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Suzuki Burgman AN400 Supplementary Service Manual

Other manuals for Burgman AN400: Service Manual

Summary of Burgman AN400

  • Page 1

    Top bottom an400/a/zak9 supply 99501-34170-01e cover14 09.09.12 (back: 5mm) 5/1 dic303 bk pantone 303c pantone 485 pantone 294 an400/a/za printed in japan k9 k 9 9 9 5 0 1 - 3 4 1 7 0 - 0 1 e a n 4 0 0 /a /z a supplementary service manual su pp le m en ta ry s er vic e m an ua l use this manual with...

  • Page 2: Foreword

    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 man- ...

  • Page 3: Table of Contents

    00 0 1 2 3 4 5 6 9 precautions............................................................... 00-i precautions ............................................................ 00-1 general information ................................................... 0-i general information ..............................

  • Page 5: Section 00

    Table of contents 00- i 00 section 00 contents precautions precautions ...............................................00-1 precautions........................................................... 00-1 warning / caution / note......................................00-* general precautions .................

  • Page 6: Precautions

    00-1 precautions: precautions 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 p...

  • Page 7: Section 0

    Table of contents 0- i 0 section 0 contents general information general information ................................ 0a-1 general description .............................................0a-1 symbols ...............................................................0a-* abbreviations .....................

  • Page 8: General Information

    0a-1 general information: general information general information general description abbreviations (an400a/zak9) b905h10101012 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) ...

  • Page 9

    General information: 0a-2 suzuki an400za (2009-model) right side left side country and area codes (an400/a/zak9) b905h10101014 the following codes stand for the applicable country(-ies) and area(-s). I905h1010005-01 i905h1010006-02 model code country or area effective frame no. An400 k9 e-02 u.K. Js...

  • Page 10

    0a-3 general information: specifications specifications (an400k9) b905h10107005 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 s...

  • Page 11

    General information: 0a-4 electrical specifications (an400zak9) b905h10107007 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 ...

  • Page 12

    0a-5 general information: special tools and equipment special tool b905h10108002 09900–20803 thickness gauge 09900–20806 thickness gauge 09900–25008 multi circuit tester set 09900–25009 needle-point probe set 09904–41010 suzuki diagnostic system set 09930–82710 mode select switch 99565–01010–020 cd-...

  • Page 13: Service Data

    Service data: 0c-1 general information service data 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) transmission unit: mm (in) except ratio thrott...

  • Page 14

    0c-2 service data: service data (an400a/zak9) b905h10307005 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) wattage unit: w item standard / specification note fuse size headlight hi 10 a e-0...

  • Page 15

    Service data: 0c-3 brake + wheel unit: mm (in) 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 chassis item standard limit brake disc thickness front 4.5 ± 0.2 (0.18 ± 0.008) 4.0 (0...

  • Page 16

    0c-4 service data:.

  • Page 17: Section 1

    Table of contents 1- i 1 section 1 contents engine precautions ................................................. 1-* precautions.............................................................. 1-* precautions for engine........................................... 1-* engine general information and diag...

  • Page 18

    1-ii table of contents repair instructions .............................................. 1c-* ecm removal and installation............................ 1c-* ckp sensor inspection ....................................... 1c-* ckp sensor removal and installation ................ 1c-* iap sensor inspect...

  • Page 19

    Table of contents 1-iii engine coolant description .................................1f-* cooling fan thermo-switch description..............1f-* engine coolant temperature sensor description .........................................................1f-* schematic and routing diagram.....................

  • Page 20

    1-iv table of contents turn signal / side-stand relay removal and installation...........................................................1i-* side-stand / ignition interlock system parts inspection............................................................1i-* starter clutch component.................

  • Page 21: Engine Mechanical

    Engine mechanical: 1d-1 engine engine mechanical schematic and routing diagram throttle cable routing diagram (an400/a/zak9) b905h11402003 “ a ” “d” 8 7 “c” 9 upside inside 4 5 6 3 4 4 “a” 2 5 1 3 “b” 4 4 5 3 upside inside i905h1140001-02 1. Clamp : bind the parking brake cable, starter motor lead w...

  • Page 22

    1d-2 engine mechanical: repair instructions engine bottom side assembly (an400/a/zak9) b905h11406036 for engine bottom side assembly other than the following, refer to “engine bottom side assembly” in related manual. Crankcase • install the o-rings (1) and (2). • install the dowel pins. Caution ! Re...

  • Page 23

    Engine mechanical: 1d-3 • tighten the crankcase bolts to the specified torque. Tightening torque crankcase bolt (m6): 11 n·m (1.1 kgf-m, 8.0 lbf-ft) crankcase bolt (m8): 22 n·m (2.2 kgf-m, 16.0 lbf- ft) caution ! Tighten the larger diameter crankcase bolts first and then smaller ones diagonally and ...

  • Page 24: Fuel System

    1g-1 fuel system: engine fuel system repair instructions fuel pump components (an400/a/zak9) b905h11706017 1. Fuel level gauge 5. Fuel pump 9. Fuel pump mounting bolt 2. O-ring 6. Fuel mesh filter : 10 n ⋅m (1.0 kgf-m, 7.0 lbf-ft) 3. Fuel pressure regulator assembly 7. Dust cover : apply engine oil....

