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I'm not terribly talented with tools, but I do want to keep up with some basic maintenance on my AN400... The MOM isn't very helpful - I'm trying to figure out the instruction to "clean the cooling fan" every 1800 miles. Where the heck is the cooling fan? The MOM doesn't tell me... Here's another - the air filter drain plug? I've been trying to locate a Clymers or Haynes service/repair manual for my AN 400... So far, can only find the Suzuki Service Manual for $70.. The MOM is pretty sparse with information, especially for a wrenchaphobic like me. Geez, I wish that there were bike maintenance classes so I could learn how to do this stuff - kinda scary to me, using my new bike as a learning tool. Advice? (Yeah, well besides taking it to the dealer for everything...)
 

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If you don't ride in the rain, the drain plug shouldn't worry you, but typically (I have a 650) the plug is on the bottom of the air cleaner box, mine looks like a clear hose that is closed on 1 end. As for cleaning the cooling fan, honestly this is the first I heard of it. I would think the fan is directly behind the radiator, as in a car. If you ride in a very dusty or dirty area this might be a concern. I've run hard and in town @ 95 degrees, but haven't even heard mine run yet.
In the early 70's I owned a Suzuki GT 750 water cooled, there was a bracket for the fan they used to have on it, but found out it never came on so they stopped putting them on.
 

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I know where the air box oil drain plug is...open your seat and take off the plastic panel that gives you access to the idle adjustment. There are two screws I believe that hold this on. It is on the left side (as to are sitting on the scooter)of the air cleaner box and you may even have to remove it. It is a 1.5" tube that sit on the lowest level of the air box. Sounds like a lot of trouble doesn't it. I checked mine at 1000 kms and it had no fluid in it.

The filter for the cooling fan I have not cleaned myself and I don't think I'll be cleaning it as frequently as they sugguest. If I were commuting on dirt roads I think I would be. It lies behind the radiator and I think even more troublesome to get at. Wait until you have to do the tappets...lots of body panels have to come off. Oil changes are easy.
 

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bikinbiddy said:
I'm not terribly talented with tools, but I do want to keep up with some basic maintenance on my AN400... The MOM isn't very helpful - I'm trying to figure out the instruction to "clean the cooling fan" every 1800 miles. Where the heck is the cooling fan? The MOM doesn't tell me... Here's another - the air filter drain plug? I've been trying to locate a Clymers or Haynes service/repair manual for my AN 400... So far, can only find the Suzuki Service Manual for $70.. The MOM is pretty sparse with information, especially for a wrenchaphobic like me. Geez, I wish that there were bike maintenance classes so I could learn how to do this stuff - kinda scary to me, using my new bike as a learning tool. Advice? (Yeah, well besides taking it to the dealer for everything...)
Hi

To stand the best chance of doing your own maintenance and servicing you honestly do need the Suzuki Service Manual, I understand the cheapest place in the States to get it from is here:

https://www.oneidasuzuki.com/store/xcart/customer/product.php?productid=18234&cat=559&page=2

Remember to order the correct one for your machine (use the drop down menu.

You will not be cleaning the cooling fan as such, but rather the cooling fan filter which must be washed out BUT NOT oiled. You will need to take a panel off to access. Actually this is covered in my owners manual quite well (page 39 in mine - yours probably different)

The Air filter drain plug - well you can probably access that by taking off one cover - but I am not familiar with the later Burgs. I would not bother until you have the service manual and then do it when you rip out the whole air filter housing to clean the air filter. (Although it is covered (not very well ) in my owners manual -pages 35-36)

Do not be daunted by your lack of wrench experience, with the manual and some basic tools you will be able to tackle most things and better (or more reliably) than most dealers. Of course this forum is a great resource too. View the photo gallery too, while the 650 is a different machine there are similarities - the way to remove and replace the plastic rivet pins for example.

Please invest in the Service Manual it will pay for itself very quickly and you will ascend the learning curve (even those of us with wrench experience do this) more quickly.

Regards
 

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Timothy Ma said:
I[snipped]
The filter for the cooling fan I have not cleaned myself and I don't think I'll be cleaning it as frequently as they sugguest. If I were commuting on dirt roads I think I would be. It lies behind the radiator and I think even more troublesome to get at. Wait until you have to do the tappets...lots of body panels have to come off. Oil changes are easy.
Tim

While I do not have the later Burg I would be suprised if they have have moved the cooling fan filter. The Cooling fan filter I refer to is the one that filters the air which is forced over the transmission belt and pulleys. I think it is in a similar place on the 650 too! It is easy to do and well worth doing until you develop experience of how quickly it chokes in your environment.

In my owners manual it is on page 39 (may be different in yours).

As far as I am aware there is no filter on the radiator fan (the radiator does that!).

Regards
 

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Bikinbuddy, I got my 400 manual from Oneida Suzuki. It isn't perfect -- some of the exploded views could really be better -- but it's way, WAAY better than what comes with the Burgie.

