Suzuki AN400 2003 Manuals

Manuals and User Guides for Suzuki AN400 2003. We have 1 Suzuki AN400 2003 manual available for free PDF download: Service Manual

Suzuki AN400 2003 Service Manual

Suzuki AN400 2003 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
- 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
Servicing Information

329
- Troubleshooting
  330
  - Malfunction Code and Defective Condition
    330
  - Engine
    332
  - Radiator (Cooling System)
    336
  - Chassis
    337
  - Brakes
    338
  - Electrical
    339
  - Battery
    340
- Special Tools
  341
- Wiring Harness, Cable and Hose Routing
  345
  - Wiring Harness Routing
    345
  - License Plate Light
    346
  - Cable Routing
    347
  - Speedometer Cable Routing
    348
  - Seat Lock Cable Routing
    349
  - Rear Shock Absorber Hose Routing
    350
  - Front Brake Hose Routing
    351
  - Rear Brake Routing
    352
  - Radiator Hose Routing
    353
  - Fuel Tank, Fuel Tank Lower Cover Mounting
    354
  - Throttle Body Installation/Hose Routing
    355
  - Side-Stand Set-Up
    356
  - Center Stand Set-Up
    356
- Tightening Torque
  357
  - Engine
    357
  - Fi System and Intake Air System
    358
  - Chassis
    359
  - Tightening Torque Chart
    360
- Wiring Diagram
  361
- Service Data
  363
  - Trunk Light
    371
  - Turn Signal Light
    371
  - Turn Signal Indicator Light
    371
  - High Beam Indicator Light
    371
  - Brake-Lock Indicator Light
    371
  - Oil Change Indicator Light
    371
  - Emission Control Systems
    375
    
    Fuel Injection System
    375
    
    Crankcase Emission Control System
    376
    
    Exhaust Emission Control System (Pair System)
    377
    
    Noise Emission Control System
    378
  - Pair (Air Supply) System Inspection
    379
    
    Hose
    379
    
    Pair Reed Valve
    379
    
    Pair Control Solenoid Valve
    379
  - Pair (Air Supply) System Hose Routing
    381
  - Heated Oxgen Sensor (Ho2S) Inspection
    382

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