  • Page 25

    Fuel system: 1g-2 fuel pump disassembly and assembly (an400/ a/zak9) b905h11706018 disassembly 1) remove the fuel pump assembly. Refer to “fuel pump assembly removal and installation” in related manual. 2) remove the dust cover (1). 3) for the other procedure, refer to “fuel pump disassembly and ass...

  • Page 26

    1g-3 fuel system:.

  • Page 27: Section 2

    Table of contents 2- i 2 section 2 contents suspension precautions ................................................. 2-* precautions.............................................................. 2-* precautions for suspension ................................... 2-* suspension general diagnosis.........

  • Page 28

    2-ii table of contents specifications.......................................................2d-7 service data........................................................ 2d-* tightening torque specifications........................2d-7 special tools and equipment .............................2d-7 recomm...

  • Page 29: Rear Suspension

    Rear suspension: 2c-1 suspension rear suspension repair instructions rear swingarm construction (an400/a/zak9) b905h12306018 1 2 3 5 4 i905h1230001-01 1. Rear swingarm 3. Swingarm cushion no. 2 5. Swingarm cushion cover 2. Swingarm cushion no. 3 4. Swingarm cushion no. 1.

  • Page 30: Wheels and Tires

    2d-1 wheels and tires: suspension wheels and tires repair instructions front wheel components (an400a/zak9) b905h12406013 2 3 3 6 7 1 9 7 11 10 12 4 4 (a) 5 (b) 8 (b) 8 (c) 13 fwd fw d i905h1240001-02 1. Front wheel 6. Collar 11. Wheel balancer : 6 n ⋅m (0.6 kgf-m, 4.5 lbf-ft) 2. Spacer 7. Brake dis...

  • Page 31

    Wheels and tires: 2d-2 front wheel assembly construction (an400a/zak9) b905h12406014 (c) 3 (b) 2 “ b ” “ a ” (a) 1 (b) 2 (c) 3 lh rh (d) 4 i905h1240010-02 1. Front axle “a”: clearance : 23 n ⋅m (2.3 kfg-m, 16.5 lbf-ft) 2. Front brake caliper mounting bolt “b”: 0.36 – 1.62 mm (0.014 – 0.064 in) : 6 n...

  • Page 32

    2d-3 wheels and tires: front wheel assembly removal and installation (an400a/zak9) b905h12406015 caution ! • the abs is made up of many precision parts; never subject it to strong impacts or allow it to become dirty or dusty. • do not hit the front wheel speed sensor rotor when dismounting the front...

  • Page 33

    Wheels and tires: 2d-4 rear wheel components (an400a/zak9) b905h12406016 2 1 5 6 8 10 4 (a) 3 (b) 7 9 (c) 12 11 fwd fw d i905h1240006-01 1. Rear axle 7. Rear axle nut : 23 n ⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Brake disc 8. Tire : 120 n ⋅m (12.0 kgf-m, 87.0 lbf-ft) 3. Brake disc bolt 9. Air valve : 6 n ⋅...

  • Page 34

    2d-5 wheels and tires: rear wheel assembly construction (an400a/zak9) b905h12406017 “ a ” (b) 3 (a) 1 (b) 2 lh rh 4 (c) 5 i905h1240011-04 1. Rear axle nut 5. Rear wheel speed sensor rotor bolt : 6 n ⋅m (0.6 kgf-m, 4.5 lbf-ft) 2. Rear brake caliper mounting bolt “a”: 0.16 – 1.62 mm (0.006 – 0.064 in)...

  • Page 35

    Wheels and tires: 2d-6 rear wheel assembly removal and installation (an400a/zak9) b905h12406018 caution ! • the abs is made up of many precision parts; never subject it to strong impacts or allow it to become dirty or dusty. • do not hit the front wheel speed sensor rotor when dismounting the front ...

  • Page 36

    2d-7 wheels and tires: specifications tightening torque specifications b905h12407002 note the specified tightening torque is described in the following. “front wheel components (an400a/zak9)” (page 2d-1) “front wheel assembly construction (an400a/zak9)” (page 2d-2) “rear wheel components (an400a/zak...

  • Page 37: Section 4

    Table of contents 4- i 4 section 4 contents brake precautions ................................................. 4-* precautions.............................................................. 4-* precautions for brake system ............................... 4-* brake fluid information.....................

  • Page 38

    4-ii table of contents parking brake cable (brake-lock cable) routing diagram ............................................... 4d-* repair instructions .............................................. 4d-* parking brake system (brake-lock system) inspection.................................................

  • Page 39

    Brake control system and diagnosis: 4a-1 brake brake control system and diagnosis schematic and routing diagram front brake hose routing diagram (an400a/zak9) b905h14102003 1 5 6 7 3 6 10 1 5 9 3 10 “b” “a” 3 10 11 9 4 3 5 6 2 2 (a) (a) (a) (a) (b) 8 (b) i905h1410001-02 1. Abs control unit/hu 9. Rea...

  • Page 40

    4a-2 brake control system and diagnosis: rear brake hose routing diagram (an400a/zak9) b905h14102004 1 “a” 1 2 1 2 3 1 “a” 2 4 “b” 2 “c” “ b ” “ a ” (a) i905h1410003-01 1. Rear brake pipe no. 2 “b”: fix the brake hose to its hose clamp. 2. Rear brake hose no. 2 “c”: after positioning the clamp with ...

