В данной статье я постараюсь перечислить узлы и состав процедур технического обслуживания (ТО) SUZUKI Burgman (Skywave) AN400, которые требуют к себе внимания в процессе эксплуатации. Основной акцент будет на особенности данной техники. Отдельно приведем регламент ТО из сервис мануала и пройдемся по недокументированным нюансам. Информация будет полезной для тех, кто предпочитает самостоятельно обслуживать свою технику, т.к. есть ряд моментов, которые становятся понятными с опытом и не указаны в сервис мануалах.
Определить какая именно модификация AN400 у вас в руках, легко можно воспользовавшись соответствующей статьей.
И так, начнем..
В таблицах ниже приведены рекомендуемые производителем действия и нами расходные материалы. Также указаны некоторые комментарии курсивом, не от производителя.
| График ТО AN400X,Y,K1-K6 (кузов CK41, CK42, CK43) | |||||
| Пробег | 1000 | 6000 | 12000 | 18000 | 24000 |
| Время в месяцах | 1 | 2 | 12 | 18 | 24 |
| Воздушный фильтр | Очистка каждые 3000 км | ||||
| Винты крепления выпускного коллектора к ГБЦ (23 Нм), глушителя к выпускному коллектору (30 Нм) и глушителя к кронштейну (23 Нм) | T | T | T | T | T |
| Прверка/регулировка зазора клапанов (впуск ~0,1 мм, выпуск ~0,2 мм) | I | I | I | I | I |
| Свеча зажигания (NGK CR7E, зазор 0,7-0,8 мм.) | I | R | I | R | |
| Топливопровод | I | I | I | I | |
| Замена каждые 4 года (проблем без замены не зафиксировано) | |||||
| Моторное масло (MOTUL 5000 10W40) | R | R | R | R | R |
| Масляный фильтр | R | R | |||
| Масло в редукторе (MOTUL HD 80W90) | R | R | |||
| Проверка/регулировка оборотов холостого хода (1400 +-100) | I | I | I | I | I |
| Проверка/регулировка свободного хода ручки газа (2-4 мм) | I | I | I | I | I |
| Фильтр вариатора | Очистка каждые 3000 км, если пыльно — 1000 км | ||||
| Шланги системы охлаждения ДВС | I | I | I | I | |
| Замена каждые 4 года (проблем без замены не зафиксировано) | |||||
| Антифриз (MOTUL motocool expert) | Замена каждые 2 года | ||||
| Ремень вариатора | I | R | |||
| Проверка системы контроля выбросов (работа соленоида, запорного клапана (не применимо к CK41)) | I | I | |||
| Замена шлангов системы PAIR | Замена каждые 4 года (Реально приходят в негодность) | ||||
| Тормозные колодки | I | I | I | I | I |
| Тормозные шланги | I | I | I | I | |
| Замена каждые 4 года (проблем без замены не зафиксировано, кроме увеличенной мягкости тормозных ручек, если только мягкость не забирает весь свободный ход ручки) | |||||
| Тормозная жидкость | I | I | I | I | |
| Замена каждые 2 года (темный цвет говорит о необходимости замены) | |||||
| Рулевая стойка, плавность хода, отсутствие люфтов | I | I | I | ||
| Перья вилки, сальники | I | I | |||
| Задний амортизатор | I | I | |||
| Износ шин, давление (перед 110/90-13 M/C 55P 1,8 атм. 130/70-13 M/C 63P 2,5 атм.) | I | I | I | I | I |
| Крепеж элементов подвески | T | T | T | T | T |
| T — протяжка, I — проверка, R — замена на новый |
| График ТО AN400K7-K9 L0-> (кузов CK44, CK45) | |||||
| Пробег | 1000 | 6000 | 12000 | 18000 | 24000 |
| Время в месяцах | 1 | 2 | 12 | 18 | 24 |
| Воздушный фильтр | I | I | R | I | |
| Винты креплпния выпускного коллектора к ГБЦ (23 Нм) и глушителя к кронштейну (23 Нм) | T | T | T | ||
| Прверка/регулировка зазора клапанов (впуск ~0,15 мм, выпуск ~0,25 мм) нужны регулировочные шайбы | I | ||||
| Свеча зажигания (NGK CR7E, 0,7-0,8 мм.) | I | R | I | R | |
| Топливопровод | I | I | I | I | |
| Моторное масло (MOTUL 5100 10W40) | R | R | R | R | R |
| Маслянный фильтр | R | R | |||
| Масло в редукторе (MOTUL HD 80W90) | R | R | |||
| Проверка/регулировка свободного хода ручки газа (2-4 мм) | I | I | I | I | I |
| Фильтр вариатора | Очистка каждые 3000 км, если пыльно — 1000 км | ||||
| Шланги системы охлаждения ДВС | I | I | I | I | |
| Антифриз (MOTUL moto expert) | Замена каждые 2 года | ||||
| Ремень вариатора | I | R | |||
| Тормозные колодки | I | I | I | I | I |
| Тормозные шланги | I | I | I | I | |
| Замена каждые 4 года (проблем без замены не зафиксировано, кроме увеличенной мягкости тормозных ручек, если только мягкость не забирает весь свободный ход ручки) | |||||
| Тормозная жидкость | I | I | I | I | |
| Замена каждые 2 года (темный цвет говорит о необходимости замены) | |||||
| Рулевая стойка, плавность хода, отсутствие люфтов | I | I | I | ||
| Перья вилки, сальники | I | I | |||
| Задний аммортизатор | I | I | |||
| Износ шин, давление (перед 120/80 14M/C 58S 1,8 атм. 150/70 13M/C 63P 2,5 атм.) | I | I | I | I | I |
| Крепеж элементов подвески | T | T | T | T | T |
| T — затяжка I — проверка R — замена на новый |
Дальше то, о чем молчат сервисные мануалы:)
в процессе эксплуатации до 2006 г. включительно (кузова СК41, СК42, СК43) моторы любили масло. Любовь прямо пропорциональна близости капитального ремонта ДВС. Ресурс данного мотора примерно 50000 и зависит от стиля езды, внимательности владельца и качества используемых ГСМ. Сориентироваться по расходу можно следующим образом (при условии использовании подходящего масла):
- от 0 до 250 мл. на 1000 км — идеально
- от 250 до 500 мл. на 1000 км — все еще в норме, но нужно готовиться к капиталке
- от 500 до 1000 мл. на 1000 км — нужно делать капиталку
- свыше 1000 мл. на 1000 км — если аппарат еще едет — вы везучий человек.
