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Author Topic: Burgman 400 Key Chip?  (Read 9341 times)
gurock1
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« on: November 26, 2013, 05:09:16 AM »

My friend bought a 2003 Burgman 400 and it died shortly thereafter.  The ignition lock seemed to be jammed and not working.  He had it towed to a Suzuki dealer in Lake of the Ozarks who told him that the ignition had been rewired to work with a key that doesn't have a chip.  I know little about 400s and nothing about key chips for them.  Does anyone have any ideas?
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« Reply #1 on: November 26, 2013, 01:32:09 PM »

That doesn't make much sense if it has been running all a long.

Side stand switch?  Brake switches need replacing? Starter switch need replacing? (these are all under $10 parts)  New relay?

Can it be hot wired by laying a screwdriver over the relay and starting? If so that indicates a wiring issue.  Just have to find it.

The ignition part doesn't make sense to me but what do I know...
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Leo38
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« Reply #2 on: November 26, 2013, 04:23:37 PM »

Euro models have the Suzuki Advanced Immobilizer System (SAIS) with immobilizer chip in the ignition key.
North American model keys have only the tamper resistant magnetic cover magnets.

Euro key.
http://www.carmo.nl/index.php?main_page=product_info&cPath=4102_4108&products_id=1338&language=en
Note that the protusion containing the magnets in the key head is angled toward the 10 o'clock position
On a key with no SAIS, the protusion is straight up toward 12 o'clock.



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« Reply #3 on: November 26, 2013, 07:58:39 PM »

If it's not an SAIS (Euro) model, info on the the keys and their "shutter magnets" is in the following thread (at least for 2004 and up):
http://maxi-scoots.com/scoot/index.php?topic=5655.msg67295#msg67295  

I found a thread on Burgman USA which indicates there was a recall on 2003 and some 2004 models' ignition switch, but the reference therein was a bad link.  I'll keep looking as time allows.  It apparently required taking off the back (contact) end of the switch and replacing it.  Maybe someone had the problem on this scoot and tried to fix it themselves.  Perhaps the dealer needs to check old recalls.
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« Reply #4 on: November 26, 2013, 08:31:23 PM »

The ignition switch recall may have nothing to do with this problem but it's a recall that should be addressed regardless.  I don't know the 2003 version but I'd not be surprised to find that the dealer doesn't know what the real problem is.  Sadly, it's rare to find a motorcycle dealer who knows much about scooters.

See http://www.suzukicycles.com/~/media/Recalls/AN400%20650IgnitionSwitch.ashx

9/7/2005 - 2003 and Certain 2004 AN400/650 Ignition Switch Terminal Case Replacement

RE: Recall Campaign for Ignition Switch of AN400 and AN650
Affected model and VIN range
AN400K3 32100005 Nov 11, 2002 to 32102014 June 2, 2003
AN400K4 42100001 Aug 5, 2003 to 42101092 Jan 9, 2004

From http://www.motorcyclistonline.com/motorcycle_recalls/49/2003/suzuki/an400_burgman/36695.html:
Recall ID #36695 - ELECTRICAL SYSTEM:IGNITION:SWITCH
Recall Date
AUG 29, 2005

Motorcycle Affected
2003 SUZUKI AN400 BURGMAN

Summary
ON CERTAIN SCOOTERS, IF THE IGNITION SWITCH IS NOT FULLY TURNED FROM THE 'OFF' TO THE 'ON' POSITION, THERE MAY BE UNSTABLE CONTACT BETWEEN THE IGNITION SWITCH CONTACTS. THIS CAN CAUSE ARCING IN THE IGNITION SWITCH.

Consequence
HEAT FROM THE ARCING CAN MELT THE INTERNAL SWITCH BASE PLATE. IF THE SCOOTER IS RIDDEN IN THIS CONDITION, THE IGNITION SWITCH MAY FAIL. IF THIS HAPPENS, THE ENGINE WILL STALL, THE LIGHTS WILL GO OUT, AND THE OPERATOR MAY BE UNABLE TO RESTART THE SCOOTER. THIS COULD RESULT IN A CRASH.

Remedy
DEALERS WILL REPLACE THE IGNITION SWITCH TERMINAL CASE ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 7, 2005. OWNERS MAY CONTACT SUZUKI AT 1-800-255-2550.

Potential Motorcycles Affected
5869

Notes
AMERICAN SUZUKI MOTOR CORP. 2082


Also an on-line version of the service manual for this bike popped up (may be of use to this rider in the future):
http://www.slideshare.net/guestcc7e80/suzuki-burgman-400-2003
Not much in there about the ignition switch but it physically looks pretty much like the more recent ones.
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Buffalo
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« Reply #5 on: November 27, 2013, 12:06:40 AM »

As others have said, there is no chip in the key on North American spec models.  \

The lock set is a long assembly.  The key tumbler is at the top of it where the shutter is.  The actual electrical switch is about 10 inches down at the bottom of it.  In between are the mechanism that pulls the cable to open the trunk and the mechanism that locks the fork.  If it is jammed I would expect it to be in either the tumbler, fork lock or trunk cable release.  The electrical switch is just plastic and not strong enough to jam anything.  

Bad news is Suzuki does not sell individual parts to fix the assembly except for the shutter.  You have to buy the whole thing and it is kind of pricey.  You can see what it looks like on this fiche.  Item number 13 is the ignition switch assembly.  If you want all your locks to use the same key then you need item number 15 which includes the ignition switch, fuel cap, and glove box lock.   http://www.partshark.com/fiche_section_detail.asp?section=300331&category=Scooters&make=SUZUKI&year=2003&fveh=7244 

 
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Craig
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06 Burgman 400, 51,952 miles
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« Reply #6 on: November 27, 2013, 02:04:31 AM »

Here's what it looks like in the manual ...



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gurock1
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« Reply #7 on: November 27, 2013, 02:59:29 AM »

Thanks all!!  I will pass the info on to my internet illiterate friend.  He said that t he bike was with a Suzuki dealer in Lake of the Ozarks.
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