  • Page 41

    Brake control system and diagnosis: 4a-3 repair instructions front brake hose removal and installation (an400a/zak9) b905h14106016 caution ! • this brake system is filled with an ethylene glycol- based dot 4 brake fluid. Do not mix different types of fluid such as silicone-based or petroleum-based. ...

  • Page 42

    4a-4 brake control system and diagnosis: specifications tightening torque specifications b905h14107002 note the specified tightening torque is described in the following. “front brake hose routing diagram (an400a/zak9)” (page 4a-1) “rear brake hose routing diagram (an400a/zak9)” (page 4a-2) referenc...

  • Page 43: Abs

    Abs: 4e-1 brake abs precautions precautions for abs (an400a/zak9) b905h14500001 refer to “precautions for abs (an400a/zak9)” in section 00 (page 00-1) and “precautions for electrical circuit service” in section 00 in related manual. Abs information (an400a/zak9) b905h14500002 warning ! • be sure to ...

  • Page 44

    4e-2 abs: abs control unit description (an400a/zak9) b905h14501002 abs control unit (1) calculates signals input from each one of front and rear wheel speed sensors, monitors the slipping conditions of the wheels and, at the same time, sends control signal to hydraulic unit (hu) (2). This abs contro...

  • Page 45

    Abs: 4e-3 abs control unit calculating process the abs controls and its calculations, in addition to the self-diagnosing and the fail-safe processes, occur during the abs control unit calculating process. Abs control is performed in one cycle every 10/1 000 seconds. In addition, if a malfunction is ...

  • Page 46

    4e-4 abs: hydraulic unit (hu) description (an400a/zak9) b905h14501003 the hydraulic unit operates the solenoid valves based upon the signal which is output from the abs control unit. The brake fluid pressure is then adjusted accordingly. The hydraulic unit controls the front and rear brake systems i...

  • Page 47

    Abs: 4e-5 self-diagnosis function and abs indicator light description (an400a/zak9) b905h14501006 the abs control unit performs the self-diagnosis and can store any electronically detected malfunctions as diagnostic trouble codes. If a malfunction has occurred, the indicator light lights up to infor...

  • Page 48

    4e-6 abs: stored dtcs (diagnostic trouble codes) as for the diagnostic trouble code, the code of the first malfunction occurred during one ignition on period will be stored. Pay attention to the fact that even though there may occur several malfunctions in one on-period, only one code will be stored...

  • Page 49

    Abs: 4e-7 schematic and routing diagram abs wiring diagram (an400a/zak9) b905h14502001 refer to “wire color symbols” in section 0a in related manual. Ba t on off lock ig a t gnd prk ill o/g br w/b o/g b/y b/y b/w b/w b/w b/w r/w r r b/r b/bl o/g w/b gr b/w b/y w/r w/b r/bl r/b gr br b/r o o/y w/y b/...

  • Page 50

    4e-8 abs: abs unit diagram (an400a/zak9) b905h14502002 refer to “wire color symbols” in section 0a in related manual. Battery ignition ignition abs brake light switch brake light switch abs indicator light solenoid battery (+) fail safe relay motor relay ground front wheel speed sensor rear wheel sp...

  • Page 51

    Abs: 4e-9 front wheel speed sensor routing diagram (an400a/zak9) b905h14502003 “c” “b” 1 “f” 2 “a” “b” “e” 1 1 “d” 1 “g” 3 “h” i905h1450071-02 1. Clamp “d”: clamp the white taping point of sensor lead wire and the protector of brake hose. 2. Leg shield brace “e”: clamp the white taping point of sens...

  • Page 52

    4e-10 abs: rear wheel speed sensor routing diagram (an400a/zak9) b905h14502004 1 2 3 “c” 3 1 “a” “b” “d” 4 “b” i905h1450072-06 1. Rear wheel speed sensor “b”: pass the rear wheel speed sensor lead wire along the speed sensor lead wire. 2. Sensor bracket pin “c”: outside marking 3. Sensor bracket “d”...

  • Page 53

    Abs: 4e-11 component location abs components location (an400a/zak9) b905h14503001 1 2 3 4 5 6 7 i905h1450011-03 1. Abs control unit/hu 3. Mode select coupler 5. Front wheel speed sensor rotor 7. Rear wheel speed sensor rotor 2. Sds coupler 4. Front wheel speed sensor 6. Rear wheel speed sensor.

  • Page 54

    4e-12 abs: diagnostic information and procedures abs troubleshooting (an400a/zak9) b905h14504001 many of the abs malfunction diagnosing operations are performed by checking the wiring continuity. Quick and accurate detection of malfunctions within the complex circuitry assures the proper operation o...

  • Page 55

    Abs: 4e-13 information gathering to properly diagnose a malfunction, one must not make guesses or assumptions about the circumstances that caused it. Proper diagnosis and repair require duplicating the situation in which the malfunction occurred. If a diagnosis is made without duplicating the malfun...

  • Page 56

    4e-14 abs: pre-diagnosis inspection (an400a/zak9) b905h14504019 the mechanical and hydraulic components of the brake system should be inspected prior to performing any electrical checks. These inspections may find problems that the abs could not detect; thus, shortening repair time. Brake brake flui...