Правильно проведенный капитальный ремонт ДВС даст мотору еще от 30 до 50 т. км. При условии нормальной обкатки. Ремонтный размер есть сейчас один — 0.5. Потом производится замена цилиндра на новый.
Одним словом за расходом масла необходимо следить. Для предотвращения езды с масляным голоданием можно установить датчик давления масла в магистраль высокого давления ДВС и вывести оповещение на приборную панель.
По кузову CK44, CK45, такой статистики пока нет. ДВС был переработан и вероятно это дало свои плоды — случаи чрезмерного расхода масла не фиксируются. Однако после модификации ДВС был укомплектован слабой цепью ГРМ (12760-19F00), которая со временем вытягивается. Это было замечено и цепь позднее заменили на более прочную (12760-19F01). Аппараты в кузове CK44 выпуска 2007 года как правило нуждаются в замене цепи на новую. Симптомы — ухудшившаяся динамика из-за смещения фаз газораспределения в следствии растянувшейся цепи ГРМ.
Слабым местом кузовов CK41 и CK42 является шлицы на заднем колесном диске. Со временем и при некачественной затяжке гайки заднего колеса шлицы истончаются и потом полностью исчезают, вал начинает проворачиваться. Колесный диск при этом требует замены. На CK43 кузове применена ступица (64110-14G00), что искоренило проблему, но уже через 3 года в кузовах CK44 и CK45 шлицы вернулись на диск (нахожу это решение странным).
Датчик скорости на CK41, CK42 и CK43 расположен на переднем колесе и имеет вращающуюся втулку (34983-14G01), которая с периодичностью 10-20 т.к. требует замены. В CK44 и CK45 перенесли на заднее колесо, ресурс значительно увеличен.
Фильтр вариатора на всех моделях требует периодической очистки в зависимости от запыленности среды эксплуатации аппарата, чистка раз в 1000-3000 км. Эту процедуру проводить нужно для предотвращения перегрева колокола сцепления. Если фильтр будет забит пылью перегрев и деформация колокола не заставят себя долго ждать.
Задний моно-амортизатор CK41, CK42 и CK43 (62100-14FE0) имеет гидравлический регулятор жесткости пружины. Со временем жидкость из регулятора уходит через уплотнители, т.к. система всегда находится под давлением. При этом пружина перестает сжиматься под действием регулятора и находится в полностью открытом состоянии. Проявляется это в максимальной мягкости подвески и, как следствие задевании лежачих полицейских. Раз в 2-3 года регулятор необходимо проверять и до заправлять жидкостью. С кузова CK44 регулятор заменили на механический (62100-05H10), такой же, который ранее устанавливался на более дешевые AN250 и внимания он требовать перестал (правда и регулировка его стала неудобной, из под днища с применением специального ключа (09822-00005) из штатного набора инструментов).
На CK41 кузове, есть необходимость подстройки стояночного тормоза (если вы хотите, чтобы он работал), когда ручка начинает упираться в нижний край механизма включения стояночного тормоза, из-за износа тормозных колодок, необходимо компенсировать износ специальным винтом на суппорте, ослабив контргайку. Есть еще одна причина по которой желательно не лениться и подстройку все-таки делать — со временем регулировочный винт приржавеет к втулке на столько, что при попытке его выкрутить (при установке новых тормозных колодок, к примеру, он просто отломится и для установки колодок нужно будет демонтировать втулку с рычагом стояночного тормоза совсем и думать что с этим дальше делать. С CK42 кузова применили автоматическую систему подстройки, ничего руками подстраивать не нужно.
При замене тормозных колодок на всех всех суппортах с направляющими (CK41,CK42,CK43 задние, CK44,CK45 задние и передние) необходимо проверять плавность движения суппорта по направляющим. Если движение затруднено или его нет, нужно чистить и смазывать направляющие. В противном случае суппорт будет подклинивать и затем перекашивать, что в свою очередь, кроме снижения эффективности торможения, приведет к неравномерному износу отверстий под направляющие в суппорте и необходимости замены тормозного суппорта. Наличие выработки отверстий под направляющие будет хорошо видно по диагональному износу тормозных колодок.
