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Suzuki AN400 2007 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: AN400 Burgman Model Designation: Skywave 400 Year: 2007 Codes Chassis Code: CK43A 👋 Introduction Market Position Segment: Maxi-scooter Target Audience: Commuters, touring riders,...
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Type: Motorcycle
Vendor:
Sku: 370252
Suzuki AN400 2007 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
AN400 Burgman
Model Designation:
Skywave 400
Year:
2007
Codes
Chassis Code:
CK43A
👋 Introduction
Market Position
Segment:
Maxi-scooter
Target Audience:
Commuters, touring riders, and general scooter enthusiasts seeking reliable and capable transport.
Competitive Analysis
Key Competitors:
Yamaha TMAX, Honda Silver Wing, Kymco Xciting, SYM Maxsym.
Value Proposition:
Offers a blend of comfortable riding, practical storage, and reliable performance at a competitive price point.
Key Features
Scooter Features:
Spacious under-seat storage, comfortable seating for rider and passenger, aerodynamic fairing for wind protection, reliable fuel-injected engine.
Manual Utility:
Empowers owners to perform maintenance and repairs, saving on labor costs and extending the lifespan of the vehicle.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
Digital (PDF)
Page Count
Page Count:
Approximately 300+
📖 Manual Coverage
Systems Covered
Engine Service:
Full disassembly, assembly, inspection, and repair of the engine and its components.
Fuel System:
Fuel injection system, fuel pump, injectors, throttle body, fuel lines, and fuel tank.
Cooling System:
Radiator, coolant hoses, water pump, thermostat, and fan operation.
Ignition System:
Spark plugs, ignition coils, ECU control, and timing adjustments.
Transmission And Drivetrain:
CVT (Continuously Variable Transmission) operation, belt, clutch, reduction gears, and final drive.
Chassis And Frame:
Frame inspection, front fork assembly, rear shock absorber, and swingarm.
Braking System:
Front and rear brake calipers, master cylinders, brake lines, pads, discs, and ABS (if applicable).
Electrical System:
Wiring diagrams, battery, starter, charging system (alternator/stator), lighting, and fuses.
Bodywork And Trim:
Fairings, seats, storage compartments, and trim piece removal/installation.
Controls And Instruments:
Handlebar controls, levers, cables, dashboard instruments, and sensors.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, brake fluid replacement, and coolant checks.
Troubleshooting Diagnostics:
Step-by-step guides for diagnosing common problems and fault codes.
Disassembly Assembly:
Detailed procedures for removing and reinstalling major components.
Component Rebuilding:
Instructions for rebuilding specific engine parts, brake calipers, and other assemblies.
Adjustment Procedures:
Carburetor (if applicable), throttle cable, parking brake, and suspension adjustments.
Technical Depth
Depth Level:
Comprehensive; covers everything from basic checks to full engine rebuilds and electrical system diagnostics.
Diagnostic Tools:
References specialized Suzuki diagnostic tools and methods where applicable.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick information retrieval.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Diagram Clarity:
Clear, detailed exploded diagrams and wiring schematics.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, SOHC, 4-valve, single-cylinder
Displacement:
378 cc
Bore X Stroke:
83.0 mm x 71.5 mm
Compression Ratio:
10.2:1
Performance
Horsepower:
Approximately 32 HP @ 7,000 RPM (Actual figures may vary slightly)
Torque:
Approximately 34 Nm @ 5,500 RPM (Actual figures may vary slightly)
Fuel System
Fuel Delivery:
Fuel Injection (Suzuki's SDTV - Suzuki Dual Throttle Valve system)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
15.0 Liters (3.96 US gal)
Lubrication
Oil Type:
SAE 10W-40 API SG or higher
Oil Capacity W Filter:
Approximately 1.6 Liters
Oil Capacity Wo Filter:
Approximately 1.4 Liters
Ignition
Ignition System:
Electronic ignition (Transistorized)
Spark Plug Type:
NGK CR9E / DENSO U27ETR (Check manual for exact specification)
🔧 Transmission
Standard
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Features
Clutch:
Automatic centrifugal clutch
Drive System:
V-belt, automatic transmission, chain drive (final drive)
Fluid Specifications
Transmission Oil Type:
Suzuki Scooter Gear Oil (or equivalent API GL-4, SAE 80W-90)
Fluid Capacities
Final Drive Oil Capacity:
Approximately 110 ml
📐 Dimensions
Exterior
Length:
2,265 mm (89.2 in)
Width:
755 mm (29.7 in)
Height:
1,375 mm (54.1 in)
Wheelbase:
1,555 mm (61.2 in)
Weights
Dry Weight:
Approximately 196 kg (432 lbs)
Curb Weight:
Approximately 208 kg (459 lbs)
Cargo
Underseat Storage:
Spacious, capable of holding two full-face helmets or equivalent cargo.
