🏷️ Basic Information

Make:

Suzuki

Model:

AN400

Model Alias:

Burgman 400

Year:

2003

Vehicle Type:

Scooter / Maxi-Scooter

👋 Introduction

Positioning:

The Suzuki AN400 Burgman, launched in its current generation prior to 2003, positioned itself as a premium maxi-scooter, blending motorcycle-like performance with scooter convenience and storage. It was a strong contender in the European and North American markets for commuters and touring riders.

Competitors:

Key competitors included the Yamaha TMAX, Honda Silver Wing, and Aprilia Scarabeo.

Features:

Spacious under-seat storage, comfortable seating for two, robust engine, and good wind protection, making it ideal for longer journeys and daily commuting.

📋 Manual Details

Coverage Areas:

Comprehensive service and repair for the 2003 Suzuki AN400 Burgman.

Page Count:

400

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine System:

Disassembly, assembly, troubleshooting, and specifications for the 385cc liquid-cooled engine.

Fuel System:

EFI system, fuel pump, injectors, throttle body, fuel tank, and fuel lines.

Transmission System:

CVT (Continuously Variable Transmission) unit, clutch, drive and driven pulleys, belt inspection and replacement.

Chassis System:

Frame inspection and repair, suspension (front fork, rear shock absorber), steering system.

Braking System:

Front and rear hydraulic disc brakes, brake fluid specifications, bleeding procedures, caliper and master cylinder service.

Electrical System:

Ignition system, charging system (stator, regulator/rectifier, battery), lighting, starter motor, wiring diagrams, ECU.

Body And Trim:

Fairing removal and installation, seat, storage compartment, body panels.

Cooling System:

Radiator, cooling fan, water pump, coolant specifications, bleeding.

Exhaust System:

Muffler, exhaust pipe inspection and replacement.

Preventative Maintenance:

Oil change, filter replacement, spark plug service, air filter cleaning/replacement, brake fluid flush, coolant flush, CVT belt inspection.

Troubleshooting:

Diagnostic procedures for common starting, running, electrical, and braking issues.

Component Overhaul:

Engine top-end rebuild, carburetor/EFI adjustments, transmission disassembly/reassembly, brake caliper overhaul.

Electrical Diagnostics:

Testing charging system components, ignition coil, starter solenoid, and troubleshooting wiring faults using provided diagrams.

Suspension Service:

Fork oil change, seal replacement, rear shock absorber inspection.

Depth Level:

Factory-level detailed repair and maintenance procedures, suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format:

PDF

Searchability:

Searchable text content for quick access to information.

Print Quality:

High-resolution scans of original factory documentation, suitable for printing.

Binding Type:

N/A (Digital PDF Format)

Paper Type:

N/A (Digital PDF Format)

⚙️ Engine Specifications

Engine Type:

Four-stroke, liquid-cooled, SOHC, 4-valve

Displacement:

385 cc (23.5 cubic inches)

Bore X Stroke:

83.0 mm x 73.6 mm

Compression Ratio:

10.2:1

Horsepower:

Approximately 32 HP @ 7,000 RPM (Varies slightly by market and specific tuning)

Torque:

Approximately 3.5 kg-m (34 Nm) @ 6,000 RPM (Varies slightly)

Fuel Delivery:

Fuel Injection (EFI) with Suzuki's electronic fuel injection system.

Fuel Type:

Unleaded gasoline, 87 octane minimum (91 RON)

Ignition System:

Digital CDI with electronic advance

Oil Type:

Suzuki recommends SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.

Oil Capacity:

1.7 L (1.8 US qt) without filter change; 1.8 L (1.9 US qt) with filter change.

🔧 Transmission

Transmission:

Automatic CVT (Continuously Variable Transmission)

Drive Type:

Belt drive

Clutch Type:

Wet, multi-plate automatic clutch

Cvt Fluid:

Refer to manual for specific CVT fluid type and capacity, typically a specialized transmission fluid.

📐 Dimensions

Overall Length:

2,205 mm (86.8 in)

Overall Width:

755 mm (29.7 in)

Overall Height:

1,425 mm (56.1 in)

Wheelbase:

1,555 mm (61.2 in)

Ground Clearance:

135 mm (5.3 in)

Dry Weight:

197 kg (434 lbs)

Curb Weight:

205 kg (452 lbs)

Payload Capacity:

Refer to owner's manual; typically around 175 kg (385 lbs)

Fuel Tank Capacity:

14 L (3.7 US gal)

🛡️ Safety Features

Safety Features:

While specific crash ratings for motorcycles/scooters are less common than for cars, the AN400's design includes integrated fairings for rider protection from elements and potential road debris.

Braking System:

Dual hydraulic disc brakes (front), single hydraulic disc brake (rear) for strong stopping power. Some markets may have offered ABS as an option.

Lighting:

Halogen headlights, LED tail light and brake lights for improved visibility.

Bodywork:

Integrated fairings and windscreen provide a degree of rider protection.

💡 Technology Features

Features:

The 2003 AN400 primarily focused on functional utility rather than advanced infotainment. It typically featured a digital odometer and trip meter, analog tachometer, and indicator lights. Optional accessories might have included upgraded audio systems in some markets.

Features:

ABS was an optional feature on some models, enhancing braking safety. Advanced rider aids common in modern vehicles were not present.

Features:

No built-in connectivity features such as Bluetooth or smartphone integration were standard.

🔧 Maintenance

Engine Oil Change:

Every 4,000 km (2,500 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

Every 8,000 km (5,000 miles) or 12 months.

Air Filter Inspection:

Every 4,000 km (2,500 miles), clean or replace as needed.

Spark Plug Replacement:

Every 8,000 km (5,000 miles).

Cv Belt Inspection:

Every 12,000 km (7,500 miles) or 24 months. Replace as needed based on wear.

Brake Fluid Replacement:

Every 2 years, or as per manual recommendations. Inspect for contamination.

Coolant Replacement:

Every 2 years or 24,000 km (15,000 miles).

Engine Oil:

SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil.

Brake Fluid:

DOT 4, as per Suzuki's specifications.

Coolant:

Suzuki Super Long Life Coolant (SLLC) or equivalent high-quality ethylene glycol-based antifreeze with distilled water, mixed 50/50.

Common Problems:

Occasional issues can include premature wear on the CVT belt or variator rollers, charging system issues (rectifier/stator failure), and potential leaks from the water pump seal or coolant lines. Fuel injection system maintenance is also crucial.

📚 Vehicle History

Brand History:

Suzuki Motor Corporation, established in 1909, has a long history in motorcycle manufacturing, known for innovation and performance across various segments, from small displacement commuters to high-performance sportbikes and scooters.

Burgman Lineage:

The Burgman series began in 1998 with the AN250. The AN400 was introduced shortly after, establishing the Burgman as Suzuki's flagship maxi-scooter line, characterized by its large size, comfort, and touring capability. The 2003 model represents a significant iteration in this lineage.

Manufacturing Locations:

Primarily manufactured by Suzuki in Japan, with potential assembly in other regions for specific markets.

🏆 Awards & Recognition

Market Reception:

The Burgman line, including the AN400, consistently received positive reviews for its comfort, practicality, and performance for its segment, making it a popular choice for commuting and light touring.