🏷️ Basic Information

Make:

Suzuki

Model:

AN400 Burgman

Year:

2003

Chassis Code:

CK43

Engine Code:

Z402

👋 Introduction

Segment:

Maxi-scooter, urban mobility, light touring

Target Audience:

Commuters, city riders, those seeking comfortable and practical two-wheeled transportation

Competitors:

Yamaha Majesty 400, Honda Silver Wing 400 (less common), Kymco Xciting 400

Features:

Spacious under-seat storage, comfortable riding posture, automatic transmission (CVT), aerodynamic fairing, efficient fuel injection

Manual Value:

Empowers owners and technicians with the knowledge to maintain and repair the AN400 Burgman effectively, saving time and money.

📋 Manual Details

Primary Coverage:

Complete service and repair for the 2003 Suzuki AN400 Burgman

Secondary Coverage:

Maintenance, diagnostics, troubleshooting, electrical systems, engine, transmission, chassis, bodywork

Estimated Pages:

300-500

Type:

Service and Repair Manual

Language:

English

Format:

Digital Download (WINRAR/PDF)

📖 Manual Coverage

Engine:

Engine overhaul, component inspection, lubrication system, cooling system, fuel system (injection), exhaust system

Transmission:

CVT (Continuously Variable Transmission) operation, inspection, belt replacement, clutch assembly, final drive

Brakes:

Front and rear brake systems (disc brakes), hydraulic lines, master cylinders, calipers, pad replacement, bleeding procedures

Electrical:

Wiring diagrams, lighting system, ignition system, battery, charging system (stator, regulator/rectifier), starter motor, fuses, relays, sensors

Chassis Suspension:

Front fork (telescopic), rear shock absorber, swingarm, bearings, wheel hub inspection

Bodywork:

Body panel removal and installation, seat, fairings, storage compartment access, lighting components

Maintenance:

Oil change, filter replacement, spark plug replacement, air filter cleaning/replacement, drive belt inspection/replacement, brake fluid flush, coolant flush

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides

Repair:

Detailed step-by-step instructions for component disassembly, repair, and reassembly

Specifications:

Torque specifications for all fasteners, fluid capacities, clearances, and measurements

Depth:

Comprehensive coverage from basic rider maintenance to advanced engine and electrical system diagnostics and repairs

📊 Manual Specifications

Format Details:

Digital download, typically provided as a compressed WINRAR archive containing searchable PDF files

Quality:

High-resolution scans or digital creation, allowing for clear printing of diagrams and text

Type:

N/A (Digital Download)

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Type:

Four-stroke, liquid-cooled, SOHC, 4-valve

Displacement:

385 cc

Bore X Stroke:

83.0 mm x 72.0 mm

Compression Ratio:

10.2:1

Horsepower Est:

32.5 HP @ 7,500 RPM

Torque Est:

35 Nm @ 6,000 RPM

Type:

Fuel Injection (Suzuki PGM-FI, likely Mikuni or Keihin throttle body)

Fuel Type:

Unleaded gasoline, minimum octane rating 87

Oil Type:

Suzuki recommends API SG or higher, SAE 10W-40 semi-synthetic or synthetic motorcycle oil

Oil Capacity W Filter:

Approx. 1.8 Liters (1.9 US qt)

Type:

Liquid-cooled

Coolant Type:

Suzuki Super Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors)

Type:

Digital CDI with electronic ignition timing advance

Spark Plug Type:

NGK CR9E or DENSO U27FER9 (check manual for exact fitment)

🔧 Transmission

Type:

Automatic CVT (Continuously Variable Transmission) with Wet Multi-Plate Clutch

Type:

N/A

Engagement:

Automatic, centrifugal clutch engagement

Cvt Fluid Type:

SUZUKI GEAR OIL API GL-5 SAE 80W-90 (for final drive)

Final Drive Capacity:

Approx. 200 ml (0.21 US qt)

📐 Dimensions

Overall Length:

Approx. 2235 mm (88.0 in)

Overall Width:

Approx. 750 mm (29.5 in)

Overall Height:

Approx. 1385 mm (54.5 in)

Wheelbase:

Approx. 1555 mm (61.2 in)

Ground Clearance:

Approx. 135 mm (5.3 in)

Dry Weight:

Approx. 182 kg (401 lbs)

Curb Weight:

Approx. 198 kg (437 lbs)

Gross Vehicle Weight Rating Gvwr:

N/A (typically not specified for scooters)

Underseat Storage:

Large, cavernous storage, capable of fitting two full-face helmets

Front Storage:

Glove box/compartment in the front fairing

Tank Size:

Approx. 13.0 Liters (3.4 US gal)

Front Tire:

120/80-14 M/C 58S

Rear Tire:

150/70-13 M/C 64S

Wheel Type:

Cast aluminum alloy

Bolt Pattern:

N/A (integrated hub design)

🛡️ Safety Features

Crash Test Results:

N/A (Motorcycle/Scooter safety testing is different from automobiles)

Braking:

Front and rear disc brakes

Lighting:

Dual halogen headlights, LED taillight, turn signals

Chassis Design:

Steel tube frame for rigidity

Ride Comfort:

Plush suspension and comfortable seating contribute to rider control and reduced fatigue.

💡 Technology Features

Features:

Basic dashboard with speedometer, odometer, fuel gauge, engine temp warning light. No advanced infotainment systems typically found on this model.

Features:

N/A (No electronic rider aids like ABS or traction control on this specific model year).

Features:

N/A

🔧 Maintenance

Initial Service:

Typically around 1,000 km (600 miles) - oil change, chain adjustment (if applicable, though this is CVT), general inspection.

Regular Maintenance:

Oil changes every 3,000-6,000 km (2,000-4,000 miles), air filter inspection/cleaning every 6,000 km (4,000 miles), spark plug replacement every 12,000 km (7,500 miles), drive belt inspection every 18,000 km (12,000 miles).

Major Service:

Valve clearance check/adjustment, cooling system flush, brake fluid replacement typically recommended every 2-3 years or 24,000 km (15,000 miles).

Engine Oil:

SAE 10W-40, API SG or higher (semi-synthetic or synthetic recommended)

Brake Fluid:

DOT 4

Coolant:

Ethylene glycol-based, Suzuki Super Long Life Coolant or equivalent (50/50 mix with distilled water)

Common Wear Items:

Drive belt (can wear and slip), battery (typical for all vehicles), brake pads, tires.

Potential Electrical:

Voltage regulator/rectifier failure can occur with age and heat, affecting charging system. Check wiring harness connections for corrosion.

Fuel System:

Fuel pump issues or clogged injectors are rare but possible, particularly with stale fuel.

Oil Filter:

HF131 (e.g., HiFloFiltro) or 16510-07H00-000 (Suzuki OEM)

Air Filter:

13780-14F00-000 (Suzuki OEM) or equivalent aftermarket

📚 Vehicle History

Manufacturer:

Suzuki Motor Corporation, Japan

Burgman Lineage:

The AN400 Burgman is part of Suzuki's long-standing and popular Burgman maxi-scooter line, known for blending motorcycle-like performance with scooter convenience. The 2003 model represents a significant iteration in its development.

Manufacturing Location:

Japan (primarily)

Market Introduction:

The Burgman line was introduced in the late 1990s, with the AN400 specifically evolving over the years. The 2003 model benefited from design refinements and performance enhancements from earlier versions.

🏆 Awards & Recognition

Market Reputation:

Praised for comfort, practicality, and value in the maxi-scooter segment during its production run.