Suzuki AN400 Service Manual

Engine Mechanical: 1D-51
Cam Chain Tensioner Inspection
B705H11406060
Inspect the cam chain tensioner in the following
procedures:
1) Remove the cam chain tensioner. Refer to “Engine
Bottom Side Disassembly (Page1D-37)”.
2) Inspect the contacting surface of the cam chain
tensioner. If it is worn or damaged, replace the cam
chain tensioner with a new one.
3) Install the cam chain tensioner. Refer to “Engine
Bottom Side Assembly (Page1D-44)”.
Conrod and Crankshaft Inspection
B705H11406025
Refer to “Engine Bottom Side Disassembly (Page1D-
37)”.
Refer to “Engine Bottom Side Assembly (Page1D-44)”.
Conrod Small End I.D.
Measure the conrod small end inside diameter using the
small bore gauge.
If the conrod small end inside diameter exceeds the
service limit, replace the conrod.
Conrod small end I.D.
Service limit: 20.040 mm (0.789 in)
Special tool
(A): 09900–20605 (Dial calipers (1/100 mm, 10 –
34 mm))
Conrod Big End Side Clearance
Inspect the conrod side clearance using the thickness
gauge.
If the clearance exceeds the limit, inspect the conrod big
end width and crank pin width.
If the width exceed the limit, replace conrod or
crankshaft.
Conrod big end side clearance
Limit: 1.00 mm (0.04 in)
Special tool
(A): 09900–20803 (Thickness gauge)
Conrod big end width
Standard: 21.95 – 22.00 mm (0.864 – 0.866 in)
Conrod Deflection
Move the small end sideways while holding the big end
immovable in thrust direction.
Measure the amount of deflection.
Turn the conrod and see if it moves smoothly without
play and noise.
This method can check the extent of wear on the parts of
the conrod’s big end.
Conrod deflection
Service limit: 3.0 mm (0.12 in)
Special tool
(A): 09900–20607 (Dial gauge (1/100 mm, 10
mm))
(B): 09900–20701 (Magnetic stand)
(C): 09900–21304 (V-block (100 mm))
I705H1140144-01
(A)
I705H1140145-02
(A)
I705H1140146-02
(A)
(B)
(C)
I705H1140147-02

Suzuki AN400 Specifications

General

Brand	Suzuki
Model	AN400
Category	Scooter
Language	English