Suzuki Burgman 400 - Service manual > Engine Top

Engine Top Side Disassembly

It is unnecessary to remove the engine assembly from the frame when servicing the engine top side.

NOTE Before servicing the engine top side with engine inplace, remove the air cleaner box, throttle body, fuel tank, exhaust pipe, muffler and etc. Refer to "Engine Assembly Removal and Installation".

! CAUTION Identify the position of each removed part.

Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original positions.

Cylinder Head Cover

1) Disconnect the spark plug cap (1).

2) Remove the bracket (2).

3) Remove the cylinder head cover (3).

Camshaft

1) Remove the spark plug. Refer to "Spark Plug Removal and Installation ".

2) Remove the cooling fan cover (1) and cooling fan filter (2).

3) Remove the generator cover plug (3) and bring the piston to TDC on the compression stroke by turning the crankshaft until the line "A" on the generator rotor aligns with the slit "B" in the generator cover.

4) After removing the cam chain tension adjuster cap bolt (4), gasket washer and spring, remove the cam chain tension adjuster (5) and gasket.

5) Remove the cam chain guide No. 2 (6) and camshaft journal holder (7).

! CAUTION Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally.

6) Remove the intake camshaft (8) and exhaust camshaft (9).

7) Remove the dowel pins.

Cylinder Head and Cylinder

1) Remove the water bypass hose (1).

2) Remove the heat shield (2).

3) Remove the cylinder head (3).

NOTE Be sure to loosen the cylinder head bolts evenly and in a crisscross pattern.

4) Remove the dowel pins and gasket.

5) Remove the cam chain guide No. 1 (4).

6) Remove the cylinder (5).

7) Remove the dowel pins and gasket.

Piston

1) Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase.

2) Remove the piston pin circlip (1).

3) Remove the piston pin and piston.

Engine Top Side Assembly

Assemble the engine top side in the reverse order of disassembly. Pay attention to the following points:

Piston

• Before installing the piston pin, apply molybdenum oil to its surface.

  M/O: Molybdenum oil (Molybdenum oil solution)

• When installing the piston, face the dent mark "A" on its head to the exhaust side of the cylinder.

NOTE Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase.

! CAUTION Use new piston pin circlips.

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