Segment:
Maxi-scooter, urban mobility, touring scooter
Competitors 2003:
Yamaha Majesty 400, Honda Silver Wing 400/600, Kymco Xciting 500
Key Features 2003:
Comfortable ride, ample storage, fuel-injected engine, good for commuting and light touring
Systems Covered:
Periodic Maintenance, Engine, Fuel Injection (FI) System, Body, Fuel System, Cooling and Lubrication System, Electrical System
Page Count:
Estimated 300-500 pages (typical for comprehensive repair manuals of this era)
Manual Type:
Workshop Repair Manual
Engine Systems:
Engine disassembly and assembly, valve clearance adjustment, piston and cylinder inspection, crankshaft and connecting rod service, camshaft and timing chain inspection, cylinder head service
Fuel Injection System:
Fuel pump testing, injector testing and cleaning, throttle body inspection and adjustment, idle speed control (ISC) system, ECU diagnosis, sensor testing (e.g., MAP, TPS, O2)
Fuel System:
Fuel tank inspection, fuel filter replacement, fuel line maintenance, fuel pump operation
Cooling Lubrication System:
Coolant replacement and bleeding, radiator inspection and cleaning, water pump service, oil change procedures, oil filter replacement, oil pressure checks, lubrication points
Electrical System:
Battery testing and maintenance, charging system (stator and regulator/rectifier), ignition system (spark plug, ignition coil), lighting system, starter motor operation, fuse and relay identification, wiring diagrams, dashboard indicators and warnings
Body Chassis:
Fairing removal and installation, seat maintenance, storage compartment access, chassis inspection, suspension component service, brake system maintenance and repair, wheel and tire service, steering system inspection
Maintenance Procedures:
Oil and filter changes, air filter replacement, spark plug replacement, coolant flush and replacement, brake fluid replacement, drive belt inspection and replacement, general lubrication
Repair Procedures:
Engine rebuilds, transmission component service (CVT belt, clutch), fuel system component replacement, electrical component diagnosis and replacement, suspension adjustments and component replacement, brake caliper servicing
Troubleshooting:
Diagnostic charts for common symptoms, electrical system troubleshooting, engine performance issues, starting problems, braking system malfunctions
Depth:
Comprehensive from basic rider maintenance to full engine and transmission overhaul. Includes detailed diagrams, torque specifications, and diagnostic procedures.
Engine Type:
4-stroke, SOHC, 4-valve, liquid-cooled single-cylinder
Bore X Stroke:
83.0 mm x 70.0 mm
Compression Ratio:
10.2:1
Horsepower Est:
Approx. 33 HP @ 7,000 RPM (varies by market)
Torque Est:
Approx. 3.6 kg-m (26 lb-ft) @ 5,000 RPM (varies by market)
Fuel Delivery:
Fuel Injection (Suzuki PGM-FI)
Fuel Type:
Unleaded gasoline
Oil Type Spec:
API SG or higher, SAE 10W-40 (recommended, refer to manual for precise specifications)
Oil Capacity:
Approx. 1.7 L (1.8 US qt) with filter change (refer to manual)
Cooling System:
Liquid-cooled
Coolant Type Spec:
Ethylene glycol based antifreeze, 50/50 mix with distilled water (refer to manual)
Safety Features Standard:
Linked braking system (front and rear applied together with rear brake lever), parking brake
Active Safety:
Good handling characteristics, effective braking system
Passive Safety:
Sturdy chassis, integrated bodywork providing some rider protection
Infotainment System:
Basic instrumentation: speedometer, tachometer, fuel gauge, odometer, trip meter, warning lights (engine, oil, battery, etc.). No advanced infotainment in 2003 models.
Driver Assistance Features:
None; this model predates widespread advanced rider assistance systems.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months (refer to manual for exact schedule)
Air Filter Interval:
Inspect every 6,000 km (3,700 miles), replace as needed or at specified intervals (refer to manual)
Spark Plug Interval:
Replace every 12,000 km (7,500 miles) or as recommended (refer to manual)
Cv Belt Interval:
Inspect every 12,000 km (7,500 miles), replace as recommended (refer to manual)
Valve Clearance Interval:
Check every 18,000 km (11,000 miles) or as recommended (refer to manual)
Coolant Capacity:
Approx. 1.3 L (1.4 US qt) (refer to manual)
Common Wear Items:
CVT drive belt wear, potential for stator failure over time, front fork seal leaks, brake pad wear
Common Maintenance Checks:
Regular checking of tire pressures, brake fluid level, coolant level, and engine oil condition is crucial for longevity.
Brand Focus:
Suzuki is known for its motorcycles and ATVs, with a strong reputation for reliable and performance-oriented engines.
Burgman Lineage:
The Burgman AN400 was a significant model in Suzuki's maxi-scooter lineup, evolving from earlier Burgman models and establishing a strong presence in the segment. The 2003 model represented a refinement of its design and engineering.
Manufacturing Location:
Typically produced in Japan, but manufacturing locations can vary by market.