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Manuals and User Guides for SUZUKI Burgman AN400. We have 3 SUZUKI Burgman AN400 manuals available for free PDF download: Service Manual, Supplementary Service Manual
Suzuki Burgman AN400 Service Manual (475 pages)
Brand: Suzuki
|
Category: Scooter
|
Size: 37.56 MB
Table of Contents
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Section 1 Engine
59
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General Information
13
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Maintenance and Lubrication
28
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Scheduled Maintenance
28
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Lubrication Points
29
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Brake Hose Replacement
41
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Table of Contents
59
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Engine General Information and Diagnosis
64
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Injection Timing Description
64
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Self-Diagnosis Function
65
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Schematic and Routing Diagram
67
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FI System Wiring Diagram
67
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Terminal Alignment of ECM Coupler (Harness Side)
68
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Component Location
69
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FI System Parts Location
69
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Diagnostic Information and Procedures
70
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Engine Symptom Diagnosis
70
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DTC Table
74
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Fail-Safe Function Table
74
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FI System Troubleshooting
75
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Self-Diagnostic Procedures
76
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Self-Diagnosis Reset Procedures
77
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Use of SDS Diagnostic Procedures
77
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Use of SDS Diagnosis Reset Procedures
78
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Show Data When Trouble (Displaying Data at the Time of DTC)
79
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Malfunction
83
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DTC «C13» (P0105-H/L): IAP Sensor Circuit Malfunction
88
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DTC «C14» (P0120/H/L): TP Sensor Circuit Malfunction
93
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DTC «C15» (P0115-H/L): ECT Sensor Circuit Malfunction
96
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DTC «C16» (P0500): Speed Sensor
99
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DTC «C21» (P0110-H/L): IAT Sensor Circuit Malfunction
102
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DTC «C23» (P1651-H/L): to Sensor Circuit Malfunction
105
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DTC «C24» (P0351): Ignition System Malfunction
108
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DTC «C28» (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction
108
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DTC «C29» (P1654-H/L): Secondary Throttle Position Sensor (STPS)
112
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DTC «C32» (P0201): Fuel Injector Circuit Malfunction
115
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DTC «C40» (P0505, P0506 or P0507): ISC Valve Circuit Malfunction
118
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DTC «C41» (P0230-H/L): FP Relay Circuit Malfunction
124
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DTC «42» (P1650): IG Switch Circuit Malfunction
126
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DTC «C44» (P0130, P0135): HO2 Sensor (HO2S) Circuit Malfunction
127
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Specifications
130
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Service Data
130
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Special Tools and Equipment
131
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Special Tool
131
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Emission Control Devices
132
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Precautions
132
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Precautions for Emission Control Devices
132
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General Description
132
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Fuel Injection System Description
132
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Crankcase Emission Control System Description
133
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Exhaust Emission Control System Description
134
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Noise Emission Control System Description
134
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Repair Instructions
135
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Heated Oxygen Sensor (HO2S) Removal and Installation
135
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Heated Oxygen Sensor (HO2S) Inspection
135
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PCV Hose Inspection
136
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PCV Hose Removal and Installation
136
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Specifications
137
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Service Data
137
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Tightening Torque Specifications
137
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ECM Removal and Installation
138
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CKP Sensor Inspection
138
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CKP Sensor Removal and Installation
138
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IAP Sensor Inspection
139
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IAP Sensor Removal and Installation
139
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TP Sensor Inspection
139
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TP Sensor Adjustment
139
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TP Sensor Removal and Installation
140
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ECT Sensor Inspection
140
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ECT Sensor Removal and Installation
140
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Speed Sensor Inspection
140
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Speed Sensor Removal and Installation
141
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IAT Sensor Inspection
141
-
IAT Sensor Removal and Installation
141
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TO Sensor Inspection
141
-
TO Sensor Removal and Installation
142
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STP Sensor Inspection
142
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STP Sensor Adjustment
142
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STP Sensor Removal and Installation
143
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ISC Valve Inspection
143
-
ISC Valve Removal and Installation
143
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Specifications
144
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Service Data
144
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Tightening Torque Specifications
144
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Special Tools and Equipment
144
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Special Tool
144
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1C-7 Engine Electrical Devices
144
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HO2 Sensor Inspection
144
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HO2 Sensor Removal and Installation
144
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Engine Mechanical
145
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Precautions
145
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Precautions for Engine Mechanical
145
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Schematic and Routing Diagram
145
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Camshaft and Sprocket Assembly Diagram
145
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Throttle Cable Routing Diagram
146
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Diagnostic Information and Procedures
147
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Compression Pressure Check
147
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Repair Instructions
148
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Engine Components Removable with the Engine in Place
148
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Engine Assembly Removal and Installation
150
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Crankcase Bracket Removal and Installation
153
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Crankcase Bracket Inspection
153
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Air Cleaner Box Removal and Installation
153
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Air Cleaner Element Inspection
154
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Air Cleaner Drain Plug Inspection
154
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Throttle Cable Removal and Installation
154
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Throttle Cable Adjustment
154
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Throttle Body Components
155
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Throttle Body Construction
156
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Throttle Body Removal and Installation
157
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Throttle Body Disassembly and Assembly
157
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Throttle Body Inspection and Cleaning
159
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Engine Top Side Disassembly
160
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Engine Top Side Assembly
162
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Camshaft Inspection
166
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Cam Chain Tension Adjuster Inspection
168
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Cam Chain Guide Inspection
169
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Cylinder Head Disassembly and Reassembly
169
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Cylinder Head Related Parts Inspection
173
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Valve Guide Replacement
176
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Valve Seat Repair
177
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Cylinder Disassembly and Assembly
177
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Cylinder Inspection
178
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Piston Ring Removal and Installation
178
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Piston and Related Parts Inspection
179
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Engine Bottom Side Disassembly
181
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Engine Bottom Side Assembly
188
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Cam Chain Tensioner Inspection
195
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Conrod and Crankshaft Inspection
195
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Width between Crankshaft Webs
196
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Bearing Inspection
196
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Bearing Removal and Installation
196
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Rear Suspension Mounting Bushing Removal and Installation
198
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Specifications
199
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Service Data
199
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Tightening Torque Specifications
201
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Special Tools and Equipment
202
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Recommended Service Material
202
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Special Tool
202
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Engine Lubrication System
205
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Precautions
205
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Precautions for Engine Oil
205
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Schematic and Routing Diagram
205
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Engine Lubrication System Chart Diagram
205
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Engine Lubrication Circuit Diagram
206
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Diagnostic Information and Procedures
207
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Engine Lubrication Symptom Diagnosis
207
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Oil Pressure Check
207
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Repair Instructions
208
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Engine Oil and Filter Replacement
208
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Oil Sump Filter Removal and Installation
208
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Oil Sump Filter Cleaning
208
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Oil Pump Removal and Installation
209
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Oil Pump Inspection
209
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Piston Cooling Nozzle Removal and Installation