Wheels And Tires
Front Tire:
120/70-15M/C 56P, tubeless
Rear Tire:
160/60-15M/C 67P, tubeless
Front Brake:
Hydraulic disc
Rear Brake:
Hydraulic disc
Suspension
Front Suspension:
Telescopic, oil-damped, coil spring
Rear Suspension:
Swingarm type, oil-spring suspension, preload adjustable
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycle safety is assessed differently than automobiles).
Active Features
Braking System:
Combined braking system (rear brake lever also actuates front brake to some degree) for improved stopping power.
Lighting:
Halogen headlights, LED taillights, turn signals for enhanced visibility.
Passive Features
Frame Construction:
Rigid steel tube frame designed for stability and rider confidence.
Ergonomics:
Comfortable riding position and accessible controls.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Not equipped with integrated infotainment systems).
Driver Assistance
Driver Assistance Features:
N/A (No advanced electronic driver assistance systems).
Connectivity
Connectivity Features:
N/A (No Bluetooth or smartphone connectivity).
Instrumentation
Instrument Panel:
Analog tachometer, digital speedometer, fuel gauge, odometer, trip meter, coolant temperature indicator, clock, and various warning lights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 4,000 km (2,500 miles) or 6 months, whichever comes first.
Air Filter Inspection:
Inspect every 4,000 km (2,500 miles), clean or replace as needed.
Spark Plug Replacement:
Replace every 12,000 km (7,500 miles).
Cvt Belt Inspection:
Inspect every 8,000 km (5,000 miles), replace when wear limits are reached.
Brake Fluid Replacement:
Replace every 24 months, regardless of mileage.
Coolant Replacement:
Replace every 24 months or 24,000 km (15,000 miles).
Fluid Specifications
Engine Oil Viscosity:
SAE 10W-40
Engine Oil API Spec:
API SG or higher
Coolant Type:
Suzuki Long Life Coolant (or equivalent ethylene glycol-based coolant with demineralized water, 50/50 mix)
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
CVT belt wear, brake pad wear, tire wear, occasional stator or rectifier issues common to many motorcycles.
Typical Complaints:
Some owners may report a less aggressive acceleration compared to smaller scooters, or find the seat height a bit tall.
Part Numbers
Oil Filter Part Number:
Suzuki OEM 16510-07300 (Verify with VIN)
Air Filter Part Number:
Suzuki OEM 13780-04J00 (Verify with VIN)
Spark Plug Part Number:
NGK CR9E (Verify with VIN)
📚 Vehicle History
Brand Heritage
Brand Focus:
Suzuki is a Japanese multinational corporation renowned for its wide range of products, including motorcycles, automobiles, marine engines, and wheelchairs. In the motorcycle segment, Suzuki is known for its performance-oriented and reliable vehicles.
Model Evolution
Burgman Lineage:
The Burgman series, introduced in the late 1990s, redefined the maxi-scooter segment with its blend of motorcycle-like comfort and scooter practicality. The AN400 model has been a consistent performer within this line, evolving through various generations.
2007 Updates:
The 2007 model likely incorporated minor refinements and styling updates over its predecessor, maintaining its position as a comfortable and capable maxi-scooter. It featured the reliable 378cc engine and a comfortable chassis.
Production
Manufacturing Origin:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The Burgman line generally receives positive reviews for its comfort, practicality, and value within the maxi-scooter market.
Ratings
Owner Satisfaction:
Generally high owner satisfaction for reliability and commuting capability.
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