Suzuki AN400, AN400ZA, AN400A, 2009 AN400, 2009 AN400ZA Supplementary Service Manual

...

AN400/A/ZA

SUPPLEMENTARY SERVICE MANUAL

USE THIS MANUAL WITH: AN400 SERVICE MANUAL (99500-34101-01E)

9 9 5 0 1 - 3 4 1 7 0 - 0 1 E

FOREWORD

This SUPPLEMENTARY SERVICE MANUAL is a supplement to SUZUKI AN400 SERVICE MANUAL. It has been prepared exclusively for the following applicable model.

Applicable model: AN400/A/ZAK9

This supplementary service manual describes only service information which differ from that of the main manual. Therefore, whenever servicing the above applicable model, consult this supplement first. And for any section, item or description not found in this supplement, refer to the main manual below.

Main Manual:

Manual Name Manual No.

AN400 SERVICE MANUAL 99500-34101-01E

Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service.

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifi-

cations have been made since then, differences may exist between the content of this manual and the actual motorcycle.

* Illustrations in this manual are used to show the basic principles of operation and work procedures. They

may not represent the actual motorcycle exactly in detail.

* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for

servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

WARNING

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.

TABLE OF CONTENTS

NOTE For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same

sections of the service manual mentioned in the “FOREWORD” of this manual.

Precautions............................................................... 00-i

Precautions ............................................................ 00-1

General Information ................................................... 0-i

General Information ............................................... 0A-1

Maintenance and Lubrication ..................................0B-*

Service Data...........................................................0C-1

Engine ......................................................................... 1-i

Precautions ............................................................... 1-*

Engine General Information and Diagnosis ............1A-*

Emission Control Devices .......................................1B-*

Engine Electrical Devices....................................... 1C-*

Engine Mechanical.................................................1D-1

Engine Lubrication System .....................................1E-*

Engine Cooling System...........................................1F-*

Fuel System ...........................................................1G-1

Ignition System....................................................... 1H-*

Starting System........................................................ 1I-*

Charging System..................................................... 1J-*

Exhaust System ......................................................1K-*

Suspension................................................................. 2-i

Precautions ............................................................... 2-*

Suspension General Diagnosis...............................2A-*

Front Suspension ....................................................2B-*

Rear Suspension....................................................2C-1

Wheels and Tires ...................................................2D-1

Driveline / Axle ........................................................... 3-*

Precautions ............................................................... 3-*

Drive Chain / Drive Train / Drive Shaft ....................3A-*

Brake ........................................................................... 4-i

Precautions ............................................................... 4-*

Brake Control System and Diagnosis ....................4A-1

Front Brakes............................................................4B-*

Rear Brakes ........................................................... 4C-*

Parking Brake......................................................... 4D-*

ABS ........................................................................ 4E-1

Transmission / Transaxle .......................................... 5-i

Precautions ............................................................... 5-*

Automatic Transmission......................................... 5A-1

Steering....................................................................... 6-i

Precautions ............................................................... 6-*

Steering General Diagnosis ....................................6A-*

Steering / Handlebar ..............................................6B-1

Body and Accessories............................................... 9-i

Precautions ............................................................... 9-*

Wiring Systems ...................................................... 9A-1

Lighting Systems.....................................................9B-*

Combination Meter / Fuel Meter / Horn..................9C-1

Exterior Parts ......................................................... 9D-1

Body Structure ....................................................... 9E-1

Table of Contents 00- i

Section 00

Precautions

CONTENTS

NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual

mentioned in the “FOREWORD” of this manual.

Precautions ...............................................00-1

Precautions........................................................... 00-1

Warning / Caution / Note...................................... 00-*

General Precautions ............................................ 00-*

Precautions for Electrical Circuit Service ............. 00-*

Precautions for ABS (AN400A/ZAK9) ................. 00-1

00-1 Precautions:

Precautions

Precautions for ABS (AN400A/ZAK9)

B905H10000004

ABS Wiring

• The ABS parts are connected to various lead wires. The coupler and lead wire connections, as well as the lead wire and wire harness routings must be done correctly. Make sure that the proper clamps are used and positioned correctly.

