2003-2009 Suzuki An650 Burgman 650 Service & Repair Manual

© COPYRIGHT SUZUKI MOTOR CORPORATION 2003 GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 DRIVE TRAIN 4 CVT 5 FI SYSTEM/ CVT SYSTEM 6 FUEL SYSTEM AND THROTTLE BODY 7 COOLING AND LUBRICATION SYSTEM 8 CHASSIS 9 ELECTRICAL SYSTEM 10 SERVICING INFORMATION 11 EMISSION CONTROL INFORMATION 12 FOREWORD This manual contains an introductory description on tion/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle bet- ter so that you can assure your customers of fast and reliable service. * This manual has been prepared on the basis of the latest specifications at the time of publi- cation. If modifications have been made since then, differences may exist between the con- tent of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcy- cles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger. the SUZUKI AN650/A and procedures for its inspec- 99500-36116-03E PartShark.com 877-999-5686

PartShark.com 877-999-5686

SUPPLEMENTS AN650K4 (’04-MODEL) 13 14 15 16 17 AN650/AK5 (’05-MODEL) AN650/AK6 (’06-MODEL) AN650/AK7 (’07 -MODEL) 18 AN650/AK9 (’09-MODEL) AN650/AK8 (’08-MODEL) 19 WIRING DIAGRAM PartShark.com 877-999-5686

HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on the first page of each section to help you find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel Brake disc Coller Dust seal Bearing Front tire Front wheel Spacer Tire valve Disc bolt Front axle ITEM N·m kgf-m lb-ft 23 2.3 16.5 65 6.5 47.0 FWD PartShark.com 877-999-5686

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. Use engine coolant. Apply oil. Use engine oil unless other- wise specified. Use fork oil. 99000-99044-10G Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply or use brake fluid. Apply SUZUKI SUPER GREASE “A”. 99000-25030 Measure in voltage range. Apply SUZUKI MOLY PASTE. 99000-25140 Measure in current range. Apply SUZUKI BOND “1207B” 99104-31140 (USA) Measure in resistance range. Apply SUZUKI BOND “1215”. 99000-31110 (Except USA) Measure in diode test range. Apply SUZUKI BOND “1216B”. 99000-31230 Measure in continuity test range. Apply THREAD LOCK SUPER “1303”. 99000-32030 Use special tool. Apply THREAD LOCK “1342”. 99000-32050 Indication of service data. Apply THREAD LOCK SUPER “1360”. 99000-32130 1216B PartShark.com 877-999-5686

ABBREVIATIONS USED IN THIS MANUAL A ABDC : After Bottom Dead Center AC : Alternating Current ACL : Air Cleaner, Air Cleaner Box API : American Petroleum Institute ATDC : After Top Dead Center ATM Pressure: Atmospheric Pressure Atmospheric Pressure Sensor (APS) A/F : Air Fuel Mixture B BBDC : Before Bottom Dead Center BTDC : Before Top Dead Center B+ : Battery Positive Voltage C CKP Sensor : Crankshaft Position Sensor (CKPS) CKT : Circuit CLP Switch : Clutch Lever Position Switch (Clutch Switch) CMP Sensor : Camshaft Position Sensor (CMPS) CO : Carbon Monoxide CPU : Central Processing Unit CVT Control Unit : Continuously Variable Transmission Control Unit (TCU) D DC : Direct Current DMC : Dealer Mode Coupler DOHC : Double Over Head Camshaft DRL : Daytime Running Light DTC : Diagnostic Trouble Code Malfunction Code E ECM : Engine Control Module Engine Control Unit (ECU) (FI Control Unit) ECT Sensor : Engine Coolant Temperature Sensor (ECTS), Water Temp. Sensor (WTS) EVAP : Evaporative Emission EVAP Canister : Evaporative Emission Canister (Canister) F FI : Fuel Injection, Fuel Injector FP : Fuel Pump FPR : Fuel Pressure Regulator FP Relay : Fuel Pump Relay FTPC Valve : Fuel Tank Pressure Control Valve (TPC Valve) G GEN : Generator GND : Ground GP Switch : Gear Position Switch H HC : Hydrocarbons HO2S : Heated Oxygen Sensor I IAC Valve : Idle Air Control Valve IAP Sensor : Intake Air Pressure Sensor (IAPS) IAT Sensor : Intake Air Temperature Sensor (IATS) IG : Ignition L LCD : Liquid Crystal Display LED : Light Emitting Diode (Malfunction Indicator Lamp) LH : Left Hand PartShark.com 877-999-5686

M MAL-Code : Malfunction Code (Diagnostic Code) Max : Maximum MIL : Malfunction Indicator Lamp (LED) Min : Minimum N NOx : Nitrogen Oxides O OHC : Over Head Camshaft OLS : Oil Level Switch OPS : Oil Pressure Switch P PCV : Positive Crankcase Ventilation (Crankcase Breather) R RH : Right Hand ROM : Read Only Memory S SAE : Society of Automotive Engineers T TO Sensor : Tip Over Sensor (TOS) TP Sensor : Throttle Position Sensor (TPS) PartShark.com 877-999-5686