  • Page 57

    Abs: 4e-15 abs component wheel speed sensor – sensor rotor clearance inspection inspect the clearance between the wheel speed sensor and sensor rotor for each wheel using the thickness gauge. Special tool (a): 09900–20803 (thickness gauge) (b): 09900–20806 (thickness gauge) wheel speed sensor – sens...

  • Page 58

    4e-16 abs: abs indicator light inspection (an400a/zak9) b905h14504020 wiring diagram refer to “abs unit diagram (an400a/zak9)” (page 4e-8). Troubleshooting step action yes no 1 1) check if the abs indicator light lights up when turning the ignition switch on. Does the abs indicator light up? Go to s...

  • Page 59

    Abs: 4e-17 3 (the abs indicator light does not light up) 1) remove the upper meter panel. Refer to “upper meter panel removal and installation” in section 9d in related manual. 2) open the fuse box and inspect the signal fuse (1). Caution ! If a fuse is blown, find the cause of the problem and corre...

  • Page 60

    4e-18 abs: 5 1) connect the combination meter coupler. 2) turn the ignition switch on with the abs control unit coupler disconnected, measure the voltage between “21” (br) and “24” (b/w) at the coupler. Special tool (a): 09900–25008 (multi circuit tester set) tester knob indication voltage ( ) norma...

  • Page 61

    Abs: 4e-19 7 (the abs indicator light does not go off) 1) turn the ignition switch off. 2) remove the upper meter panel. Refer to “upper meter panel removal and installation” in section 9d in related manual. 3) open the fuse box and inspect the signal fuse (1). Caution ! If a fuse is blown, find the...

  • Page 62

    4e-20 abs: 9 1) connect the combination meter coupler. 2) turn the ignition switch on with the abs control unit coupler disconnected, measure the voltage between “21” (br) and “24” (b/w) at the coupler. Special tool (a): 09900–25008 (multi circuit tester set) tester knob indication voltage ( ) norma...

  • Page 63

    Abs: 4e-21 10 1) turn the ignition switch off. 2) short the mode select coupler terminals (o – b/w) using the special tool. Special tool (a): 09930–82710 (mode select switch) 3) check for continuity between “13” (o) and “24” (b/w) at the coupler. Special tool (a): 09900–25008 (multi circuit tester s...

  • Page 64

    4e-22 abs: dtc (diagnostic trouble code) output (an400a/zak9) b905h14504021 note • even through the abs is operating correctly, a dtc is memorized in any of the following conditions. – if the motorcycle is put on its centerstand, the engine is started and only the rear wheel is rotated. – previous m...

  • Page 65

    Abs: 4e-23 6) turn the ignition switch on. The abs indicator light starts flashing to indicate the dtc. Refer to “dtc table (an400a/zak9)” (page 4e-31). Note • if there is a dtc, the abs indicator light keeps flashing cyclically and repeatedly. • if there is no dtc, the abs indicator light keeps lig...

  • Page 66

    4e-24 abs: use of sds note • don’t disconnect couplers from abs hu, the battery cable from the battery, abs hu ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized informat...

  • Page 67

    Abs: 4e-25 dtc (diagnostic trouble code) deleting (an400a/zak9) b905h14504022 use of mode select switch 1) remove the meter panel. Refer to “meter panel removal and installation” in section 9d in related manual. 2) connect the combination meter coupler. 3) connect the special tool to the mode select...

  • Page 68

    4e-26 abs: 6) after deleting the dtcs, repeat the code output procedure and make sure that no dtcs remain (the abs indicator light no longer flashes). Note if any dtcs remain, perform the appropriate procedures, then delete the codes. If dtcs are left stored, confusion may occur and unnecessary repa...

  • Page 69

    Abs: 4e-27 8) follow the displayed instructions. 9) check that both “current dtc” (4) and “past dtc” (5) are deleted (nil). 10) close the sds tool and turn the ignition switch off. 11) disconnect the sds tool and reinstall the removed parts. 12) ride the motorcycle at more than 30 km/h (18.6 mile/h)...

  • Page 70

    4e-28 abs: data sampled from abs hu system active control inspection (an400a/zak9) b905h14504024 1) remove the upper meter panel. Refer to “upper meter panel removal and installation” in section 9d in related manual. 2) set up the sds tool. (refer to the sds operation manual for further details.) sp...

  • Page 71

    Abs: 4e-29 4) click “active control” (2). 5) click “abs hu operating” (3). 6) click “next” according to the screen indication. A) abs hu operating (1/7) b) abs hu operating (2/7) c) abs hu operating (3/7) note • if the front wheel is selected, place the motorcycle on the center stand and lift the fr...

  • Page 72

    4e-30 abs: note • in normal cases, the front brake lever feels a reaction force and the front wheel turns discontinuously. At the same time, the abs hu operating sound will be heard. • the abs hu motor operates for 6 seconds and then stops automatically. G) abs hu operating (7/7) note • inspect the ...

  • Page 73

    Abs: 4e-31 dtc table (an400a/zak9) b905h14504002 * 1 : it goes off after running at more than 10 km/h (6.2 mile/h). * 2 : the wheel speed sensor lead wire is connected to the abs control unit, but a short-circuit or faulty continuity inside the abs control unit caused this dtc to appear, therefore, ...

