2003 Suzuki AN400 Burgman Factory Service Manual (P/N 99500-34080-03E)

This Spanish-language Suzuki factory service manual covers the carbureted AN400 and is identified on the cover as P/N 99500-34080-03E. This is a 241-page PDF. Its repair procedures and reliance on precision measuring equipment, electrical meters, holding tools, and secure vehicle support make it suited to professional technicians and experienced DIY mechanics who can work confidently from Spanish workshop instructions.

Powertrain and Fuel System Documentation

• Periodic-service coverage includes valve-clearance adjustment, spark-plug and filter service, fluid maintenance, compression and oil-pressure testing, automatic-clutch engagement and lock-up checks, and brake-lock adjustment.
• Engine repair content covers removal and installation, disassembly, cylinder-head and valvetrain inspection, camshaft and timing-chain components, cylinder and piston checks, and the opening stages of variator and centrifugal-clutch service.
• Fuel-system procedures address tank removal and inspection, fuel-pump testing, and KEIHIN CVK36 carburetor removal, disassembly, cleaning, inspection, assembly, fuel-level measurement, and float-height adjustment.
• Cooling-system work includes radiator and hose service, pressure-cap inspection, fan-switch and temperature-sensor testing, thermostat checks, water-pump disassembly and assembly, and coolant-circuit bleeding.
• Chassis repair sections cover body-panel removal, front and rear wheels, wheel bearings, brake calipers and master cylinders, the combined-brake delay valve, front fork and steering service, rear suspension, and tires.
• Electrical coverage provides troubleshooting and test procedures for charging, starting, and ignition systems, along with starter motor and relay checks, regulator/rectifier and generator tests, speedometer inspection, switches, lighting, and battery service.

Configuration-Specific Service Information

The KEIHIN CVK36 section distinguishes E-02/E-04/E-34, E-22, and E-18 configurations by carburetor bore identification, idle specifications, and pilot-screw and heater arrangements. Factory tables cover the main and pilot jets, jet needle, needle jet, throttle valve, fuel level, float height, and throttle-cable adjustment. The accompanying system descriptions explain the vacuum fuel pump, fuel shutoff and tank-pressure-control valves, diaphragm operation, low-speed and main circuits, auto-enricher, carburetor heater, float chamber, and accelerator pump.

The service-data pages consolidate component-specific torque tables, capacities and approved fluids, valve and valvetrain clearances, cylinder and piston inspection limits, clutch and transmission wear data, cooling-system test values, electrical resistance and peak-voltage specifications, brake and wheel limits, and suspension data. The illustrated special-tool directory identifies equipment by Suzuki number, including multimeter 09900-25008, fuel-level gauge 09913-10760, compression gauge 09915-64510 with adapter 09915-63310, valve adjuster 09917-14910, and clutch-spring compressor 09922-31420.

Named technical illustrations include the lubrication-system diagram, complete electrical wiring diagram, main-harness routing, cooling-hose routing, front and combined-brake hose routing, and fuel-tank/hose routing. These views support repair work where connector location, cable placement, hose routing, or oil flow cannot be established reliably from specifications alone.

The carburetor section warns against clearing jets or passages with wire because their calibrated surfaces can be damaged. The automatic-clutch lock-up test also limits the full-throttle interval because holding it longer can damage the clutch or engine.

Important File Scope

This PDF begins with Periodic Maintenance at printed page 2-1; Section 1 is not included. The Engine chapter stops after printed page 3-40, in the middle of the movable driven-pulley/clutch-shoe procedure, and resumes with Fuel and Lubrication at 4-1. The later engine pages listed in the chapter contents—including the remaining driven-pulley work, V-belt, starter clutch, oil pump, crankshaft, crankcases, final-reduction components, and engine assembly—are therefore not part of this file. Sections 4 through 8 continue through printed page 8-32, including troubleshooting, wiring, routing diagrams, special tools, torque tables, and service specifications.

Fuel-system service requires good ventilation and a work area free of flames or sparks. Use secure lifting and support equipment for engine, wheel, brake, and suspension work, and use the specified holding or compression tools for spring-loaded drive components.