NOTE

If all of the connections are not properly connected, the ABS may not operate correctly. For connector and coupler precautions. Refer to “Precautions for Electrical Circuit Service” in related manual.

ABS Control Unit/HU

• Never allow dust or water to contact the ABS control unit/HU.

• Never subject the ABS control unit/HU to strong impacts or allow them to be dropped.

I649G1000003-02

• The ABS control unit/HU cannot be disassembled. Replace the whole unit with a new one.

I649G1000004-02

I649G1000005-02

Table of Contents 0- i

Section 0

General Information

CONTENTS

NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual

mentioned in the “FOREWORD” of this manual.

General Information ................................ 0A-1

General Description ............................................. 0A-1

Symbols ...............................................................0A-*

Abbreviations .......................................................0A-*

Vehicle Side View (AN400K7) .............................0A-*

Vehicle Side View (AN400ZK7) ...........................0A-*

Vehicle Identification Number ..............................0A-*

Fuel / Oil / Engine Coolant Recommendation......0A-*

Engine Coolant Recommendation .......................0A-*

BREAK-IN Procedures.........................................0A-*

Country and Area Codes .....................................0A-*

Wire Color Symbols .............................................0A-*

Warning, Caution and Information Labels

Location .............................................................0A-*

Abbreviations (AN400A/ZAK9) ........................... 0A-1

Vehicle Side View (AN400/A/ZAK9).................... 0A-1

Country and Area Codes (AN400/A/ZAK9)......... 0A-2

Component Location ........................................... 0A-*

Electrical Components Location ..........................0A-*

Specifications.......................................................0A-3

Specifications (AN400K7) ....................................0A-*

Specifications (AN400ZK7) ..................................0A-*

Specifications (AN400K8) ....................................0A-*

Specifications (AN400ZK8) ..................................0A-*

Specifications (AN400K9) ................................... 0A-3

Specifications (AN400AK9)................................. 0A-3

Specifications (AN400ZAK9) .............................. 0A-4

Special Tools and Equipment ............................. 0A-5

Special Tool ........................................................ 0A-5

Maintenance and Lubrication..................0B-*

Precautions........................................................... 0B-*

Precautions for Maintenance ...............................0B-*

General Description ............................................. 0B-*

Recommended Fluids and Lubricants..................0B-*

Scheduled Maintenance ...................................... 0B-*

Periodic Maintenance Schedule Chart.................0B-*

Lubrication Points ................................................0B-*

Repair Instructions .............................................. 0B-*

Air Cleaner Element Removal and Installation .....0B-*

Air Cleaner Element Inspection ...........................0B-*

Spark Plug Removal and Installation ...................0B-*

Spark Plug Inspection and Cleaning ....................0B-*

Valve Clearance Inspection and Adjustment .......0B-*

Fuel Line Inspection ............................................ 0B-*

Evaporative Emission Control System (E-33

Only).................................................................. 0B-*

Engine Oil and Filter Change .............................. 0B-*

Final Reduction Gear Oil Replacement............... 0B-*

Cooling Fan Filter Removal and Installation ....... 0B-*

Cooling Fan Filter Inspection and Cleaning ........ 0B-*

Drive V-belt Removal and Installation ................. 0B-*

Drive V-belt Inspection ........................................ 0B-*

Throttle Cable Play Inspection and

Adjustment ........................................................ 0B-*

Cooling System Inspection.................................. 0B-*

Air Bleeding From the Cooling Circuit ................. 0B-*