SAE-TO-FORMER SUZUKI TERM This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION A Air Cleaner ACL Air Cleaner, Air Cleaner Box B Barometric Pressure BARO Barometric Pressure, Atmospheric Pressure (APS, AP Sensor) Battery Positive Voltage B+ Battery Voltage, +B C Camshaft Position Sensor CMP Sensor Camshaft Position Sensor (CMPS) Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS), Crank Angle D Data Link Connector DLC Dealer Mode Coupler Diagnostic Test Mode DTM –––– Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code E Electronic Ignition El –––– Engine Control Module ECM Engine Control Module (ECM) Fl Control Unit, Engine Control Unit (ECU) Engine Coolant Level ECL Coolant Level Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Tem- perature Water Temperature Engine Speed RPM Engine Speed (RPM) Evaporative Emission EVAP Evaporative Emission Evaporative Emission Canister EVAP Canister –––– (Canister) Exhaust Control System EXCS EXC System (EXCS) Exhaust Control Valve EXCV EXC Valve (EXCV) Exhaust Control Valve Actuator EXCVA EXCV Actuator (EXCVA) Purge Valve Purge Valve Purge Valve (SP Valve) F Fan Control FC –––– Fuel Level Sensor –––– Fuel Level Sensor, Fuel Level Gauge Fuel Pump FP Fuel Pump (FP) PartShark.com 877-999-5686

SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION G Generator GEN Generator Ground GND Ground (GND, GRD) I Idle Air Control Valve IAC Valve IAC Valve (IACV) Idle Speed Control ISC –––– Ignition Control IC Electronic Spark Advance (ESA) Ignition Control Module ICM –––– Intake Air Temperature IAT Intake Air Temperature (IAT), Air Tempera- ture M Malfunction Indicator Lamp MIL LED Lamp Malfunction Indicator Lamp (MIL) Manifold Absolute Pressure MAP Intake Air Pressure, Intake Vacuum Mass Air Flow MAF Air Flow O On-Board Diagnostic OBD Self-Diagnosis Function Diagnostic Open Loop OL –––– P Programmable Read Only Memory PROM –––– Pulsed Secondary Air lnjection PAIR Pulse Air Control (PAIR) R Random Access Memory RAM –––– Read Only Memory ROM ROM S Secondary Air Injection AIR –––– Secondary Throttle Control Sys- tem STCS STC System (STCS) Secondary Throttle Valve STV ST Valve (STV) Secondary Throttle Valve Actuator STVA STV Actuator (STVA) T Tank Pressure Control Valve TPC Valve TPC Valve (TPCV) Throttle Body TB Throttle Body (TB) Throttle Body Fuel Injection TBI Throttle Body Fuel Injection (TBI) Throttle Position Sensor TP Sensor TP Sensor (TPS) Transmission Control Module TCM CVT Control Unit (TCU) PartShark.com 877-999-5686

WIRE COLOR B : Black G : Green P : Pink Bl : Blue Gr : Gray R : Red Br : Brown Lbl : Light blue V : Violet Dg : Dark green Lg : Light green W : White Dgr : Dark gray O : Orange Y : Yellow B/Bl : Black with Blue tracer B/G : Black with Green tracer B/R : Black with Red tracer B/Y : Black with Yellow tracer Bl/G : Blue with Green tracer Bl/W : Blue with White tracer Br/B : Brown with Black tracer G/B : Green with Black tracer G/R : Green with Red tracer G/Y : Green with Yellow tracer Gr/R : Gray with Red tracer Gr/Y : Gray with Yellow tracer Lg/Y : Light green with Yellow tracer O/Bl : Orange with Blue tracer O/R : Orange with Red tracer O/Y : Orange with Yellow tracer P/W : Pink with White tracer R/Bl : Red with Blue tracer R/W : Red with White tracer W/B : White with Black tracer W/G : White with Green tracer W/Y : White with Yellow tracer Y/Bl : Yellow with Blue tracer Y/R : Yellow with Red tracer B/Br : Black with Brown tracer B/O : Black with Orange tracer B/W : Black with White tracer Bl/B : Blue with Black tracer Bl/R : Blue with Red tracer Bl/Y : Blue with Yellow tracer Br/W : Brown with White tracer G/Bl : Green with Blue tracer G/W : Green with White tracer Gr/B : Gray with Black tracer Gr/W : Gray with White tracer Lg/B : Light green with Black tracer O/B : Orange with Black tracer O/G : Orange with Green tracer O/W : Orange with White tracer P/B : Pink with Black tracer R/B : Red with Black tracer R/G : Red with Green tracer R/Y : Red with Yellow tracer W/Bl : White with Blue tracer W/R : White with Red tracer Y/B : Yellow with Black tracer Y/G : Yellow with Green tracer Y/W : Yellow with White tracer SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION V Voltage Regulator VR Voltage Regulator Volume Air Flow VAF Air Flow PartShark.com 877-999-5686

2003-2009 Suzuki An650 Burgman 650 Service & Repair Manual

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