Suzki Burgman AN400. Manual - part 10

ENGINE     3-3

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE

Engine components which can be removed while the engine is installed on the chassis are listed below. For
the installing and removing procedures, refer to respective paragraphs describing each component.
CENTER OF ENGINE

LEFT OF ENGINE

RIGHT OF ENGINE

ITEM

REMOVAL

INSTALLATION

Starter motor

3-10

3-82

Air cleaner

3-4

----

Throttle body

3-5

----

PAIR reed valve

3-23

----

Cylinder head

3-13

3-78

Cam chain tension adjuster

3-12

3-81

Spark plug

3-10

2-7

Cylinder head cover

3-11

3-81

Camshaft

3-13

3-79

Cam sprocket

3-13

3-79

Valve

3-25

3-34

Cylinder

3-14

3-78

Piston

3-14

3-77

ITEM

REMOVAL

INSTALLATION

Fixed drive face

3-17

3-74

Movable drive face

3-17

3-74

Clutch housing

3-17

3-73

Clutch shoe/movable driven face assembly

3-17

3-72

Drive V-belt

3-17

3-72

Transmission cover

3-17

3-72

Oil sump filter

3-18

3-70

Rear axle shaft

3-18

3-71

Idle shaft

3-18

3-71

Driveshaft

3-17, 50

3-72

ITEM

REMOVAL

INSTALLATION

Muffler

3-6

2-5

Rear wheel

3-6

7-49

Rear brake caliper

3-7

7-58

Generator

3-15

3-75

Oil pump

3-19

3-69

Starter idle gear

3-20

3-68

Balancer driven gear

3-20

3-68

Water pump

3-15

3-75

Oil filter

3-15

3-76

3-4     ENGINE

ENGINE REMOVAL AND REMOUNTING

ENGINE REMOVAL

• Remove the trunk box. (

!

7-18)

• Remove the front box. (

!

7-14)

• Drain the engine oil. (

!

2-8)

• Drain the engine coolant. (

!

6-3)

• Drain the final gear oil. (

!

2-10)

• Disconnect the breather hose 

 

1

.

• Remove the IAP sensor coupler 

 

2

.

• Disconnect the fuel injector coupler 

 

3

.

• Disconnect the ECT sensor/ignition coil coupler 

 

4

.

• Disconnect the IAT sensor coupler 

 

5

.

• Remove the hose 

 

6

.

• Loosen the air cleaner hose clamp screw 

 

7

.

• Remove the air cleaner mounting bolts 

 

8

.

• Disengage the hooks on the bottom of the air cleaner box and

then remove the air cleaner box 

 

9

.

ENGINE     3-5

• Remove the PAIR hose 

 

1

.

• Remove the intake pipe bolts and then remove the intake pipe

 

2

 along with the throttle body 

 

3

.

• Remove the O-rings 

 

4

 and insulator 

 

5

.

• Disconnect the starter motor lead wire 

 

6

 and engine ground

lead wire 

 

7

.

• Disconnect the generator coupler 

 

8

 and CKP sensor coupler

 

9

.

• Disconnect the clamps 

 

0

, 

 

A

.

3-6     ENGINE

• Remove the water hoses 

 

1

 and 

 

2

.

• Remove the exhaust pipe bolts 

 

3

.

• Remove the muffler mounting nuts and then remove the muf-

fler 

 

4

.

• Remove the gasket.

• Remove the muffler bracket 

 

5

.

• Remove the rear wheel nuts.
• Remove the rear wheel 

 

6

.

• Remove the axle nut 

 

7

.