Radiator Hose Inspection.................................... 0B-*

Brake System Inspection .................................... 0B-*

Brake Hose Replacement ................................... 0B-*

Air Bleeding from Brake Fluid Circuit .................. 0B-*

Brake Fluid Replacement.................................... 0B-*

Tire Inspection..................................................... 0B-*

Steering System Inspection ................................ 0B-*

Front Fork Inspection .......................................... 0B-*

Rear Suspension Inspection ............................... 0B-*

Exhaust Pipe and Muffler Mounting

Inspection.......................................................... 0B-*

Chassis Bolt and Nut Inspection ......................... 0B-*

Compression Pressure Check ............................ 0B-*

Oil Pressure Check ............................................. 0B-*

SDS Check.......................................................... 0B-*

Automatic Clutch Inspection................................ 0B-*

Parking Brake (Brake-lock) Inspection................ 0B-*

Parking Brake (Brake-lock) Adjustment .............. 0B-*

Specifications....................................................... 0B-*

Tightening Torque Specifications........................ 0B-*

Special Tools and Equipment ............................. 0B-*

Recommended Service Material ......................... 0B-*

Special Tool ........................................................ 0B-*

Service Data ............................................. 0C-1

Specifications.......................................................0C-1

Service Data (AN400/ZK7).................................. 0C-*

Service Data (AN400/ZK8).................................. 0C-*

Tightening Torque List ........................................ 0C-*

Service Data (AN400K9).....................................0C-1

Service Data (AN400A/ZAK9).............................0C-2

Tightening Torque List (AN400AK9) ...................0C-3

0A-1 General Information:

General Information

General Description

Abbreviations (AN400A/ZAK9)

NOTE

Please refer to the AN400K8 service manual for other abbreviations which are not given in this manual.

A: ABS: Anti-lock Brake System

Vehicle Side View (AN400/A/ZAK9)

B905H10101013

NOTE

Difference between illustration and actual motorcycles may exist depending on the markets.

SUZUKI AN400 (2009-model)

Right Side

SUZUKI AN400A (2009-model)

Right Side

B905H10101012

I905H1010003-01

Left Side

I905H1010001-01

I905H1010004-02

I905H1010002-02

General Information: 0A-2

SUZUKI AN400ZA (2009-model)

Left Side

Right Side

I905H1010005-01

Country and Area Codes (AN400/A/ZAK9)

The following codes stand for the applicable country(-ies) and area(-s).

Model Code Country or Area Effective Frame No.

E-02 U.K. JS1CG111200100924 – E-03 U.S.A. (Except for California) JS1CK44A 92100001 – E-19 E.U. JS1CG111100135961 –

AN400 K9

AN400A K9

AN400ZA K9

E-24 Australia JS1CG111300100360 – E-28 Canada JS1CK44A 92100001 – E-33 California JS1CK44A 92100001 – E-51 Korea JS1CG111590100001 – E-54 Israel JS1CG111490100001 – E-02 U.K. JS1CG113200100001 – E-03 U.S.A. (Except for California) JS1CK44B 92100001 – E-19 E.U. JS1CG113100100001 – E-24 Australia JS1CG113300100001 – E-28 Canada JS1CK44B 92100001 – E-33 California JS1CK44B 92100001 – E-54 Israel JS1CG113490100001 – E-02 U.K. JS1CG114200100001 – E-19 E.U. JS1CG114100100001 –

I905H1010006-02

B905H10101014

0A-3 General Information:

Specifications

Specifications (AN400K9)

NOTE

• These specifications are subject to change without notice.

• Any differences between the AN400K8 (’08-model) and AN400K9 (’09-model) in specifications are indicated an asterisk mark (*).

Dimensions and Curb Mass

Item Specification Remark Overall length 2 270 mm (89.4 in) Overall width 760 mm (29.9 in) Overall height 1 385 mm (54.5 in) Wheelbase 1 585 mm (62.4 in) Ground clearance 125 mm (4.9 in) Seat height 710 mm (28.0 in) * Curb mass 216 kg (476 lbs)

Specifications (AN400AK9)

NOTE

• These specifications are subject to change without notice.

• Any differences between the AN400K9 (’09-model) and AN400AK9 (’09-model) in specifications are indicated with an asterisk mark (*).