209
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Piston Cooling Nozzle Inspection
210
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Specifications
210
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Service Data
210
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Tightening Torque Specifications
210
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Special Tools and Equipment
211
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Special Tool
211
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Engine Cooling System
212
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Precautions
212
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Engine Cooling System Warning
212
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General Description
212
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Cooling System Description
212
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Engine Coolant Description
212
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Cooling Fan Thermo-Switch Description
213
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Engine Coolant Temperature Sensor Description
214
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Schematic and Routing Diagram
215
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Cooling Circuit Diagram
215
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Radiator Hose Routing Diagram
216
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Component Location
216
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Engine Cooling System Components Location
216
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Diagnostic Information and Procedures
217
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Engine Cooling Symptom Diagnosis
217
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Repair Instructions
217
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Cooling Circuit Inspection
217
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Radiator Cap Inspection
218
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Radiator Removal and Installation
218
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Radiator Cleaning
219
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Radiator Hose Inspection
219
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Radiator Hose Removal and Installation
220
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Radiator Reservoir Tank Removal and Installation
220
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Cooling Fan Inspection
220
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Cooling Fan Removal and Installation
221
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Cooling Fan Thermo-Switch Removal and Installation
221
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Cooling Fan Thermo-Switch Inspection
222
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ECT Sensor Removal and Installation
222
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ECT Sensor Inspection
222
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Thermostat Removal and Installation
222
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Thermostat Inspection
223
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Water Pump Components
224
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Water Pump Construction
225
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Water Pump Removal and Installation
225
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Water Pump Disassembly and Assembly
226
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Water Pump Related Parts Inspection
228
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Specifications
229
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Service Data
229
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Tightening Torque Specifications
229
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-
Special Tools and Equipment
230
-
Recommended Service Material
230
-
Special Tool
230
-
-
Fuel System
231
-
Precautions
231
-
Precautions for Fuel System
231
-
-
Schematic and Routing Diagram
232
-
Fuel Tank Hose Construction
232
-
-
Diagnostic Information and Procedures
233
-
Fuel System Diagnosis
233
-
-
Repair Instructions
235
-
Fuel System Components
235
-
Fuel Tank Heat Shield Construction
236
-
Fuel Cut Valve Removal and Installation
236
-
Fuel Tank Removal and Installation
237
-
Fuel Pump Assembly Removal and Installation
238
-
Fuel Drain Tray and FTPC Valve Removal and Installation
239
-
Fuel Cut Valve Inspection
240
-
FTPC Valve Inspection
240
-
Fuel Pump Disassembly and Assembly
240
-
Fuel Pressure Inspection
242
-
Fuel Pump Relay Inspection
243
-
Fuel Mesh Filter Inspection
243
-
Fuel Level Gauge Inspection
243
-
Fuel Pump Inspection
244
-
Fuel Injector Inspection
244
-
Fuel Injector Removal and Installation
244
-
-
Specifications
245
-
Service Data
245
-
Tightening Torque Specifications
245
-
-
Special Tools and Equipment
246
-
Special Tool
246
-
-
Ignition System
247
-
General Description
247
-
Immobilizer Description (for
247
-
-
Schematic and Routing Diagram
248
-
Ignition System Diagram
248
-
-
Diagnostic Information and Procedures
249
-
Ignition System Symptom Diagnosis
249
-
No Spark or Poor Spark
250
-
-
Repair Instructions
251
-
Spark Plug Removal and Installation
251
-
Spark Plug Inspection and Cleaning
251
-
Ignition Coil Inspection
251
-
Ignition Coil Assembly Removal and Installation
252
-
Spark Plug Removal and Installation
252
-
Spark Plug Inspection
252
-
CKP Sensor Inspection
252
-
CKP Sensor Removal and Installation
254
-
Engine Stop Switch Inspection
254
-
Ignition Switch Inspection
254
-
Ignition Switch Removal and Installation
254
-
-
Specifications
255
-
Service Data
255
-
-
Special Tools and Equipment
255
-
Special Tool
255
-
-
Starting System
256
-
Schematic and Routing Diagram
256
-
Starting System Diagram
256
-
-
Component Location
256
-
Starting System Components Location
256
-
-
Diagnostic Information and Procedures
257
-
Starter Motor will Not Run
257
-
-
Repair Instructions
258
-
Starter Motor Components
258
-
Starter Motor Removal and Installation
258
-
Starter Motor Disassembly and Assembly
259
-
Starter Motor Inspection
260
-
Starter Relay Removal and Installation
261
-
Starter Relay Inspection
261
-
Turn Signal / Side-Stand Relay Removal and Installation
262
-
Side-Stand / Ignition Interlock System Parts Inspection
262
-
Starter Clutch Component
264
-
Starter Clutch Removal and Installation
264
-
Starter Clutch Inspection
265
-
Starter Clutch Disassembly and Assembly
265
-
Starter Button Inspection
266
-
-
Specifications
266
-
Service Data
266
-
Tightening Torque Specifications
266
-
-
Special Tools and Equipment
267
-
Recommended Service Material
267
-
Special Tool
267
-
-
Charging System
268
-
Schematic and Routing Diagram
268
-
Charging System Diagram
268
-
-
Component Location