  • Page 74

    4e-32 abs: caution ! When disconnecting couplers and turning the ignition switch on, disconnect the abs control unit coupler in order to prevent a dtc from being stored. Each time a resistance is measured, the ignition switch should be set to off. Dtc “13” (c1613): wheel speed sensor rotor malfuncti...

  • Page 75

    Abs: 4e-33 3 1) check that the front wheel speed sensor is mounted securely. Is the sensor mounted securely? Go to step 4. Tighten the mounting bolts. 4 1) inspect the front tire and wheel. Refer to “tire inspection” in section 0b in related manual and “front wheel related parts inspection” in secti...

  • Page 76

    4e-34 abs: dtc “14” (c1614): wheel speed sensor rotor malfunction (r) (an400a/zak9) b905h14504004 troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a/zak9)” (page 4e-25). Possible cause • rear wheel speed sensor rot...

  • Page 77

    Abs: 4e-35 3 1) check that the rear wheel speed sensor is mounted securely. Is the sensor mounted securely? Go to step 4. Tighten the mounting bolts or replace the bracket if necessary. 4 1) inspect the rear tire and wheel. Refer to “tire inspection” in section 0b in related manual and “rear wheel r...

  • Page 78

    4e-36 abs: dtc “22” (c1622): abs actuator circuit malfunction (f) (an400a/zak9) b905h14504005 troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a/zak9)” (page 4e-25). Possible cause • wire harness discontinuity • fr...

  • Page 79

    Abs: 4e-37 3 1) check that the front wheel speed sensor is mounted securely. Is the sensor mounted securely? Replace the abs control unit/hu. Tighten the mounting bolts. Step action yes no i905h1450032-01.

  • Page 80

    4e-38 abs: dtc “23” (c1623): abs actuator circuit malfunction (r) (an400a/zak9) b905h14504006 troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a/zak9)” (page 4e-25). Possible cause • wire harness discontinuity • re...

  • Page 81

    Abs: 4e-39 3 1) check that the rear wheel speed sensor is mounted securely. Is the sensor mounted securely? Replace the abs control unit/hu. Tighten the mounting bolts or replace the bracket if necessary. Step action yes no i905h1450035-01.

  • Page 82

    4e-40 abs: dtc “25” (c1625): wheel speed sensor related malfunction (an400a/zak9) b905h14504007 troubleshooting possible cause • incorrect tire size, poor tire pressure • deformed wheel, etc. Step action yes no 1 1) check that the specified tires are installed. Tire type and size front: bridgestone ...

  • Page 83

    Abs: 4e-41 3 1) inspect both wheel speed sensor rotors for damage and check that no foreign objects are caught in the rotor openings. Are the rotors ok? Go to step 4. Clean or replace the rotor. 4 1) inspect the clearances of the front and rear wheel speed sensor – sensor rotor using the thickness g...

  • Page 84

    4e-42 abs: dtc “35” (c1635): abs motor malfunction (an400a/zak9) b905h14504008 wiring diagram refer to “abs unit diagram (an400a/zak9)” (page 4e-8). Troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a/zak9)” (page 4...

  • Page 85

    Abs: 4e-43 3 1) turn the ignition switch off. 2) remove the meter panel. Refer to “meter panel removal and installation” in section 9d in related manual. 3) check the abs control unit coupler for loose or poor contacts. If ok, then disconnect the abs control unit coupler. Refer to “abs control unit ...

  • Page 86

    4e-44 abs: dtc “41” (c1641): wheel speed sensor signal malfunction (f) (an400a/zak9) b905h14504009 troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a/zak9)” (page 4e-25). Possible cause • poor contact in the front ...

  • Page 87

    Abs: 4e-45 3 1) check that the front wheel speed sensor is mounted securely. Is the sensor mounted securely? Go to dtc “42” (c1642). (refer to “dtc “42” (c1642): wheel speed sensor circuit open (f) (an400a/ zak9)” (page 4e-46).) tighten the mounting bolts. Step action yes no i905h1450032-01.

  • Page 88

    4e-46 abs: dtc “42” (c1642): wheel speed sensor circuit open (f) (an400a/zak9) b905h14504010 wiring diagram refer to “abs unit diagram (an400a/zak9)” (page 4e-8). Troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a/...

  • Page 89

    Abs: 4e-47 step action yes no 1 1) turn the ignition switch off. 2) remove the meter panel. Refer to “meter panel removal and installation” in section 9d in related manual. 3) check the abs control unit coupler and front wheel speed sensor coupler for loose or poor contacts. If ok, then disconnect t...

  • Page 90

    4e-48 abs: 2 1) disconnect the front wheel speed sensor coupler. 2) measure the resistance between “a” (w) and ground at the front wheel speed sensor coupler. Special tool (a): 09900–25008 (multi circuit tester set) tester knob indication resistance ( Ω) normal value (“a” – ground) ∞Ω (infinity) is ...

  • Page 91

    Abs: 4e-49 4 1) measure the resistance between “b” (bl) and ground at the front wheel speed sensor coupler. Special tool (a): 09900–25008 (multi circuit tester set) tester knob indication resistance ( Ω) normal value (“b” – ground) ∞Ω (infinity) is the resistance between “b” and ground ok? Inspect t...

