🏷️ Basic Information

Make:

Suzuki

Model:

Burgman 400

Model Code:

AN400K3

Year:

2003

👋 Introduction

Market Position:

The Suzuki Burgman 400 (AN400K3) represents Suzuki's entry into the maxi-scooter segment, offering a blend of comfort, practicality, and performance for commuting and light touring. It competed with other established maxi-scooters focusing on user-friendliness and storage.

Competitive Analysis:

At its release, the AN400K3 was positioned against competitors such as the Yamaha Majesty 400 and Honda Silver Wing 500, highlighting its accessible power and agile handling for urban environments while still providing reasonable highway capability. Its large under-seat storage was a key selling point.

Key Features:

Generous under-seat storage compartment, comfortable seating position, aerodynamic fairing, reliable four-stroke engine, automatic transmission (CVT), and a user-friendly riding experience suitable for both novice and experienced riders. This manual is crucial for maintaining these features.

📋 Manual Details

Coverage Areas:

All workshop procedures, detailed instructions, step-by-step diagrams

Page Count:

Estimated 300-500 pages (typical for comprehensive factory service manuals)

Manual Type:

Factory Service Manual

Language:

English

Format:

ZIP/PDF

📖 Manual Coverage

Systems Covered:

Engine, Fuel System, Cooling System, Lubrication System, Electrical System, Ignition System, Transmission (CVT), Drive Train, Suspension (Front & Rear), Brakes (Front & Rear), Steering System, Frame, Bodywork, Maintenance, Troubleshooting, Diagnostics

Procedures Included:

Routine maintenance, scheduled service, disassembly and reassembly of all major components, diagnostic procedures, repair instructions, wiring diagrams, torque specifications, special tool requirements, adjustments, component testing, electrical troubleshooting, fuel system servicing, carburetor/fuel injection tuning (if applicable), brake system bleeding and service, suspension component replacement, body panel removal and installation, emission control systems servicing.

Technical Depth:

Comprehensive workshop-level detail, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic fluid changes to complete engine and transmission overhauls, including intricate electrical system diagnostics.

Diagnostic Procedures:

Detailed troubleshooting flowcharts for common and uncommon issues, diagnostic codes (if applicable), resistance values, voltage checks, and component testing procedures for all major electrical and mechanical systems.

Torque Specifications:

Comprehensive list of torque values for all fasteners and critical components, ensuring proper assembly and preventing damage.

Special Tools:

Identification and usage instructions for any specialized tools required for specific maintenance or repair procedures, such as fly wheel holders, bearing pullers, or clutch compressors.

Wiring Diagrams:

Complete and detailed electrical wiring diagrams, color-coded for easy tracing of circuits, including starter system, ignition system, lighting, charging system, and indicator lights.

Bodywork And Trim:

Procedures for removal, installation, and adjustment of all body panels, fairings, seat assembly, storage compartment, and trim pieces, including fastener locations and types.

Chassis And Suspension:

Detailed diagrams and procedures for front fork disassembly/reassembly, rear shock absorber replacement, swingarm maintenance, and wheel bearing service.

Brakes System:

Comprehensive coverage of front and rear brake systems, including disc and caliper inspection, pad replacement, hydraulic system bleeding, master cylinder overhaul, and brake line maintenance.

Engine Rebuild:

Complete engine disassembly and reassembly procedures, including piston, cylinder, crankshaft, valve train, and oil pump servicing, with detailed specifications for clearances and tolerances.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High-resolution, suitable for printing individual pages or entire sections with clear diagrams and text.

Binding Type:

N/A (Digital format, printable)

Paper Type:

N/A (Digital format, printable on user's choice of paper)

⚙️ Engine Specifications

Primary Engine:

4-stroke, liquid-cooled, SOHC, 2-valve single-cylinder

Displacement:

378cc

Bore X Stroke:

83.0 mm x 71.2 mm

Compression Ratio:

10.2 : 1

Fuel System:

Mikuni BSR32 carburetor (specific model may vary by region, but common for K3)

Ignition:

Digital CDI

Cooling System:

Liquid-cooled

Lubrication:

Forced lubrication (wet sump)

Performance Estimate Hp:

Approx. 30-33 HP (at crankshaft, varies by region and tune)

Performance Estimate Torque:

Approx. 24-26 Nm (at crankshaft, varies by region and tune)

🔧 Transmission

Standard:

Automatic (CVT - Continuously Variable Transmission)

Features:

Smooth acceleration, wide gear ratio range for efficient power delivery, scooter-style operation with twist-and-go throttle.