--Chris
 

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I have a 04 burgman 400, the cooling fan filter is on the left side (when you are sitting on the bike)under that big black cover, it is the round sponge type and it is yellow/dark grey edges.
I try cleaning it by hand but it still looks pretty dirty.
Maybe I'll just buy a new one, they shouldn't be too expensive.
I know the air filter is around $20.00 (cdn) so the cooling fan filter should be less.
 

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They should clean up easy - I did mine in hot washing up liquid solution.

A new one is around is the equivalent of $15(US) including taxes here in the UK so you should be able to pick one up for around $10(US)!! :wink:

Buying new is not really an option on a 2000mile service item.
 

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Hey thanks Norm,

I thought there was a filter behind the radiator just before the electric fan?? You are correct though because I guess the filter for the belt drive filters the air that "cools" the belt. I have cleaned this. Easy to do.
 

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When you finish washing it by hand, does it look like new again
or does it still look pretty dirty in the centre. I washed mine, and the centre still looks pretty black, that's why I was thinking about buying a new one every 1 or 2 years, since they are not that expensive anyway.


Is it ok to put the cooling fan filter in the washer under the
gentle cycle and let it air dry?
 

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philtag6000 said:
When you finish washing it by hand, does it look like new again
or does it still look pretty dirty in the centre. I washed mine, and the centre still looks pretty black, that's why I was thinking about buying a new one every 1 or 2 years, since they are not that expensive anyway.


Is it ok to put the cooling fan filter in the washer under the
gentle cycle and let it air dry?
When new these filters are black in colour (well mine was). If you wash by hand until the rinse water is clean then that is clean enough. I would not bother to stick in the washing machine or dish washer - hand wash is good enough.

I would reserve buying new for when it develops a defect like a tear or such like as a result of washing.

I have 2 though one ready to fit and then I clean the one I remove - but later, dry and put in a sealable food bag until I need it next. I will be buying a new engine air filter so that I can adopt the same policy. But there is no real need for this - it is just to save down time.

Regards
 

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Hi all,

Ive been lurking for months now and am ready to ask a question. How the hell do you get off the side panels to get to the filter? Ive taken off the bottom belly panel after much push-pinning but still couldnt get to the clutch filter. I need to take off one panel above the belly panel but finally gave up and put it back together. So how does one take off the side panels to get to the appropriate maintenance item? Even the body shop at the car dealership I work in cant figure it out! Ive ridden bikes for 30 years and now Im beginning to feel incompetent. Can someone explain how to get off one panel or do they all have to come off?

Btw Ive had "Burgman" for two months and 3000 miles and love it except for the poor ride quality over rough roads.

ekp
 

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Glad to have you no longer 'lurking in the shadows' ekp. :) I have yet to try removing the 'tupperware' on my 400... but I'm sure on of the other forum members here will be willing to help you out.
 

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EKP

First I will help you but it is not easy to describe this as pictures are needed. The process of removing the tupperware (and it is only one panel here) is easy but difficult to describe in text alone.

I will say this - get the Service Manual!

I have done this but did not take pictures, so will research the best way of presenting and disseminating this info.

I will post later today.

But I say this again - get the Service Manual.

Finally welcome to the forum :hello2:

PS: Did I mention the Service Manual is a good start in learning how to service and maintain your bike! :read2:

PPS: Set the rear shock to it its highest/hardest setting - that will improve your ride.
 

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EKP

I have posted the method of gaining access to the cooling fan filter in the photo gallery.

I have created 2 sub folders:

1. Left Side Leg Shield (Removal).
2. Cooling Fan Filter

I will put some explanatory text in later, its getting late here and I'm beat!
But it is fairly straightforward with the pics alone.

http://burgmanusa.com/gallery/NormanB
 

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Thank you very much NormanB for the excellent pics and explaination on this procedure. I wouldve been hesistant to pull off floor pads for fear of breaking something. This is far more complicated than I couldve imagined. Strongly considering a service manual for future maintainence procedures and such. I can now forge ahead with confidence.

NormanB, I have ny rear shock set at 3 as the stiffer settings seem to hurt as much as softer settings, only no centerstand touch and grind in hard cornering :).

The reason for previous lurking was simply due to the fact that I have limited allowance of time on my internet plan and havent had any questions that werent already answered by someone else. This forum is really great and far more interesting than the Super Sherpa forum I frequented when I owned that bike.

Thanks again for the info and friendship this forum offers. I will be back for future comments and questions.

ekp
 

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Hey EKP

First you are welcome.

It is not complicated at all - you just need the inside info the manual (or ths forum) provides because it is **** well near impossible to figure how the tupperware oragami is achieved with the Mk 1 eyeball alone.

As I get time I will document the 400 maintenance procedures - if I remember to take the pics! :wink:
 
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