retainer and stem.

Special tool
(A): 09916-14510 (Valve spring compressor)
(B): 09916-14530 (Valve spring compressor attachment)
(C): 09919-28610 (Sleeve protector) : 09916-84511 (Tweezers)

• Be sure that the rounded lip "F" of the cotter fits snugly into the groove "G" in the stem end.

1. Valve spring retainer
2. Cotter

• Install the other valves and springs in the same manner as described previously.

! CAUTION

• Be sure to restore each spring and valve to their original positions.
• Be careful not to damage the valve and valve stem when handling it.

 

• Install the tappet shims and the tappets to their original positions.

NOTE

• Apply engine oil to the stem end, shim and tappet before fitting them.
• When seating the tappet shim, be sure the figure printed surface faces the tappet.

See also: