🏷️ Basic Information

Make:

Suzuki

Model:

Burgman AN400

Model Variant:

AN400

Generation:

First Generation (AZ50/AN400)

Chassis Code:

AZ50 Series (Refer to specific model year for exact VIN range)

👋 Introduction

Segment:

Maxi-scooter segment, offering a blend of comfort, practicality, and performance for urban commuting and touring.

Target Audience:

Commuters seeking a comfortable and capable scooter, touring riders looking for a practical and efficient machine, and owners who perform their own maintenance.

Competitors:

Honda Silver Wing, Yamaha Majesty, Kymco Xciting, Aprilia Atlantic.

Comfort:

Spacious seating, large windscreen for wind protection, comfortable riding position.

Practicality:

Generous under-seat storage, available with ABS on some models.

Performance:

Robust 385cc liquid-cooled engine, capable of highway speeds.

📋 Manual Details

Manual Type:

Factory Service Manual

Language:

German

Format:

PDF

Compatible Os:

Windows, macOS

Distribution Format:

ZIP archive containing PDF files

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, assembly, inspection, and repair of engine components including cylinder, piston, crankshaft, connecting rod, valves, camshaft, and timing system.

Fuel System:

Fuel injection system (throttle body, injectors, fuel pump, fuel pressure regulator), fuel tank, and lines. Includes diagnostics and calibration procedures.

Cooling System:

Radiator, water pump, thermostat, cooling fan, and coolant flow paths. Includes flushing and filling procedures.

Ignition System:

Ignition coil, spark plug, CDI unit, and related wiring. Includes timing adjustments and troubleshooting.

Transmission And Drivetrain:

Continuously Variable Transmission (CVT) operation, belt inspection and replacement, clutch system, final drive assembly, and lubrication. Includes roller weight and spring tension specifications.

Brakes:

Hydraulic brake system (front and rear discs), brake calipers, master cylinders, brake lines, and brake fluid specifications. Includes bleeding procedures and pad/disc wear limits.

Suspension:

Front telescopic forks and rear shock absorber. Includes fork oil type, level, and replacement, as well as rear suspension adjustment and overhaul.

Steering:

Handlebar assembly, steering stem bearings, and related components. Includes bearing adjustment and replacement procedures.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting system (headlight, taillight, indicators), horn, and all wiring harnesses. Includes wiring diagrams and troubleshooting charts.

Chassis And Bodywork:

Frame inspection, body panel removal/installation, seat, fairings, and storage compartments. Includes torque specifications for all fasteners.

Maintenance:

Regular scheduled maintenance tasks, including oil changes, filter replacements (oil, air), spark plug checks and replacement, brake fluid changes, coolant flushes, and drive belt inspection.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, including starting problems, poor running conditions, electrical faults, and braking system malfunctions. Includes symptom-based fault finding.

Repair:

Detailed, step-by-step repair instructions for all major and minor components, from engine rebuilds to electrical system repairs and bodywork touch-ups.

Overhaul:

Complete overhaul procedures for the engine, transmission, suspension components, and brake system.

Adjustments:

Carburetor synchronization (if applicable to later models/variants, though AN400 is FI), valve clearance adjustments, throttle cable free play, and brake lever free play.

Special Tools:

Identification and usage instructions for specialized tools required for specific procedures, such as engine timing tools, clutch removal tools, and bearing pullers.

Depth:

Comprehensive from basic rider maintenance to advanced workshop-level diagnostics and complete engine/transmission rebuilds.

Diagrams Illustrations:

Detailed, step-by-step exploded views and schematic diagrams for all major systems and components.

Specifications:

Includes all critical technical specifications such as torque values, clearances, fluid capacities, electrical resistance values, and performance data.

📊 Manual Specifications

File Type:

PDF

Searchable Text:

Likely (depending on PDF creation method), allowing for quick keyword searches.

Printability:

Designed for printing specific pages or chapters for workshop use, allowing for protection of the digital original.

Binding:

N/A (Digital PDF format)

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Type:

4-stroke, 4-valve, SOHC, liquid-cooled, 2-cylinder (typically a single cylinder for AN400, this might be a typo in the product name for 'AN400 Suzuki Burgman')

Displacement:

385 cc (Note: AN400 refers to 385cc. If 'AN400' is literal, it's 385cc. If it refers to a 400cc class, it's commonly around 385-400cc for this model. The manual covers the 385cc variant.)