Transmission Fluid Type:

SAE 10W-40 or 10W-30 API SG or higher (specific Suzuki recommendation in manual)

Transmission Fluid Capacity:

Approx. 0.16 L (for reference, check manual for exact figure)

📐 Dimensions

Exterior Length:

Approx. 2200 mm

Exterior Width:

Approx. 740 mm

Exterior Height:

Approx. 1350 mm

Wheelbase:

Approx. 1545 mm

Ground Clearance:

Approx. 130 mm

Seat Height:

Approx. 755 mm

Dry Weight:

Approx. 185 kg

Fuel Tank Capacity:

Approx. 13 Liters

Cargo Capacity:

Large under-seat storage compartment, capable of fitting two full-face helmets or substantial cargo.

🛡️ Safety Features

Ratings:

N/A (Motorcycle safety ratings are typically not standardized like automotive vehicles)

Active Features:

Disc brakes front and rear, responsive handling, good visibility.

Passive Features:

Durable frame construction, rider ergonomics promoting control.

Lighting:

Dual Halogen headlights, LED taillight/brake light.

💡 Technology Features

Infotainment:

Basic analog and digital instrument cluster with speedometer, tachometer, fuel gauge, odometer, trip meter, clock, and indicator lights. No advanced infotainment systems like modern motorcycles/cars.

Lighting Technology:

Halogen headlights for main illumination, LED for taillight and brake light for improved visibility and longevity.

🔧 Maintenance

Service Intervals Oil Change:

Every 4,000 km or 6 months (whichever comes first, refer to manual for precise Suzuki recommendation)

Service Intervals Air Filter:

Inspect every 4,000 km, replace as needed or at 12,000 km intervals.

Service Intervals Spark Plug:

Replace every 8,000 km (or based on type, e.g., Iridium plugs may have longer intervals).

Service Intervals Valve Clearance:

Check every 12,000 km or 12 months.

Fluid Specifications Engine Oil:

SAE 10W-40 API SG or higher. Suzuki Genuine Oil recommended. Capacity: Approx. 1.8 L with filter change.

Fluid Specifications Coolant:

Permanent type coolant (ethylene glycol based), Suzuki Long Life Coolant recommended. Mix 50/50 with distilled water. Capacity: Approx. 1.5 L.

Fluid Specifications Brake Fluid:

DOT 4 (check manual for specific Suzuki recommendation for front and rear systems).

Known Issues:

Potential for carburetor issues (if applicable by region) requiring cleaning/adjustment, CVT belt wear over time, occasional electrical connector corrosion, front fork seal leaks on high-mileage units. The manual provides diagnosis and repair for these.

Tire Pressure Front:

Approx. 200 kPa (2.0 kgf/cm2, 29 psi) when cold.

Tire Pressure Rear:

Approx. 220 kPa (2.2 kgf/cm2, 32 psi) when cold.

Spark Plug Type:

NGK CR9E or DENSO U27ESR-N (check manual for exact specification and gap)

📚 Vehicle History

Brand Heritage:

Suzuki Motor Corporation has a long and distinguished history in motorcycle manufacturing, known for innovation, reliability, and performance across various segments from small commuter bikes to high-performance sportbikes and touring machines.

Model Evolution:

The Burgman series was introduced in the late 1990s, with the 400cc model becoming a cornerstone for Suzuki's maxi-scooter offering. The AN400K3 represents a specific iteration of this popular platform, building on previous designs and preparing for future updates.

Production:

The AN400 Burgman series has been in continuous production for many years, with the K3 designation referring to models produced around the 2003 model year. Production locations typically included Japan and potentially other global facilities.

🏆 Awards & Recognition

Recognitions:

While specific awards for the AN400K3 might not be widely publicized, the Burgman line has consistently received positive reviews for its practicality, comfort, and value in the maxi-scooter market.

Ratings:

Consistently rated well by motorcycle publications for its comfort, storage, and urban maneuverability.

Certifications:

Meets all relevant emissions and safety standards for its respective model year and market of sale.