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1. AN400 15 4 06 2010 Issue No ervice Bulletin Subject CLUTCH JUDDER AND OR NOISE Applicable Model AN400K7 K8 Effective Engine or Frame No Reference SERVICE MANUAL 99500 34101 01E SUPPLEMENTARY SERVICE 99501 34170 01E CONDITION Clutch judder and or clutch shoe noise at road speeds of 20 to 40 KPH when accelerating from a stop under certain riding conditions repeated clutch used during daily stop and go commuting in heavy traffic This condition does not affect scooters that are used on highways or city streets with light traffic conditions CAUSE Excessive dust entry into CVT chamber area CORRECTION Cleaning the cooling fan filter at the prescribed 3 000 km maintenance interval and at the same time cleaning the associated CVT parts according to the following procedure will help prevent clutch judder and or clutch shoe noise CLEANING PROCEDURE 1 Disassemble the CVT according to the procedure described in the 2007 AN400 Service Manual Refer to section 5A and the 2009 Supplement Clean the inside of the CVT chamber with compressed alr 2 Clean the cooling fan filter with compressed air Way of Life SUZUKI SUZUKI AUSTRALIA PTY LIMITED A C N 001 828 164 DEALER CIRCULATION Dealer Service Service Workshop Workshop Workshop Principal PANE DEpI pales NNG Administration Technician 3 Using compressed air clean the inside of the drive pulley including the gaps between the fins 4
2. Apply contact cleaner to a cloth and clean the sliding surfaces of the drive pulley 5 Clean the plate using compressed air If necessary clean with contact cleaner 6 Clean the dampers with compressed air If necessary clean with contact cleaner Reassemble the removable drive assembly according to Service Manual procedure 8 Clean the fixed drive pulley using compressed air 9 Clean the clutch side driven face pulley using compressed air 10 Clean the engine side driven face using compressed air 11 Clean the clutch shoe using compressed air Ensure that the shoe friction material is completely clean 12 Clean the clutch housing with compressed air If necessary apply contact cleaner to a cloth and clean the clutch housing 13 Clean all cogs on the belt with compressed air 14 Apply contact cleaner to the cloth and clean the drive pulley face 15 Apply contact cleaner to a cloth and clean the driven pulley faces Reassemble the CVT according to the procedure described in the 2007 AN400 Service Manual Refer to section 5A of both the Service Manual and the K9 Ssupplement on Suzukinet CVT AIR DUCT PARTS INSTALLATION On a customer complaint basis only of clutch judder and or shoe noise even after cleaning the dust from the CVT chamber and filter install one of each of the AN4O0AK9 type CVT Air Duct parts which are listed below When installing these parts follow the procedures described in th
3. e 2007 AN400 Service Manual Refer to section 5A and the 2009 Supplement If necessary clean all CVT parts again according to this Service Bulletin _ Part Number Description 3 17851 05H10 Hose 4 11380 05H40 5 11382 05430 6 11371 05H20 11486 05H00 8 11489 05H00 9 1 11487 05100 lamp Cushi Cushi 1488 05HO00 Cushi Cushi Cushi i CLUTCH SHOE AND HOUSING INSTALLATION On a customer complaint basis only of clutch judder and or shoe noise even after cleaning the dust from the CVT chamber and installing the late type Air Duct parts install the AN4OOAK9 type Clutch Housing 21220 05H20 and Clutch Shoe Assy 21501 05H20 When installing these parts follow the procedures Described in the 2007 AN400 Service Manual Refer to section 5A If necessary clean all CVT parts again according to this Service Bulletin il Clutch shoe assy eC La 21501 05H20 iF am ri a z Ti a i Fa j Clutch housing lt lt tt AAN 21220 05H20 WARRANTY CLAIM NOTE CLEANING THE COOLING FAN FILTER AND ASSOCIATED CVT PARTS IS MAINTENANCE WHICH IS NOT WARRANTABLE Should you need further clarification on this matter please contact SAPL service department CVT Air Duct Parts Installation Clutch Shoe amp Housing Installation Detailed Failure Clutch judder noise Install CVT Air Detailed Failure Clutch judder noise Install Clutch Information Duct Parts per Bulletin 09 06 I
4. nformation Shoe and Housing per Bulletin 09 06 Labour Operation GA9999 Labour Operation GA9999 wows QO Causal Part No 11383 05H40 Causal Part No 212270 05H20 Complaint Code 26 Complaint Code Defect Code Defect Code Replaced Parts Part numbers you replaced Replaced Parts 21501 05H20 oy Sdwa a Complaint Code

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