Suzki Burgman AN400. Manual - part 81

 

  Index      Motorcycles     Suzki Burgman AN400 - service and repair manual 2002 year

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  79  80  81  82   ..

 

 

Suzki Burgman AN400. Manual - part 81

 

 

SERVICING INFORMATION     9-11

ELECTRICAL

Complaint

Symptom and possible causes

Remedy

No sparking or poor 
sparking.

1. Defective ignition coil/plug cap or crankshaft posi-

tion sensor.

2. Defective spark plug.
3. Defective generator.
4. Defective ECM.
5. Defective tip over sensor.
6. Open-circuited wiring connections.

Replace.

Replace.
Replace.
Replace.
Replace.
Check and repair.

Spark plug soon 
become fouled with 
carbon.

1. Mixture too rich.
2. Idling speed set too high.

3. Incorrect gasoline.
4. Dirty air cleaner element.
5. Too cold spark plug.

Consult FI system.
Adjust idle adjust screw or 
repalce the IAC valve.
Change.
Clean or replace.
Replace with hot type plug.

Spark plug become 
fouled too soon.

1. Worn piston rings.
2. Worn piston or cylinder.
3. Excessive clearance of valve stems in valve guides.
4. Worn stem oil seals.

Replace.
Replace.
Replace.
Replace.

Spark plug elec-
trodes overheat or 
burn.

1. Too hot spark plug.

2. Overheated the engine.
3. Loose spark plug.
4. Too lean mixture.

Replace with cold type 
plug.
Tune up.
Retighten.
Consult FI system.

Generator does not 
charge.

1. Open- or short-circuited lead wires, or loose lead 

connections.

2. Short-circuited, grounded or open generator coil.
3. Short-circuited or panctured regulator/rectifier.

Repair or replace or 
retighten.
Replace.
Replace.

Generator does 
charge, but charg-
ing rate is below the 
specification.

1. Lead wires tend to get short- or open-circuited or 

loosely connected at terminals.

2. Grounded or open-circuited startor coil or generator.
3. Defective regulator/rectifier.
4. Defective cell plates in the battery.

Repair or retighten.

Replace.
Replace.
Replace the battery.

Generator over-
charges.

1. Internal short-circuit in the battery.
2. Damaged or defective resistor element in the 

regu-lator/recitifier.

3. Poorly grounded regulator/rectifier.

Replace the battery.
Replace.

Clean and tighten ground 
connection.

Unstable charging.

1. Lead wire insulation frayed due to vibration, 

resulting in intermittent short-circuiting.

2. Internally short-circuited generator.
3. Defective regulator/rectifier.

Repair or replace.

Replace.
Replace.

Starter button is not 
effective.

1. Run down battery.

2. Defective switch contacts.

3. Brushes not seating properly on starter motor

commutator.

4. Defective starter relay or starter interlock switch.

5. Defective main fuse.

Repair or replace.
Replace.
Repair or replace.

Replace.
Replace.

9-12     SERVICING INFORMATION

BATTERY

Complaint

Symptom and possible causes

Remedy

“Sulfation”, acidic 
white powdery sub-
stance or spots on 
surfaces of cell 
plates.

1. Cracked battery case.
2. Battery has been left in a run-down condition for a 

long time.

Replace the battery.
Replace the battery.

Battery runs down 
quickly.

1. Trouble in charging system.

2. Cell plates have lost much of their active material 

as a result of overcharging.

3. Internal short-circuit in the battery.
4. Too low battery voltage.
5. Too old battery.

Check the generator, regu-
lator/rectifier and circuit 
connections and make nec-
essary adjustments to 
obtain specified charging 
operation.
Replace the battery, and 
correct the charging sys-
tem.
Replace the battery.
Recharge the battery fully.
Replace the battery.

Battery “sulfation”.

1. Incorrect charging rate.

(When not in use battery should be checked at 
least once a month to avoid sulfation.)

2. The battery was left unused for too long.

Replace the battery.

Replace the battery if badly 
sulfated.

SERVICING INFORMATION     9-13

SPECIAL TOOLS

09900-20102
Vernier calipers

09900-20202
Micrometer
(25 – 50 mm)

09900-20204
Micrometer
(50 – 75 mm)

09900-20205
Micrometer
(0 – 25 mm)

09900-20508
Cylinder gauge set

09900-20602
Dial gauge
(1/1 000 mm, 1 mm)

09900-20605
Dial calipers
(1/100 mm, 10 – 34 mm)

09900-20607
Dial gauge
(1/100 mm, 10 mm)

09900-20701
Magnetic stand

09900-20803/
09900-20806
Thickness gauge

09900-20805
Tire depth gauge

09900-21304
V-block (100 mm)

09900-22301/
09900-22302
Plastigauge

09900-22403
Small bore gauge
(18 – 35 mm)

09900-25008
Multi circuit tester
set

09900-26006
Tachometer

09910-32812
Crankshaft installer

09910-32870
Attachment

09910-60611
Universal clamp
wrench

09913-50121
Oil seal remover

09913-70210
Bearing installer
set

09913-75830
Bearing installer

09915-63310
Compression gauge
adaptor

09915-64512
Compression gauge

09915-74511
Oil pressure gauge

9-14     SERVICING INFORMATION

09915-74521
Oil pressure gauge
hose

09915-74540
Oil pressure gauge
hose attachment

09915-77331
Pressure gauge

09916-10911
Valve lapper set

09916-14510
Valve lifter

09916-14910
Valve lifter
attachment

09916-20610
Valve seat
cutter (N–125)

09916-20620
Valve seat
cutter (N–122)

09916-21111
Valve seat cutter
set

09916-24311
Solid pilot
(N–100 – 5.0)

09916-24935
Valve seat cutter
(N–608)

09916-34542
Valve guide
reamer handle

09916-34550
Valve guide
reamer (5.5 mm)

09916-34580
Valve guide
reamer (10.8 mm)

09916-57330
Valve guide
installer

09916-57340
Valve guide
installer attachment

09916-84511
Tweezers

09917-14920
Valve clearance
adjusting driver

09917-47011
Vacuum pump
gauge

09920-13120
Crankcase/
crankshaft separator

09921-20240
Bearing remover
set

09922-21410
Long socket (46 mm)

09922-31420
Clutch spring
compressor

09923-73210
Bearing remover

09923-74511
Bearing remover

 

 

 

 

 

 

 

Content   ..  79  80  81  82   ..