268
-
Charging System Components Location
268
-
-
Diagnostic Information and Procedures
269
-
Charging System Symptom Diagnosis
269
-
Battery Runs down Quickly
270
-
-
Repair Instructions
271
-
Battery Current Leakage Inspection
271
-
Regulated Voltage Inspection
271
-
Generator Coil Resistance Inspection
272
-
Generator No-Load Performance Inspection
272
-
Regulator/Rectifier Inspection
272
-
Generator Removal and Installation
273
-
Battery Components
275
-
Battery Initial Charging
275
-
Battery Visual Inspection
276
-
Battery Recharging
277
-
Battery Removal and Installation
277
-
-
Specifications
278
-
Service Data
278
-
Tightening Torque Specifications
278
-
-
Special Tools and Equipment
278
-
Special Tool
278
-
-
Exhaust System
279
-
Precautions
279
-
Precautions for Exhaust System
279
-
-
Repair Instructions
279
-
Exhaust System Components
279
-
Exhaust Pipe / Muffler Removal and Installation
280
-
Exhaust System Inspection
282
-
HO2 Sensor Inspection
282
-
-
Specifications
283
-
Tightening Torque Specifications
283
-
-
Special Tools and Equipment
283
-
Recommended Service Material
283
-
-
-
Section 2 Suspension
285
-
Precautions
286
-
Precautions for Suspension
286
-
-
Suspension General Diagnosis
287
-
Diagnostic Information and Procedures
287
-
Suspension and Wheel Symptom Diagnosis
287
-
-
Repair Instructions
288
-
Front Fork Components
288
-
Front Fork Removal and Installation
289
-
Front Fork Disassembly and Assembly
290
-
Front Fork Inspection
295
-
Front Fork Parts Inspection
295
-
-
Front Suspension
288
-
Specifications
296
-
Service Data
296
-
Tightening Torque Specifications
296
-
-
Special Tools and Equipment
297
-
Recommended Service Material
297
-
Special Tool
297
-
-
Rear Suspension
298
-
Repair Instructions
298
-
Rear Suspension Components
298
-
Rear Suspension Assembly Construction
299
-
Rear Swingarm Components
300
-
Rear Shock Absorber and Rear Shock Absorber Assembly Removal and Installation
301
-
Rear Suspension Inspection
302
-
Rear Shock Absorber Inspection
302
-
Rear Shock Absorber Gas Pressure Release
302
-
Rear Suspension Adjustment
303
-
Rear Swingarm Removal and Installation
303
-
Rear Swingarm Related Parts Inspection
304
-
Rear Swingarm Dust Seal / Bearing Removal and Installation
305
-
Cushion Lever and Cushion Rod Inspection
306
-
Cushion Lever Bearing Removal and Installation
307
-
Crankcase Bracket Construction
308
-
Crankcase Bracket Removal and Installation
309
-
Crankcase Bracket Related Parts Inspection
309
-
Crankcase Bracket Bearing Removal and Installation
310
-
-
Specifications
311
-
Service Data
311
-
Tightening Torque Specifications
311
-
-
Special Tools and Equipment
312
-
Recommended Service Material
312
-
Special Tool
312
-
-
Precautions
313
-
Precautions for Wheel and Tire
313
-
-
Wheels and Tires
313
-
Repair Instructions
314
-
Front Wheel Components
314
-
Front Wheel Assembly Construction
315
-
Front Wheel Assembly Removal and Installation
316
-
Front Wheel Related Parts Inspection
317
-
Front Wheel Dust Seal / Bearing Removal and Installation
318
-
Rear Wheel Components
320
-
Rear Wheel Assembly Removal and Installation
321
-
Rear Wheel Related Parts Inspection
323
-
Tire Removal and Installation
323
-
Wheel/Tire/Air Valve Inspection and Cleaning
325
-
Air Valve Removal and Installation
326
-
Wheel Balance Check and Adjustment
326
-
-
Specifications
327
-
Service Data
327
-
Tightening Torque Specifications
327
-
-
Special Tools and Equipment
328
-
Recommended Service Material
328
-
Special Tool
328
-
-
-
Section 3 Driveline / Axle
329
-
Precautions
330
-
Precautions for Driveline/Axle
330
-
-
Drive Chain / Drive Train / Drive Shaft
331
-
Diagnostic Information and Procedures
331
-
Drive Chain and Sprocket Symptom Diagnosis
331
-
-
Repair Instructions
332
-
Final Gear Components
332
-
Final Gear Assembly Removal and Installation
333
-
Final Gear Disassembly and Assembly
334
-
Final Drive Gear Bearing Inspection
338
-
-
Specifications
339
-
Tightening Torque Specifications
339
-
-
Special Tools and Equipment
339
-
Recommended Service Material
339
-
Special Tool
339
-
-
-
Section 4 Brake
341
-
Precautions
343
-
Precautions for Brake System
343
-
Brake Fluid Information
343
-
-
Brake Control System and Diagnosis
344
-
Schematic and Routing Diagram
344
-
Front Brake Hose Routing Diagram
344
-
Rear Brake Hose Routing Diagram
345
-
-
Diagnostic Information and Procedures
346
-
Brake Symptom Diagnosis
346
-
-
Repair Instructions
346
-
Brake Light Switch Inspection
346
-
Brake Fluid Level Check
347
-
Brake Hose Inspection
347
-
Air Bleeding from Brake Fluid Circuit
347
-
Brake Fluid Replacement
348
-
Front Brake Hose Removal and Installation
349
-
Rear Brake Hose Removal and Installation
349
-
Front Brake Master Cylinder Components
350
-
Front Brake Master Cylinder Assembly Removal and Installation
351
-
Front Master Cylinder / Brake Lever Disassembly and Assembly
352
-
Front Master Cylinder Parts Inspection
353
-
Rear Brake Master Cylinder Components
354
-
Rear Brake Master Cylinder Assembly Removal and Installation
355
-
Rear Master Cylinder / Brake Lever Disassembly and Assembly
355
-
Rear Master Cylinder Parts Inspection
355
-
Service Data
356
-
-
Special Tools and Equipment
357
-
Recommended Service Material
357
-
Special Tool
357
-
-
Front Brakes
358
-
Repair Instructions
358
-
Front Brake Components
358
-
Front Brake Pad Inspection
359
-
Front Brake Pad Replacement
359
-
Front Brake Caliper Removal and Installation
360
-
Front Brake Caliper Disassembly and Assembly
361
-
Front Brake Caliper Parts Inspection
362
-
Front Brake Disc Removal and Installation
363
-
Front Brake Disc Inspection
363
-
-
Specifications
364
-
Service Data
364
-
Tightening Torque Specifications
364
-
-
Special Tools and Equipment
365
-
Recommended Service Material
365
-
Special Tool
365
-
-
Repair Instructions
366
-
Rear Brake Components
366
-
Rear Brake Pad Inspection
367
-
Rear Brake Pad Replacement
367
-
Rear Brake Caliper Removal and Installation
368
-
Rear Brake Caliper Disassembly and Assembly
369
-
Brake Caliper Piston Disassembly and Assembly
372
-
Rear Brake Caliper Parts Inspection
373
-
Rear Brake Disc Removal and Installation
374
-
Rear Brake Disc Inspection
374
-
-
Rear Brakes
366
-
Special Tools and Equipment
375
-
Recommended Service Material
375
-
Special Tool
375
-
-
Specifications
375
-
Tightening Torque Specifications
375
-
-
Parking Brake
376
-
General Description
376
-
Parking Brake System (Brake-Lock System) Description
376
-
-
Schematic and Routing Diagram
381
-
Parking Brake Cable (Brake-Lock Cable) Routing Diagram
381
-
-
Repair Instructions
382
-
Parking Brake System (Brake-Lock System) Inspection
382
-
Parking Brake System (Brake-Lock System) Removal and Installation
382
-
-
-
Section 5 Tranmission / Transaxle
385
-
Precautions
386
-
Precautions for Transmission/Transaxle
386
-
-
Automatic Transmission
387
-