Bore X Stroke:

75.0 mm x 83.0 mm (for the 385cc engine)

Compression Ratio:

10.2:1

Power Output:

Approx. 30-32 HP at 7,000 RPM (varies by market and specific tuning)

Torque:

Approx. 32-34 Nm at 6,000 RPM (varies by market and specific tuning)

Fuel Type:

Unleaded gasoline

Fuel Capacity:

13.0 Liters (3.4 US gallons)

Fuel Delivery:

Electronic Fuel Injection (EFI) with Mikuni throttle body

Idle Speed:

1,300 +/- 100 RPM

Oil Type:

SAE 10W-40 API SG or higher (Refer to manual for exact Suzuki specifications)

Oil Capacity With Filter:

2.2 Liters (2.3 US quarts)

Oil Capacity Without Filter:

2.0 Liters (2.1 US quarts)

🔧 Transmission

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Optional Transmission:

N/A (CVT is standard)

Drive System:

Belt drive to rear wheel

Clutch Type:

Automatic centrifugal clutch

Final Drive Oil Type:

SAE 80 API GL-4 Gear Oil (Check manual for specific Suzuki recommendation)

Final Drive Oil Capacity:

0.2 Liters (0.21 US quarts)

📐 Dimensions

Overall Length:

2,235 mm (88.0 in)

Overall Width:

775 mm (30.5 in)

Overall Height:

1,390 mm (54.7 in)

Wheelbase:

1,555 mm (61.2 in)

Ground Clearance:

135 mm (5.3 in)

Seat Height:

705 mm (27.8 in)

Dry Weight:

Approximately 200 kg (441 lbs)

Curb Weight:

Approximately 210 kg (463 lbs) (with all fluids and full tank)

🛡️ Safety Features

Braking System:

Front: Hydraulic disc, Rear: Hydraulic disc (ABS optional on some models)

ABS:

Optional Anti-lock Braking System (check specific model year and configuration)

Lighting:

Halogen headlight, LED taillight/brake light, clear lens turn signals.

Storage Security:

Lockable under-seat storage, glove compartment.

💡 Technology Features

Instrument Cluster:

Analog speedometer, tachometer, digital odometer, trip meter, fuel gauge, clock, and various indicator lights (oil, battery, engine check).

ABS Availability:

Available as an option on certain models/model years, providing enhanced braking stability.

Charging Ports:

N/A (typically not equipped with integrated USB or 12V outlets on this generation)

🔧 Maintenance

Engine Oil Change:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

Every 12,000 km (7,500 miles) or 12 months.

Air Filter Cleaning Replacement:

Inspect every 6,000 km (3,700 miles), clean or replace as needed. Replace every 18,000 km (11,000 miles).

Spark Plug Inspection Replacement:

Inspect every 6,000 km (3,700 miles), replace as needed. Typical replacement interval around 20,000-30,000 km.

Cvt Belt Inspection:

Inspect every 12,000 km (7,500 miles), replace as needed based on wear.

Brake Fluid Change:

Every 24 months, regardless of mileage.

Coolant Flush Replacement:

Every 24 months or 24,000 km (15,000 miles).

Engine Oil Grade:

SAE 10W-40 API SG or higher (Refer to manual for exact Suzuki specifications)

Brake Fluid Type:

DOT 4

Coolant Type:

Ethylene glycol-based permanent antifreeze (50/50 mix with distilled water)

Common Wear Items:

CVT belt wear, front fork seal leaks, brake pad wear, and battery aging.

Potential Engine Issues:

Minor oil consumption with high mileage, potential CDI unit failure (rare).

Electrical Quirks:

Occasional issues with starter solenoids or charging system components, typically due to age and mileage.

📚 Vehicle History

Manufacturer:

Suzuki Motor Corporation, a Japanese multinational corporation renowned for its motorcycles, automobiles, and marine engines.

Introduction Year:

1998

First Generation Period:

1998-2001

Design Philosophy:

To create a comfortable, practical, and powerful maxi-scooter that bridges the gap between traditional scooters and motorcycles.

Manufacturing Location:

Japan (primary)

🏆 Awards & Recognition

Industry Acclaim:

Recognized for its comfort, practicality, and reliability within the maxi-scooter market, establishing Suzuki's presence in this segment.