Dimensions and Curb Mass

Curb mass

* 223 kg (491 lbs) E-33 * 222 kg (489 lbs) Others

B905H10107005

B905H10107006

General Information: 0A-4

Electrical

Item Specification Remark lgnition type Electronic ignition (Transistorized) lgnition timing 7° B. T. D. C at 1 450 r/min Spark plug NGK: CR7E or DENSO: U22ESR-N Battery 12 V 32.4 kC (9 Ah)/10 HR Generator Three-phase A.C. generator Main fuse 30 A

Fuse

10/10/15/10/15/10 A E-02, 19, 24, 54 15/15/15/10/15/10 A E-03, 28, 33

* ABS fuse 15/20 A

Headlight

12 V 60/55 W (H4) + 55 W (H7) E-02, 19, 24, 54

12 V 60/55 W (H4) x 2 E-03, 28, 33 Position/Parking light 12 V 5 W x 2 E-02, 19, 24, 54 Position light 12 V 5 W x 2 E-03, 28, 33 Brake light/Taillight 12 V 21/5 W x 2 License plate light 12 V 5 W Helmet box light 12 V 5 W

Front turn signal light

12 V 27/8 W E-03, 28, 33

12 V 21 W Others Rear turn signal light 12 V 21 W Speedometer/Tachometer light LED Coolant temperature meter light LED Fuel level meter light LED Turn signal indicator light LED x 2 High beam indicator light LED Brake-lock indicator light LED Oil change indicator LCD Fuel injection warning light LED Immobilizer indicator light LED E-02, 19, 24, 54 * ABS indicator light LED

Specifications (AN400ZAK9)

NOTE

• These specifications are subject to change without notice.

• Any differences between the AN400AK9 (’09-model) and AN400ZAK9 (’09-model) in specifications are indicated with an asterisk mark (*).

Dimensions and Curb Mass

Item Specification Remark Overall length 2 270 mm (89.4 in) Overall width * 825 mm (32.5 in) Overall height 1 385 mm (54.5 in) Wheelbase 1 585 mm (62.4 in) Ground clearance 125 mm (4.9 in) Seat height 710 mm (28.0 in) Curb mass * 225 kg (496 lbs)

B905H10107007

0A-5 General Information:

Special Tools and Equipment

Special Tool

09900–20803

Thickness gauge

09930–82710

Mode select switch

09900–20806

Thickness gauge

99565–01010–020

CD-ROM Ver.20

09900–25008

Multi circuit tester set

09900–25009

Needle-point probe set

B905H10108002

09904–41010

SUZUKI Diagnostic system set

General Information

Service Data

Service Data: 0C-1

Specifications

Service Data (AN400K9)

B905H10307004

NOTE

Any differences between the AN400K8 (’08-model) and AN400K9 (’09-model) is service data are indicated an asterisk mark (*).

Clutch

Unit: mm (in)

Item Specification Limit

Clutch wheel I.D. 160 – 160.2 (6.30 – 6.31) 160.5 (6.32) Clutch shoe thickness 5.0 (2.0) 2.0 (0.08) Engage r/min Lock-up r/min 4 000 – 5 000 r/min —

Transmission

Unit: mm (in) Except ratio

Item Specification Note

Primary reduction ratio 1.000 — Reduction ratio 2.200 – 0.839 Secondary reduction ratio 2.214 — Final reduction ratio 2.666 — Drive V-belt width 25.1 (0.99) 24.1 (0.95) Movable driven face spring free length Movable drive face roller O.D. 26.00 – 26.16 (1.024 – 1.030) — Drive/driven face ware — 0.4 (0.02)

* 2 600 – 3 200 r/min —

* 145.0 (5.7) * 137.8 (5.43)

Throttle Body

Specification

* 05H2 * 05H3

I.D. No.

Item

E-02, 03, 19, 24, 28, 51, 54 E-33

Bore size 38 mm (1.5 in) ← Fast idle r/min 1 500 – 2 000 r/min ← Idle r/min 1 450 ± 100 r/min ← Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) ←

0C-2 Service Data:

Service Data (AN400A/ZAK9)

NOTE

Any differences between the AN400K9 (’09-model) and AN400A/ZAK9 (’09-model) in service data are indicated an asterisk mark (*).