Schematic and Routing Diagram
387
-
Drive Train System
387
-
-
Diagnostic Information and Procedures
388
-
Automatic Transmission Symptom Diagnosis
388
-
-
Repair Instructions
388
-
Outer Clutch Cover Cushion Construction
388
-
Clutch in / Stall Speed Inspection
389
-
V-Belt Type Continuously Variable Automatic Transmission Removal and Installation
389
-
Drive V-Belt Inspection
392
-
Cooling Fan Filter Inspection
392
-
Inner Clutch Cover Bearing Inspection
393
-
Inner Clutch Cover Bering Removal and Installation
393
-
Movable Drive Face Component
394
-
Movable Drive Face Disassembly and Assembly
394
-
Movable Drive Face Parts Inspection
395
-
Oil Seal Removal and Installation
396
-
Clutch Shoe / Movable Driven Face Components
397
-
Clutch Shoe / Movable Driven Face Disassembly and Assembly
398
-
Clutch Shoe and Movable Driven Face Parts Inspection
402
-
-
Specifications
403
-
Service Data
403
-
Tightening Torque Specifications
403
-
-
Special Tools and Equipment
404
-
Recommended Service Material
404
-
Special Tool
404
-
-
-
Section 6 Steering
405
-
Precautions
406
-
Precautions for Steering
406
-
-
Steering General Diagnosis
407
-
Diagnostic Information and Procedures
407
-
Steering Symptom Diagnosis
407
-
-
Steering / Handlebar
408
-
Repair Instructions
408
-
Handlebars Components
408
-
Handlebars Removal and Installation
409
-
Handlebars Inspection
411
-
Steering Components
412
-
Steering Removal and Installation
413
-
Steering Related Parts Inspection
416
-
Steering System Inspection
416
-
Steering Stem Bearing Removal and Installation
416
-
Steering Tension Adjustment
417
-
-
Specifications
418
-
Tightening Torque Specifications
418
-
-
Special Tools and Equipment
419
-
Recommended Service Material
419
-
Special Tool
419
-
-
Advertisement
Suzuki Burgman AN400 Service Manual (384 pages)
Brand: Suzuki
|
Category: Scooter
|
Size: 31.38 MB
Table of Contents
-
General Information 1
7
-
General Information
2
-
Servicing Information
2
-
Table of Contents
7
-
-
Periodic Maintenance
2
-
Electrical System
2
-
Warning/Caution/Note
8
-
General Precautions
8
-
Suzuki An400 ( 03-Model)
10
-
Serial Number Location
10
-
Fuel, Oil and Engine Coolant Recommendation
10
-
Fuel (for Usa and Canada)
10
-
Fuel (for Other Countries)
10
-
Engine Oil and Transmission Oil (for Usa)
11
-
Engine Oil and Transmission Oil (for Other Countries)
11
-
Final Gear Oil
11
-
Brake Fluid
11
-
Front Fork Oil
11
-
Engine Coolant
11
-
Water for Mixing
11
-
Anti-Freeze/Engine Coolant
11
-
Liquid Amount of Water/Engine Coolant
12
-
-
Break-In Procedures
13
-
Information Labels
14
-
Specifications
15
-
Dimensions and Dry Mass
15
-
Engine
15
-
Drive Train
15
-
Chassis
15
-
-
-
Electrical
16
-
Capacities
16
-
Country and Area Codes
17
-
Periodic Maintenance Schedule
19
-
Periodic Maintenance Chart
19
-
Lubrication Points
20
-
-
Maintenance and Tune-Up Procedures
21
-
Air Cleaner
21
-
Exhaust Pipe Bolt and Muffler Bolt
22
-
Valve Clearance
22
-
Spark Plug
24
-
Fuel Line
25
-
Engine Oil and Oil Filter
25
-
Final Gear Oil
27
-
Idle Speed
28
-
Throttle Cable Play
29
-
Cooling Fan Filter
30
-
Cooling System
30
-
Drive V-Belt Inspection
32
-
Pair(Air Supply)System
32
-
Brake System
33
-
Steering
37
-
Front Fork
38
-
Rear Suspension
38
-
Tire
39
-
Tire Tread Depth
39
-
Chassis Bolt and Nut
40
-
-
Compression Pressure Check
42
-
Compression Test Procedure
42
-
-
Oil Pressure Check
43
-
Oil Pressure Test Procedure
43
-
-
Automatic Clutch Inspection
44
-
Initial Engagement Inspection
44
-
Clutch «Lock-Up» Inspection
44
-
-
Brake-Lock
45
-
Inspection
45
-
Adjustment
45
-
-
-
-
Engine
47
-
Engine Components Removable with the Engine in Place
49
-
Engine Removal and Remounting
50
-
Engine Removal
50
-
Engine Remounting
54
-
-
Engine Disassembly
56
-
Engine Component Inspection and Service
69
-
Cylinder Head Cover
69
-
Camshaft Housing
70
-
Cylinder Head
71
-
Cylinder Head Distortion
72
-
Camshaft
81
-
Cam Chain Tension Adjuster
82
-
Cylinder
84
-
Piston
84
-
Conrod and Crankshaft
86
-
Movable Drive Face Assembly
88
-
Clutch Shoe/Movable Driven Face
90
-
Transmission Cover
96
-
Idle Gear
98
-
Final Driven Gear
99
-
Scissors Gear
99
-
Clutch Inner Cover
100
-
Starter Clutch
102
-
Generator
103
-
Oil Sump Filter
105
-
Oil Pump
105
-
Crankcase
105
-
-
Engine Reassembly
111
-
Crankshaft
111
-
Balancer Shaft
111
-
Crankcase
111
-
Balancer Gear
113
-
Starter Idle Gear
114
-
Cam Chain
115
-
Oil Pump
115
-
Starter Driven Gear
116
-
Generator Rotor
116
-
Oil Sump Filter
116
-
Idle Shaft
117
-
Rear Axle Shaft
117
-
Transmission/Transmission Cover
118
-
Clutch Shoe/Movable Driven Face Assembly
118
-
Movable Drive Face Assembly
120
-
Clutch Inner Cover
120
-
Generator Cover
121
-
Water Pump
121
-
Oil Filter
122
-
Piston Ring
122
-
Piston
123
-
Cylinder
124
-
Cam Chain Guide
124
-
Cylinder Head
124
-
Camshaft
125
-
Cam Chain Tension Adjuster
127
-
Cylinder Head Cover
127
-
Starter Motor
128
-
-
-
Fi System
129
-
Precautions in Servicing
130
-
Eletrical Parts
130
-
Fuse
131
-
Ecm/Various Sensors
131
-
Electrical Circuit Inspection Procedure
133
-
Using Testers
136
-
-
Fi System Technical Features
137
-
Injection Time (Injection Volume)
137
-
Compensation of Injection Time (Volume)
138
-
Injection Stop Control
138
-
Fi System Parts Location
139
-
Fi System Wiring Diagram
141
-
-
Self-Diagnosis Function
142
-
User Mode
142
-
Dealer Mode
143
-
Tps Adjustment
144
-
-
Fail-Safe Function
145
-
Fi System Troubleshooting
146
-
Customer Complaint Analysis
146
-
Self-Diagnostic Procedures
148
-
Self-Diagnosis Reset Procedure
148
-
Malfunction Code and Defective Condition
149
-
C12″ Ckp Sensor Circuit Malfunction
151
-
C13″ Iap Sensor Circuit Malfunction
153
-
C14″ Tp Sensor Circuit Malfunction
156
-
C15″ Ect Sensor Circuit Malfunction
159
-
C21″ Iat Sensor Circuit Malfunction
161
-
C23″ to Sensor Circuit Malfunction
163
-
C24″ Igintion System Malfunction
164
-
C32″ Fuel Injector Circuit Malfunction
165
-
C40″ Iac Valve Circuit Malfunction
167
-
C41″ Fp Relay Circuit Malfunction
169
-
C42″ Ig Switch Circuit Malfunction
169
-
C44″ Ho2 Sensor (Ho2S) Circuit Malfunction (E-02, 19, 54)
170
-
Sensors
172
-
-
-
Fuel System and Throttle Body
174
-
Fuel System
175
-
Removal and Disassembly
176
-
Inspection
178
-
Reassembly and Installation
179
-
Fuel Pressure Inspection
180
-
Fuel Pump Inspection
181
-
Fuel Pump Relay Inspection
182
-
Fuel Pump and Fuel Level Gauge Disassembly
182
-
Fuel Mesh Filter Inspection and Cleaning
183
-
Fuel Level Gauge Inspection
184
-
Fuel Pump and Fuel Level Gauge Reassembly
185
-
-
Throttle Body
186
-
Removal
187
-
Disassembly
189
-
Cleaning and Inspection
191
-
Reassembly
192
-
Installation
193
-
Throttle Cable Adjustment
193
-
Tp Sensor Adjustment
194
-
Fuel Injector Removal
194
-
Fuel Injector Inspection
194
-
Fuel Injector Installation
194
-
-
-
Cooling and Lubrication System
195
-
Cooling System
196
-
Description
196
-
Cooling Circuit
