🏷️ Basic Information

Make:

Suzuki

Model:

Burgman

Model Variant:

AN400

Product Name:

Suzuki AN400 BURGMAN Service Repair 2003 ONWARDS

Chassis Code:

Various depending on specific model year (e.g., CK43A, CK44A, CK45A, CK46A)

👋 Introduction

Market Position:

The Suzuki AN400 Burgman is a highly popular maxi-scooter known for its comfortable ride, practicality, and urban agility. This manual targets owners and independent repair shops seeking comprehensive repair and maintenance information.

Competitive Analysis:

Competes with other maxi-scooters in its displacement class, offering a balance of performance, economy, and touring capability. Key competitors include models from Yamaha (e.g., XMAX), Honda (e.g., Forza), and Kymco.

Key Features:

Spacious under-seat storage, comfortable seating for rider and passenger, efficient fuel injection, stable chassis, and robust performance for commuting and touring.

📋 Manual Details

Applicability:

Suzuki AN400 Burgman scooters from 2003 production onwards

Page Count:

Hundreds of pages (specific number not provided in product description, but implied to be extensive)

Manual Type:

Service Repair Manual

Language:

English (assumed for typical international market manuals)

Format:

PDF

📖 Manual Coverage

Engine Overhaul:

Complete engine disassembly, inspection, repair, and reassembly procedures

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, fuel filter, fuel tank, and throttle body diagnostics and repair

Ignition System:

Ignition coil, spark plug, CDI unit, and related wiring diagnostics and repair

Cooling System:

Radiator, cooling fan, coolant hoses, water pump, and thermostat maintenance and repair

Transmission Clutch:

Automatic transmission (CVT), clutch operation, variator, drive belt inspection, replacement, and related components

Frame Body:

Chassis inspection, frame straightening, body panel removal and installation, fairings, seat, storage compartment

Suspension Front:

Front fork disassembly, seal replacement, oil level, steering bearings, and fork tuning

Suspension Rear:

Rear shock absorber inspection, replacement, swingarm, and bushings

Brakes Front:

Brake caliper overhaul, brake pads, brake discs, brake fluid flush, master cylinder, and brake lines

Brakes Rear:

Rear brake caliper, brake pads, brake discs, brake fluid, master cylinder, and brake lines

Electrical System Charging:

Stator, rotor, voltage regulator, battery maintenance, charging system testing

Electrical System Ignition:

Spark plug, ignition coil, CDI unit, and troubleshooting

Electrical System Lighting:

Headlights, taillights, brake lights, turn signals, instrument cluster illumination, and bulb replacement

Electrical System Starting:

Starter motor, starter clutch, starter relay, and ignition switch operation

Electrical System Instruments:

Speedometer, tachometer, fuel gauge, coolant temperature gauge, and indicator lights diagnostics

Electrical System Wiring Diagrams:

Comprehensive electrical wiring diagrams for all circuits

Routine Maintenance:

Oil changes, filter replacements, air filter cleaning/replacement, spark plug replacement, drive belt inspection/replacement

Troubleshooting Diagnostics:

Step-by-step diagnostic procedures for common and complex issues across all systems

Engine Rebuilding:

Detailed instructions for engine disassembly, honing, piston and ring replacement, valve adjustments, head gasket replacement

Transmission Repair:

CVT unit disassembly, roller inspection, ramp plate lubrication, and clutch shoe service

Brake System Service:

Brake bleeding, pad and disc replacement, caliper seal replacement

Fork Rebuild:

Front fork oil change, fork seal replacement, and damping rod adjustments

Electrical Component Testing:

Testing of sensors, actuators, ignition system components, and charging system components using multimeters and specialized tools

Bodywork Repair:

Fairing repair, panel alignment, and component removal for access

Depth:

Comprehensive, covering basic maintenance to full mechanical and electrical rebuilds

Diagnostic Codes:

Includes diagnostic trouble codes (DTCs) and troubleshooting flowcharts

Torque Specifications:

Detailed torque specifications for all critical fasteners

Clearances Tolerances:

Specifications for valve clearances, piston-to-cylinder wall, and other critical tolerances

📊 Manual Specifications

File Format:

PDF

Print Quality:

High resolution, suitable for printing individual pages or the entire manual

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

4-stroke, liquid-cooled, SOHC, 2-valve (later models may have 4 valves)

Displacement:

375 cc (Note: Some sources may list slight variations, but 375cc is common)

Bore X Stroke:

75.5 mm x 83.2 mm (Typical for early models)

Compression Ratio:

11.0:1 (Typical)

Horsepower:

Approx. 25-28 HP (Varies by year and specific tuning)

Torque:

Approx. 22-25 Nm (Varies by year)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Oil Type:

API SG or higher, JASO MA certified 10W-40 semi-synthetic or synthetic motorcycle oil recommended

🔧 Transmission

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Optional Transmission:

N/A

Clutch Type:

Automatic centrifugal clutch with V-belt drive

Final Drive:

Gear reduction

📐 Dimensions

Overall Length:

Approx. 2,235 mm (Varies slightly by year)

Overall Width:

Approx. 750 mm (Varies slightly by year)

Overall Height:

Approx. 1,405 mm (Varies slightly by year)

Wheelbase:

Approx. 1,555 mm (Varies slightly by year)

Dry Weight:

Approx. 177 kg (Varies by year)

Curb Weight:

Approx. 187 kg (Varies by year)

Underseat Storage:

Spacious, capable of holding two full-face helmets

🛡️ Safety Features

Safety Ratings:

Not typically rated by formal crash test organizations like NHTSA for scooters. Focus is on design safety and operational integrity.

Brakes Type:

Disc brakes front and rear

Optional ABS:

Available on some later models or specific market variants

Lighting:

Multi-reflector headlights, LED taillight

Chassis Design:

Steel-tube frame for stability

Windscreen:

Adjustable or fixed windscreen for rider protection

💡 Technology Features

Infotainment System:

Basic; primarily focused on functional indicators rather than advanced infotainment.

Driver Assistance Features:

ABS available on select models.

Connectivity Options:

N/A

Instrumentation:

Digital speedometer, analog tachometer, fuel gauge, coolant temperature gauge, odometer, trip meter, clock, maintenance indicators.

🔧 Maintenance

Engine Oil Change:

Every 4,000 km or 6 months, whichever comes first

Oil Filter Replacement:

Every 8,000 km or 12 months

Air Filter Cleaning:

Every 4,000 km; replacement as needed

Spark Plug Replacement:

Every 8,000 km

Drive Belt Inspection:

Every 12,000 km; replacement recommended around 20,000-24,000 km or sooner if worn

Cooling System Flush:

Every 24,000 km or 24 months

Brake Fluid Replacement:

Every 24,000 km or 24 months

Engine Oil Capacity:

1.8 L (without filter change), 1.9 L (with filter change)

Coolant Type:

Suzuki Super Long Life Coolant (or equivalent ethylene glycol based antifreeze with demineralized water, 50/50 mix)

Brake Fluid Type:

DOT 4

Known Issues:

Potential for slightly weak starter motor on older models, variator wear over high mileage, fuel injector cleaning may be needed for rough idling. Refer to the manual for specific diagnostic procedures.

📚 Vehicle History

Brand Heritage:

Suzuki has a long and successful history in motorcycle and scooter manufacturing, known for engineering quality and reliability.

Model Evolution:

The AN400 Burgman was introduced in 1999 and has undergone several updates, with the 2003 onwards models representing a significant phase of its development, incorporating fuel injection and chassis improvements.

Production Locations:

Primarily manufactured in Japan, with potential assembly in other regions depending on market.

🏆 Awards & Recognition

Recognitions:

The Burgman series has consistently received positive reviews for its practicality and comfort, often being recognized as a benchmark in the maxi-scooter segment.

User Ratings:

Generally high user satisfaction for reliability and comfort.