Suzuki DR-Z400S 2001 Service Manual page 44

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE .................................. 3- 2
ENGINE REMOVAL AND REMOUNTING ................................................................................. 3- 3
ENGINE REMOVAL ............................................................................................................... 3- 3
ENGINE REMOUNTING ........................................................................................................ 3- 8
ENGINE DISASSEMBLY ............................................................................................................ 3-11
ENGINE COMPONENTS INSPECTION AND SERVICE ........................................................... 3-22
CYLINDER HEAD ................................................................................................................. 3-22
CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBLY ............................................... 3-31
CYLINDER ............................................................................................................................. 3-33
PISTON AND PISTON RING ................................................................................................. 3-33
CONROD ............................................................................................................................... 3-35
CRANKSHAFT ...................................................................................................................... 3-36
STARTER CLUTCH ............................................................................................................... 3-36
STARTER TORQUE LIMITER ............................................................................................... 3-37
OIL PUMP .............................................................................................................................. 3-37
CLUTCH ................................................................................................................................ 3-38
GEARSHIFT FORK AND GEAR ........................................................................................... 3-39
TRANSMISSION ................................................................................................................... 3-40
BEARINGS ............................................................................................................................ 3-43
OIL SEALS ............................................................................................................................ 3-46
OIL CHECK VALVE ............................................................................................................... 3-47
ENGINE REASSEMBLY ............................................................................................................. 3-48
CRANKSHAFT ...................................................................................................................... 3-48
GEARSHIFT CAM AND FORK ............................................................................................. 3-49
CRANKCASE ........................................................................................................................ 3-50
STARTER CLUTCH AND GENERATOR ROTOR ................................................................. 3-51
BALANCER SHAFT .............................................................................................................. 3-52
PRIMARY DRIVE GEAR ....................................................................................................... 3-53
GEARSHIFT CAM DRIVEN GEAR ....................................................................................... 3-53
GEARSHIFT SHAFT ............................................................................................................. 3-54
OIL PUMP .............................................................................................................................. 3-54
CAM CHAIN .......................................................................................................................... 3-55
CLUTCH ................................................................................................................................ 3-55
RIGHT CRANKCASE COVER .............................................................................................. 3-57
CLUTCH COVER ................................................................................................................... 3-57
GENERATOR ROTOR COVER ............................................................................................. 3-57
NEUTRAL SWITCH ............................................................................................................... 3-57
STARTER DRIVE GEAR COVER ......................................................................................... 3-58
PISTON RING ........................................................................................................................ 3-58
PISTON AND CYLINDER ...................................................................................................... 3-59
CYLINDER HEAD ................................................................................................................. 3-60
CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBLY ............................................... 3-61
CYLINDER HEAD COVER .................................................................................................... 3-63
CAM CHAIN TENSION ADJUSTER ..................................................................................... 3-64
PAIR (AIR SUPLY) SYSTEM (FOR E-02, 19, 54) ....................................................................... 3-65
REMOVAL .............................................................................................................................. 3-65
INSPECTION ......................................................................................................................... 3-65
REMOUNTING ...................................................................................................................... 3-67
ENGINE
CONTENTS
ENGINE 3-1
3