196
-
-
Engine Coolant
197
-
Draining Engine Coolant
197
-
-
Removal and Disassembly
198
-
Radiator
198
-
-
Inspection
199
-
Radiator
199
-
Water Hose
199
-
Cooling Fan
199
-
-
Reassembly and Remounting
200
-
Cooling Fan Thermo-Switch
201
-
Removal
202
-
Inspection
202
-
Inistallation
202
-
-
Engine Coolant Temperature Sensor
203
-
Removal
203
-
Inspection
203
-
Installation
203
-
-
Thermostat
204
-
Removal
204
-
Inspection
204
-
Installtation
205
-
-
Water Pump
206
-
Removal and Disassembly
206
-
Inspection
207
-
Reassembly and Remounting
207
-
-
Lubrication System
210
-
Oil Pressure
210
-
Oil Filter
210
-
Oil Sump Filter
210
-
Oil Pump
210
-
Engine Lubrication System Chart
210
-
Engine Lubrication System
211
-
-
-
Chassis
212
-
Exterior Parts
214
-
Construction
214
-
Removal
220
-
Fastener Removal and Reinstallation
221
-
Installation
230
-
-
Front Wheel
231
-
Removal and Disassembly
231
-
Inspection
232
-
Reassembly and Remounting
233
-
-
Front Brake
236
-
Caliper Removal and Disassembly
237
-
Caliper Inspection
238
-
Caliper Reassembly and Remounting
238
-
Brake Disc Inspection
240
-
Master Cylinder Removal and Disassembly
240
-
Master Cylinder Inspection
241
-
Master Cylinder Reassembly and Remounting
242
-
-
Handlebars
244
-
Removal
244
-
Reassembly
245
-
-
Front Fork
246
-
Removal and Disassembly
246
-
Front Fork Spring Inspection
249
-
Inner Tube and Outer Tube Inspection
249
-
Cylinder Inspection
249
-
Reassembly and Remounting
250
-
-
Steering
254
-
Removal and Disassembly
254
-
Inspection
256
-
Reassembly and Remounting
256
-
-
Rear Wheel
259
-
Removal
259
-
Inspection
260
-
Remounting
260
-
-
Rear Brake
262
-
Brake Pad Replacement
263
-
Caliper Removal and Disassembly
264
-
Caliper Inspection
266
-
Caliper Reassembly and Remounting
266
-
Brake Disc Removal
269
-
Brake Disc Inspection
270
-
Brake Disc Reassembly
270
-
Master Cylinder Removal and Disassembly
271
-
Master Cylinder Inspection
272
-
Master Cylinder Reassembly and Remounting
272
-
Delay Valve Removal
273
-
Delay Valve Remounting
273
-
Brake-Lock Cable Replacement
273
-
Brake System
276
-
-
Rear Suspension
280
-
Removal and Disassembly
280
-
Inspection
281
-
Rear Shock Absorber Disposal
282
-
Reassembly and Remounting
284
-
-
Crankcase Bracket
286
-
Removal and Disassembly
286
-
Inspection
286
-
Bearing Replacement
287
-
Reassembly and Remounting
288
-
-
Tire and Wheel
289
-
Tire Removal
289
-
Inspection
289
-
Valve Inspection
290
-
Tire Installation
291
-
Balancer Weight Installation
292
-
-
-
Electrical System
293
-
Cautions in Servicing
295
-
Connectors
295
-
Couplers
295
-
Clamps
295
-
Fuse
295
-
Semi-Conductor Equipped Parts
296
-
Battery
296
-
Connecting the Battery
296
-
Wiring Procedure
296
-
Using the Multi Circuit Tester
297
-
-
Location of Electrical Components
298
-
Battery
300
-
Charging System
300
-
Trouble Shooting
300
-
Charging System Inspection
302
-
-
Generator
300
-
Main Fuse
300
-
Starter System
305
-
Trouble Shooting
305
-
Starter Motor Removal and Disassembly
306
-
Starter Motor Inspection
307
-
Starter Motor Reassembly and Installation
308
-
Starter Relay Inspection
310
-
Side-Stand/Ignition Interlock System Parts Inspection
310
-
-
Ignition System
313
-
Troubleshooting
313
-
Ignition System Inspection
315
-
-
Combination Meter
318
-
Removal and Disassembly
318
-
Inspection
319
-
Fuel Level Meter Inspection
320
-
-
Headlight
321
-
Lamp
321
-
Front Turn Signal Light
322
-
-
Brake Light/Taillight
323
-
Rear Turn Signal Light/Brake Light/Taillight/License Light
323
-
-
Switches
324
-
Ignition Switch Removal and Remounting
324
-
Inspection
325
-
-
Battery
326
-
Specifications
326
-
Initial Charging
326
-
Servicing
327
-
Recharging Operation
328
-
Battery Removal
328
-
-
Suzuki Burgman AN400 Supplementary Service Manual (143 pages)
Brand: Suzuki
|
Category: Scooter
|
Size: 6.64 MB
Table of Contents
-
General Information
7
-
Service Data
13
-
Fuel System
24
-
Rear Suspension
29
-
Wheels and Tires
30
-
Table of Contents
38
-
Repair Instructions
41
-
Specifications
42
-
Tightening Torque Specifications
42
-
-
Abs
43
-
Precautions
43
-
Precautions for ABS (AN400A/ZAK9)
43
-
ABS Information (AN400A/ZAK9)
43
-
-
General Description
43
-
Wheel Speed Sensor Description (AN400A/ZAK9)
43
-
ABS Control Unit Description (AN400A/ZAK9)
44
-
Hydraulic Unit (HU) Description (AN400A/ZAK9)
46
-
Self-Diagnosis Function and ABS Indicator Light Description (AN400A/ZAK9)
47
-
Fail-Safe Function Description (AN400A/ZAK9)
48
-
-
Schematic and Routing Diagram
49
-
ABS Wiring Diagram (AN400A/ZAK9)
49
-
ABS Unit Diagram (AN400A/ZAK9)
50
-
Front Wheel Speed Sensor Routing Diagram (AN400A/ZAK9)
51
-
Rear Wheel Speed Sensor Routing Diagram (AN400A/ZAK9)
52
-
-
Component Location
53
-
ABS Components Location (AN400A/ZAK9)
53
-
-
Diagnostic Information and Procedures
54
-
ABS Troubleshooting (AN400A/ZAK9)
54
-
Pre-Diagnosis Inspection (AN400A/ZAK9)
56
-
ABS Indicator Light Inspection (AN400A/ZAK9)
58
-
DTC (Diagnostic Trouble Code) Output
64
-
(An400A/Zak9)
67
-
DTC (Diagnostic Trouble Code) Deleting (AN400A/ZAK9)
67
-
SDS Check (AN400A/ZAK9)
69
-
Active Control Inspection (AN400A/ZAK9)
70
-
DTC Table (AN400A/ZAK9)
73
-
DTC «13» (C1613): Wheel Speed Sensor Rotor Malfunction (F) (AN400A/ZAK9)
74
-
DTC «14» (C1614): Wheel Speed Sensor Rotor Malfunction (R) (AN400A/ZAK9)
76
-
DTC «22» (C1622): ABS Actuator Circuit Malfunction (F) (AN400A/ZAK9)
78
-
DTC «23» (C1623): ABS Actuator Circuit Malfunction (R) (AN400A/ZAK9)
80
-
DTC «25» (C1625): Wheel Speed Sensor Related Malfunction (AN400A/ZAK9)
82
-
DTC «35» (C1635): ABS Motor Malfunction (AN400A/ZAK9)
84
-
DTC «41» (C1641): Wheel Speed Sensor Signal Malfunction (F) (AN400A/ZAK9)
86
-
DTC «42» (C1642): Wheel Speed Sensor Circuit Open (F) (AN400A/ZAK9)
88
-
DTC «43» (C1643): Wheel Speed Sensor Circuit Short (F) (AN400A/ZAK9)
94
-
DTC «44» (C1644): Wheel Speed Sensor Signal Malfunction (R) (AN400A/ZAK9)
96
-
DTC «45» (C1645): Wheel Speed Sensor Circuit Open (R) (AN400A/ZAK9)
98
-
DTC «46» (C1646): Wheel Speed Sensor Circuit Short (R) (AN400A/ZAK9)
103
-
DTC «47» (C1647): Supply Voltage (Increased) (AN400A/ZAK9)
105
-
DTC «48» (C1648): Supply Voltage (Decreased) (AN400A/ZAK9)
107
-
DTC «55» (C1655): ABS Control Unit Malfunction (AN400A/ZAK9)
109
-
DTC «61» (C1661): ABS Solenoid Malfunction (AN400A/ZAK9)
111
-
-
-
Repair Instructions
113
-
ABS Control Unit Coupler Disconnect and Connect (AN400A/ZAK9)
113
-
Front Wheel Speed Sensor Removal and Installation (AN400A/ZAK9)
113
-
Rear Wheel Speed Sensor Removal and Installation (AN400A/ZAK9)
114
-
Front Wheel Speed Sensor Rotor Removal and Installation (AN400A/ZAK9)
115
-
Rear Wheel Speed Sensor Rotor Removal and Installation (AN400A/ZAK9)
115
-
Wheel Speed Sensor and Sensor Rotor Inspection (AN400A/ZAK9)
116
-
ABS Control Unit/Hu Removal and Installation (AN400A/ZAK9)
117
-
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