  • Page 92

    4e-50 abs: 6 1) check for continuity between “3” (w/r) on the abs control unit coupler and “d” (w/r) on the front wheel speed sensor coupler. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) tester knob indication continuity test ( ) normal value (“3...

  • Page 93

    Abs: 4e-51 7 1) connect the front wheel speed sensor coupler. 2) connect three 1.5 v dry cells “a” in series as shown and make sure that their total voltage is more than 4.5 v. Measure the current between (+) dry cell terminal and “12” (b/r) on the abs control unit coupler. Caution ! Dry cells conne...

  • Page 94

    4e-52 abs: dtc “43” (c1643): wheel speed sensor circuit short (f) (an400a/zak9) b905h14504011 wiring diagram refer to “abs unit diagram (an400a/zak9)” (page 4e-8). Troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a...

  • Page 95

    Abs: 4e-53 2 1) check for continuity between “2” (b/y) and “3” (w/r) at the coupler. Special tool (a): 09900–25008 (multi circuit tester set) tester knob indication continuity ( ) abs control unit coupler (harness side) is there continuity between “2” and “3”? • inspect the wire harness. (faulty sen...

  • Page 96

    4e-54 abs: dtc “44” (c1644): wheel speed sensor signal malfunction (r) (an400a/zak9) b905h14504012 troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a/zak9)” (page 4e-25). Possible cause • poor contact in the rear w...

  • Page 97

    Abs: 4e-55 3 1) check that the rear wheel speed sensor is mounted securely. Is the sensor mounted securely? Go to dtc “45” (c1645). (refer to “dtc “45” (c1645): wheel speed sensor circuit open (r) (an400a/ zak9)” (page 4e-56).) tighten the mounting bolts or replace the bracket if necessary. Step act...

  • Page 98

    4e-56 abs: dtc “45” (c1645): wheel speed sensor circuit open (r) (an400a/zak9) b905h14504013 wiring diagram refer to “abs unit diagram (an400a/zak9)” (page 4e-8). Troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a/...

  • Page 99

    Abs: 4e-57 1 5) measure the resistance between “2” (b/y) and ground at the abs control unit coupler. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) tester knob indication resistance ( Ω) normal value (“2” – ground) ∞Ω (infinity) is the resistance b...

  • Page 100

    4e-58 abs: 3 1) measure the resistance between “18” (w/y) and ground at the abs control unit coupler. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) tester knob indication resistance ( Ω) normal value (“18” – ground) ∞Ω (infinity) is the resistance...

  • Page 101

    Abs: 4e-59 5 1) check for continuity between “2” (b/y) on the abs control unit coupler and “c” (b/y) on the rear wheel speed sensor coupler. Special tool (a): 09900–25008 (multi circuit tester set) (b): 09900–25009 (needle-point probe set) tester knob indication continuity test ( ) normal value (“2”...

  • Page 102

    4e-60 abs: 7 1) connect the rear wheel speed sensor coupler. 2) connect three 1.5 v dry cells “a” in series as shown and make sure that their total voltage is more than 4.5 v. Measure the current between (+) dry cell terminal and “2” (b/y) on the abs control unit coupler. Caution ! Dry cells connect...

  • Page 103

    Abs: 4e-61 dtc “46” (c1646): wheel speed sensor circuit short (r) (an400a/zak9) b905h14504014 wiring diagram refer to “abs unit diagram (an400a/zak9)” (page 4e-8). Troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a...

  • Page 104

    4e-62 abs: 2 1) check for continuity between “12” (b/r) and “18” (w/y) at the coupler. Special tool (a): 09900–25008 (multi circuit tester set) tester knob indication continuity ( ) abs control unit coupler (harness side) is there continuity between “12” and “18”? • inspect the wire harness. (faulty...

  • Page 105

    Abs: 4e-63 dtc “47” (c1647): supply voltage (increased) (an400a/zak9) b905h14504015 wiring diagram refer to “abs unit diagram (an400a/zak9)” (page 4e-8). Troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a/zak9)” (p...

  • Page 106

    4e-64 abs: 3 1) turn the ignition switch off. 2) remove the meter panel. Refer to “meter panel removal and installation” in section 9d in related manual. 3) install the combination meter. 4) check the abs control unit coupler for loose or poor contacts. If ok, then disconnect the abs control unit co...

  • Page 107

    Abs: 4e-65 dtc “48” (c1648): supply voltage (decreased) (an400a/zak9) b905h14504016 wiring diagram refer to “abs unit diagram (an400a/zak9)” (page 4e-8). Troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a/zak9)” (p...

  • Page 108

    4e-66 abs: 2 1) start the engine at 5 000 r/min with the dimmer switch set to hi. 2) measure the voltage between the (+) and (–) battery terminals. Special tool : 09900–25008 (multi circuit tester set) tester knob indication voltage ( ) regulated voltage 14.0 – 15.5 v at 5 000 r/min is the voltage 1...

  • Page 109

    Abs: 4e-67 dtc “55” (c1655): abs control unit malfunction (an400a/zak9) b905h14504017 troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a/zak9)” (page 4e-25). Possible cause faulty abs control unit step action yes n...

  • Page 110

    4e-68 abs: 2 1) inspect both of the wheel speed sensor rotors for damage and check that no foreign objects are caught in the rotor openings. Are the rotors ok? Go to step 3. Clean or replace the rotor. 3 1) check that the front and rear wheel speed sensors are mounted securely. Are the sensors mount...

