Suzuki drz 400E, Service Manual

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ENGINE 3-1
ENGINE
CONTENTS
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 (DR-Z400E) ................................................................................. 3-36
STARTER TORQUE LIMITER (DR-Z400E) ................................................................. 3-37
OIL PUMP ..................................................................................................................... 3-37
CLUTCH ........................................................................................................................ 3-37
GEARSHIFT FORK AND GEAR .................................................................................. 3-38
TRANSMISSION ........................................................................................................... 3-39
BEARINGS .................................................................................................................... 3-42
OIL SEALS .................................................................................................................... 3-45
ENGINE REASSEMBLY ..................................................................................................... 3-47
CRANKSHAFT .............................................................................................................. 3-47
GEARSHIFT CAM AND FORK .................................................................................... 3-48
CRANKCASE ................................................................................................................ 3-49
STARTER CLUTCH AND GENERATOR ROTOR ........................................................ 3-50
BALANCER SHAFT ..................................................................................................... 3-51
PRIMARY DRIVE GEAR ............................................................................................... 3-52
GEARSHIFT CAM DRIVEN GEAR ............................................................................... 3-52
GEARSHIFT SHAFT ..................................................................................................... 3-53
OIL PUMP ..................................................................................................................... 3-53
KICK STARTER (DR-Z400) .......................................................................................... 3-54
CAM CHAIN .................................................................................................................. 3-55
CLUTCH ........................................................................................................................ 3-55
RIGHT CRANKCASE COVER ...................................................................................... 3-57
CLUTCH COVER .......................................................................................................... 3-57
GENERATOR ROTOR COVER ..................................................................................... 3-57
STARTER DRIVE GEAR COVER (DR-Z400E) ............................................................ 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
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