Electrical

Unit: mm (in)

Item Standard / Specification Note

Headlight

Meter

Fuse size

Ignition

Signal 15 A

Power source 10 A

Main 30 A

* ABS motor 20 A

* ABS valve 15 A

Wattage

Unit: W

Item

E-02, 19, 24, 54 E-03, 28, 33

Standard / Specification

Speedometer/tachometer light LED ← Engine coolant temp. gauge light LED ← Fuel level gauge light LED ← Immobilizer indicator light LED ← Oil change indicator LCD ← FI indicator light LED ← Brake-lock indicator light LED ← High beam indicator light LED ← Turn signal indicator light LED x 2 ← * ABS indicator light LED ←

10 A E-02, 19, 24, 54 15 A E-03, 28, 33 10 A E-02, 19, 24, 54

15 A E-03, 28, 33 * 10 A * 15 A

B905H10307005

Service Data: 0C-3

Brake + Wheel

Unit: mm (in)

Item Standard Limit

Brake disc thickness

Front 4.5 ± 0.2 (0.18 ± 0.008) 4.0 (0.16)

Rear 5.0 ± 0.2 (0.20 ± 0.008) 4.5 (0.18)

Brake disc runout — 0.30 (0.01)

Master cylinder bore

Master cylinder piston diameter

Brake caliper cylinder bore

Brake caliper piston diameter

Front

Rear 12.700 – 12.743 (0.500 – 0.502) —

Front

Rear 12.657 – 12.684 (0.498 – 0.499) —

Front 25.400 – 25.450 (1.000 – 1.002) —

Rear 27.00 – 27.05 (1.063 – 1.065) —

Front 25.318 – 25.368 (0.997 – 0.999) —

Rear 26.918 – 26.968 (1.060 – 1.062) —

* 14.000 – 14.043 (0.551 – 0.553) —

* 13.957 – 13.984 (0.549 – 0.551) —

Brake fluid type DOT 4 —

Wheel rim runout

Wheel axle runout

Wheel rim size

Axial — 2.0 (0.08)

Radial — 2.0 (0.08)

Front — 0.25 (0.01)

Rear — 0.25 (0.01)

Front 14 M/C x MT3.00 —

Rear 13 M/C x MT4.00 —

Tightening Torque List (AN400AK9)

B905H10307006

NOTE

Please refer to the AN400K8 service manual for other tightening torque which are not given in this manual.

Engine

Item N⋅m kgf-m lbf-ft

Main gallery plug M10 18 1.8 13.0

Chassis

Item N⋅m kgf-m lbf-ft

Brake pipe flare nut 16 1.6 11.5 Wheel speed sensor rotor bolt (Front & Rear) 6 0.6 4.5

0C-4 Service Data:

Section 1

Engine

CONTENTS

Table of Contents 1- i

NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual

mentioned in the “FOREWORD” of this manual.

Precautions ................................................. 1-*

Precautions.............................................................. 1-*

Precautions for Engine........................................... 1-*

Engine General Information and

Diagnosis ..................................................1A-*

General Description ............................................. 1A-*

Injection Timing Description .................................1A-*

Self-Diagnosis Function .......................................1A-*

Schematic and Routing Diagram........................ 1A-*

FI System Wiring Diagram ...................................1A-*

Terminal Alignment of ECM Coupler (Harness

Side)...................................................................1A-*

Component Location ........................................... 1A-*

FI System Parts Location.....................................1A-*

Diagnostic Information and Procedures............ 1A-*

Engine Symptom Diagnosis .................................1A-*

DTC Table............................................................1A-*

Fail-Safe Function Table......................................1A-*

FI System Troubleshooting ..................................1A-*

Self-Diagnostic Procedures .................................1A-*

Self-Diagnosis Reset Procedures ........................1A-*

Use of SDS Diagnostic Procedures .....................1A-*

Use of SDS Diagnosis Reset Procedures............1A-*

Show Data When Trouble (Displaying Data at

the Time of DTC) ...............................................1A-*

SDS Check ..........................................................1A-*

Malfunction Code and Defective Condition

Table ..................................................................1A-*

DTC “C12” (P0335): CKP Sensor Circuit