  • Page 111

    Abs: 4e-69 dtc “61” (c1661): abs solenoid malfunction (an400a/zak9) b905h14504018 troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting (an400a/zak9)” (page 4e-25). Possible cause faulty solenoid valve or relay step action ye...

  • Page 112

    4e-70 abs: 2 1) remove the meter panel. Refer to “meter panel removal and installation” in section 9d in related manual. 2) check the abs control unit coupler for loose or poor contacts. If ok, then disconnect the abs control unit coupler. Refer to “abs control unit coupler disconnect and connect (a...

  • Page 113

    Abs: 4e-71 repair instructions abs control unit coupler disconnect and connect (an400a/zak9) b905h14506003 disconnect 1) turn the ignition switch off. 2) remove the meter panel. Refer to “meter panel removal and installation” in section 9d in related manual. 3) pull up the coupler lock (1) and disco...

  • Page 114

    4e-72 abs: rear wheel speed sensor removal and installation (an400a/zak9) b905h14506005 caution ! • the abs is made up of many precision parts; never subject it to strong impacts or allow it to become dirty or dusty. • the wheel speed sensor cannot be disassembled. Removal 1) turn the ignition switc...

  • Page 115

    Abs: 4e-73 front wheel speed sensor rotor removal and installation (an400a/zak9) b905h14506006 caution ! • the abs is made up of many precision parts; never subject it to strong impacts or allow it to become dirty or dusty. • do not hit the front wheel speed sensor rotor when dismounting the front w...

  • Page 116

    4e-74 abs: installation refer to “wheel speed sensor and sensor rotor inspection (an400a/zak9)” (page 4e-74). Install the rear wheel speed sensor rotor in the reverse order of removal. Pay attention to the following points: • install the wheel speed sensor rotor as the letters “72t” face outside. Ti...

  • Page 117

    Abs: 4e-75 abs control unit/hu removal and installation (an400a/zak9) b905h14506009 removal warning ! When storing the brake fluid, seal the container completely and keep away from children. Caution ! • this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not mix different...

  • Page 118

    4e-76 abs: 8) remove the abs control unit/hu assembly by removing the holder mounting bolts. 9) remove the abs control unit/hu (5) from the holder (6). Installation installation is in the reverse order of removal. Pay attention to the following points: caution ! • route the brake hoses and pipes cor...

  • Page 119

    Abs: 4e-77 specifications tightening torque specifications b905h14507001 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list” in section 0c in related manual. Special tools and equipment recommended service material b905h14508001 note requ...

  • Page 120

    4e-78 abs: 09900–25008 09900–25009 multi circuit tester set needle-point probe set ) (page 4e-14) / ) (page 4e-15) / ) (page 4e-17) / ) (page 4e-18) / ) (page 4e-18) / ) (page 4e-19) / ) (page 4e-20) / ) (page 4e-21) / ) (page 4e-43) / ) (page 4e-47) / ) (page 4e-48) / ) (page 4e-48) / ) (page 4e-49...

  • Page 121: Section 5

    Table of contents 5- i 5 section 5 contents transmission / transaxle precautions ................................................. 5-* precautions.............................................................. 5-* precautions for transmission/transaxle................ 5-* automatic transmission.........

  • Page 122: Automatic Transmission

    5a-1 automatic transmission: transmission / transaxle automatic transmission repair instructions outer clutch cover cushion construction (an400/a/zak9) b905h15106015 1 2 3 5 6 7 4 “a” “ a ” “ a ” “ a ” “ a ” “ b ” i905h1510001-01 1. Clutch outer cover cushion no. 1 6. Clutch outer cover cushion no. ...

  • Page 123

    Automatic transmission: 5a-2 belt cooling duct hose construction (an400/a/zak9) b905h15106017 “a” 2 1 2 “b” i905h1510003-03 1. Belt cooling duct “a”: clamp the belt cooling duct hose at this position. 2. Belt cooling duct hose “b”: mach the groove part of belt cooling duct hose to the edge of belt c...

  • Page 124

    5a-3 automatic transmission: belt cooling duct hose removal and installation (an400/a/zak9) b905h15106018 removal 1) remove the front frame cover. Refer to “front frame cover removal and installation” in section 9d in related manual. 2) remove the left slide leg shield. Refer to “side leg shield rem...

  • Page 125: Section 6

    Table of contents 6- i 6 section 6 contents steering precautions ................................................. 6-* precautions.............................................................. 6-* precautions for steering ........................................ 6-* steering general diagnosis..........

  • Page 126: Steering / Handlebar

    6b-1 steering / handlebar: steering steering / handlebar schematic and routing diagram grip heater wiring diagram (an400zak9) b905h16202001 4 1 1 2 2 “b” “c” “a” 3 5 6 fwd up “d” i905h1620001-02 1. Grip heater (rh) 6. Clamp : bind the grip heater lead wire (lh) and grip heater switch lead wire with ...

  • Page 127

    Steering / handlebar: 6b-2 repair instructions grip heater removal and installation (an400zak9) b905h16206016 removal refer to “grip heater removal and installation (an400zk7/k8)” in related manual. Grip heater diagram installation refer to “grip heater removal and installation (an400zk7/k8)” in rel...

