Suzki Burgman AN400. Manual - part 15

ENGINE     3-23

ENGINE COMPONENT INSPECTION AND
SERVICE

CYLINDER HEAD COVER

DISASSEMBLY

• Remove the PAIR reed valve cover 

 

1

 and PAIR reed valve

 

2

.

• Remove the cylinder head cover gasket 

 

3

.

INSPECTION

• Inspect the reed valve for the carbon deposit.
• If the carbon deposit is found in the reed valve, replace the

PAIR reed valve with a new one.

REASSEMBLY

• Reassembly the cylinder head cover in the reverse order of

disassembly. Pay attention to the following points:

• Install the cylinder head cover gasket 

 

1

.

$

Replace the removed cylinder head cover gasket with
a new one.

3-24     ENGINE

• Apply THREAD LOCK to the PAIR reed valve cover bolts and

tighten them.

&

99000-32050: THREAD LOCK “1342”

CAMSHAFT HOUSING

DISASSEMBLY

• Pull out the rocker arm shafts 

 

1

 and remove the exhaust and

intake valve rocker arms (

 

2

 and 

 

3

).

ROCKER ARM SHAFT OUTSIDE DIAMETER INSPECTION

• On the sliding surface, take two measurements, at right angle

to each other.

• If the outside diameter measured is less than the standard

value, replace the shaft.

'

Rocker arm shaft O.D.(IN & EX):
Standard: 11.973 – 11.984 mm (0.471 – 0.472 in)

%

09900-20205: Micrometer (0 – 25 mm)

ROCKER ARM SHAFT INSIDE DIAMETER INSPECTION

• Measure the rocker arm inside diameter in two directions at

right angle to each other.

• If the inside diameter measured exceeds the standard value,

replace the shaft.

'

Rocker arm shaft I.D.(IN & EX):
Standard: 12.000 – 12.018 mm (0.472 – 0.473 in)

%

09900-20605: Dial calipers

REASSEMBLY

• Reassembly the camshaft housing in the reverse order of dis-

assembly. Pay attention to the following points:

• Apply engine oil to the rocker arm shafts sufficiently.

ENGINE     3-25

CYLINDER HEAD

DISASSEMBLY

• Compress the valve spring 

 

1

 using the special tools.

%

09916-14510: Valve lifter
09916-14910: Attachment

• Remove the cotter halves 

 

2

.

%

09916-84511: Tweezers

• Remove the valve spring retainer 

 

3

.

• Remove the spring 

 

4

.

• Remove the valve 

 

5

 from the other side.

• Remove the valve stem seal 

 

6

.

• Remove the spring seat 

 

7

.

• Remove the cam chain tensioner bolt 

 

8

 and gasket washer

 

9

.

• Remove the cam chain tensioner 

 

0

.

3-26     ENGINE

• Remove the thermostat cover 

 

A

.

• Remove the thermostat 

 

B

.

CYLINDER HEAD DISTORTION

• Check for distortion of the mating surface diagonally with a

straightedge and thickness gauge as shown.

• If distortion exceeds the service limit, repair or replace the cyl-

inder head.

'

Cylinder head distortion:
Service Limit: 0.05 mm (0.002 in)

%

09900-20803: Thickness gauge

VALVE FACE WEAR

• Visually inspect each valve face for wear. Replace any valve

with an abnormally worn face. The thickness of the valve face
decreases as the face wears. Measure the valve face 

 

T

. If it

is out of specification replace the valve with a new one.

'

Valve head thickness 

 

T

:

Service Limit: 0.5 mm (0.02 in)

%

09900-20102: Venier calipers