  • Page 128

    6b-3 steering / handlebar: special tools and equipment special tool b905h16208002 09900–25008 multi circuit tester set ) (page 6b-2).

  • Page 129: Section 9

    Table of contents 9- i 9 section 9 contents body and accessories precautions ................................................. 9-* precautions.............................................................. 9-* precautions for electrical system .......................... 9-* component location ..........

  • Page 130

    9-ii table of contents upper meter panel removal and installation...... 9d-* front leg shield cover removal and installation......................................................... 9d-* wind screen removal and installation ............... 9d-* front panel removal and installation ................. ...

  • Page 131: Wiring Systems

    Wiring systems: 9a-1 body and accessories wiring systems schematic and routing diagram wiring diagram (an400a/zak9) b905h19102005 refer to “wire color symbols” in section 0a in related manual..

  • Page 132

    9a-2 wiring systems: for e-02, 19, 24, 54 ba t on off lock ig a t gnd prk ill b b/w br b/w w b/w y b/w o/r p b/w r/bl o/g o/r p br o/bl v y b lg bl y/b b/g br/b b/w o/r p b/w br b/w lg b/w v o/g o/g b/w b/bl o/g b/bl b/w lg lbl b y/w y y/w b/bl b/w lg lbl b o/r w y y/w w/b o/g b/y b/y r br/w b/br w ...

  • Page 133

    Wiring systems: 9a-3 for e-03, 28, 33 ba t on off lock ig at gnd p rk ill b b/w br b/w y b/w w y b/w w o/r p b/w r/bl o/g o/r p br v y b lg bl y/b b/g br/b b/w o/r p b/w br b/w lg b/w v o/g o/g b/w b/bl o/g b/bl b/w lg lbl b y/w w/bl y/bl y/w b/bl b/w lg lbl b o/r w y y/w w/b o/g b/y b/y r br/w b/br...

  • Page 134

    9a-4 wiring systems: wiring routing diagram (an400a/zak9) b905h19102006 “c” 4 3 1 “d” [a] 2 “a” “b” “ a ” “ a ” i905h1910903-07 1. Clamp : bind the handlebar switch lead wire (rh) and grip heater lead wire (rh) [an400za only] with the clamp. Cut off the excess end of clamp. “b”: pass the handlebar s...

  • Page 135

    Wiring systems: 9a-5 “a” “b” “a” 13 “a” 1 2 3 5 4 7 6 8 9 12 10 “c” “a” “d” “e” “f” 11 “g” fwd “a” 15 14 i905h1910904-03 1. Frame 12. Clamp : bind the wiring harness and battery (–) lead wire with the clamp. 2. Parking brake cable 13. Clamp : bind the regulator/rectifier lead wire and battery lead w...

  • Page 136

    9a-6 wiring systems: 4 7 2 3 5 6 1 “j” 14 16 “i” 13 11 12 “g” 15 “k” “b” “l” 10 9 10 “f” “d” 8 “a” “b” “e” “c” “h” fwd i905h1910905-03 1. Iat sensor 15. High-tension cord 2. Stva 16. Clamp : the tip of clamp should face right side of the motorcycle. 3. Stp sensor “a”: pass the ignition coil lead wir...

  • Page 137

    Wiring systems: 9a-7 specifications service data (an400k9) b905h1910s003 note the service data is the same as the k8-model. Service data (an400a/zak9) b905h1910s004 refer to “service data (an400a/zak9)” in section 0c (page 0c-2)..

  • Page 138

    9c-1 combination meter / fuel meter / horn: body and accessories combination meter / fuel meter / horn repair instructions combination meter (abs indicator light) inspection (an400a/zak9) b905h19306014 check if the abs indicator lights up when turning the ignition switch on. If the abs indicator doe...

  • Page 139: Exterior Parts

    Exterior parts: 9d-1 body and accessories exterior parts repair instructions side leg shield cover (lh) componets (an400/z/a/zak9) b905h19406028 3 1 2 i905h1940001-01 1. Side leg shield cover (lh) 2. Screw 3. Side leg shield cover (lh).

  • Page 140: Body Structure

    9e-1 body structure: body and accessories body structure repair instructions center stand construction (an400/z/a/zak9) b905h19506008 “ a ” “ a ” “ b ” “ b ” “a” 5 1 2 3 4 (a) i905h1950001-01 1. Center stand “a”: do not apply grease to the thread portion of the bolts. 2. Center stand inner spring “a...

  • Page 141

    Body structure: 9e-2 specifications tightening torque specifications b905h19507001 note the specified tightening torque is described in the following. “center stand construction (an400/z/a/zak9)” (page 9e-1) reference: for the tightening torque of fastener not specified in this section, refer to “ti...

  • Page 142

    Prepared by april, 2009 part no. 99501-34170-01e printed in japan 140

  • Page 143: Vic

    Top bottom an400/a/zak9 supply 99501-34170-01e cover14 09.09.12 (back: 5mm) 5/1 dic303 bk pantone 303c pantone 485 pantone 294 an400/a/za printed in japan k9 k 9 9 9 5 0 1 - 3 4 1 7 0 - 0 1 e a n 4 0 0 /a /z a supplementary service manual su pp le m en ta ry s er vic e m an ua l use this manual with...