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BURGMAN AN650 (2003)
Инструкция по эксплуатации Страница: 1

Suzuki BURGMAN AN650 (2003) Инструкция по эксплуатации онлайн

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Service manual 3 1
Foreword 2
Fuel system and throttle body 2
Suzuki motor corporation 2
Component parts and work to be done 3
How to use this manual 3
To locate what you are looking for 3
Symbol 4
Abbreviations used in this manual 5
Wire color 7
General information 8
General precautions 9
Warning caution note 9
Fuel for other countries 11
Fuel for usa and canada 11
Fuel oil and engine coolant recommendation 11
Serial number location 11
Suzuki an650k3 03 model 11
Anti freeze engine coolant 12
Brake fluid 12
Engine coolant 12
Engine oil and transmission oil for other countries 12
Engine oil and transmission oil for usa 12
Final gear oil 12
Front fork oil 12
Water for mixing 12
Liquid amount of water engine coolant 13
Break in procedures 14
Cylinder identification 14
8 general information 15
Information labels 15
Chassis 16
Dimensions and dry mass 16
Drive train 16
Engine 16
Specifications 16
Capacities 17
Electrical 17
Country and area codes 18
Periodic maintenance 19
_________________ 2 2 19
Periodic maintenance chart 20
Periodic maintenance schedule 20
Lubrication points 21
Air cleaner 22
Maintenance and tune up procedures 22
Spark plug 24
Tappet clearance 25
Howto use this chart 29
Periodic maintenance 2 11 29
Shim size to be used 1 0 mm 29
Tappet shim no 12892 05c00 xxx œ 29
Tappet shim selection table intake 29
Tappet shim set 12800 05820 29
12 periodic maintenance 30
Shim size to be used 1 0 mm 30
Tappet shim no 12892 05c00 xxx 30
Tappet shim selection table exhaust 30
Tappet shim set 12800 05820 30
Engine oil and oil filter 31
Fuel hose 31
Final gear oil 33
Transmission oil 33
Cvt filter 34
Engine idle speed 36
Throttle cable play 36
Pair air supply system 37
Throttle valve synchronization 37
Cooling system 38
Cautio 39
_______ _____ _____________ ______ 39
Cautio 41
Cautio 42
Front fork 44
Steering 44
Exhaust pipe bolt and muffler mounting bolt 45
Rear suspension 45
Chassis bolt and nut 46
Compression pressure check 48
Compression test procedure 48
Oil pressure check 49
Oil pressure test procedure 49
Automatic clutch inspection 50
Cautio 50
Clutch lock up inspection 50
Initial engagement inspection 50
___________________________ _____ 50
Brake lock inspection 51
Engine 52
Center of engine 53
Engine components removable with the engine in place 53
Left side of engine 53
Right of engine 53
Engine removal 54
Engine removal and remounting 54
Engine remounting 61
Engine disassembly 63
Cautio 64
_______ __________ ______________ 64
Cylinder head cover 73
Engine component inspection and service 73
Camshaft 74
Cam chain guide 76
Cam chain tension adjuster 76
Cam chain tensioner 76
Cylinder head 77
Frosil 78
Cautio 80
Cautio 83
Cautio 84
Cylinder 85
Piston and piston ring 87
33530 clutch spring compressor 09924 84510 bearing installer set 89
38 engine 89
Clutch 89
Disassembly remove the circlip 1 with the special tools 89
Remove the clutch hub d and spacer 89
Inspection 94
Starter clutch 94
Cautio 95
Oil pressure regulator oil sump filter 95
Oil pump 95
Starter torque limiter 95
Crank balancer 96
Drive shaft 96
Conrod crankshaft 98
Cautio 105
Oil jet 106
Crankcase 107
Engine reassembly 110
Cautio 111
Cautio 120
Piston ring 120
Cylinder 121
Piston 121
Cylinder head 122
Position of camshafts and sprockets 124
Drive train 127
Construction 128
Drive train 128
Removal and disassembly 129
Inspection and replacement 130
Reassembly and remounting 133
Cvt assembly removal 136
Cvt assembly removal and installation 136
Cvt assembly installation 138
Cvt 5 5 139
Cvt disassembly and reassembly 139
Cvt disassembly 140
Cvt inspection 145
Cautio 147
Cautio 150
Cvt primary pulley shims adjustment 150
Cvt reassembly 153
Cautio 155
Fl system cvt system 162
Electrical parts 163
Precautions in servicing 163
Electrical circuit inspection procedure 166
Using testers 169
Fl system technical features 170
Injection time injection volume 170
Compensation of injection time volume 171
Injection stop control 171
Camshaft position sensor cmps 172
Cd speed sensor 172
Combination meter 172
Crankshaft position sensor ckps 172
Engine coolant temperature sensor ects 172
Fuel injector fl 172
Ignition coil ig coil 172
Pair control solenoid valve 172
System parts location 172
12 fl system 173
Cvtsystem 173
Cvt system technical features 175
Cvt system parts location 176
Self diagnosis function 179
User mode 179
Dealer mode 180
Tps adjustment 181
Fail safe function 182
Customer complaint analysis 183
Fl system cvt system troubleshooting 183
Self diagnosis reset procedure 185
Self diagnostic procedures 185
Malfunction code and defective condition 186
C11 cmp sensor circuit malfunction 188
C12 ckp sensor circuit malfunction 189
C13 iap sensor circuit malfunction 190
C14 tp sensor circuit malfunction 192
C15 ect sensor circuit malfunction 194
Cl 6 speed sensor circuit malfunction 195
C21 iat sensor circuit malfunction 197
Hl i ri i i ti i 197
I i i i i m 197
C22 ap sensor circuit malfunction 198
C23 to sensor circuit malfunction 200
C24 or c25 ignition system malfunction 201
C32 or c33 fuel injector circuit malfunction 201
C40 iac valve circuit malfunction 202
C41 fp relay circuit malfunction 202
C42 ig switch circuit malfunction 202
C44 h02 sensor ho2s circuit malfunction e 02 19 203
C50 cvt serial communication circuit malfunction 205
C51 cvt motor circuit malfunction 206
C52 cvt pulley position sensor pps circuit malfunction 208
C53 cvt speed sensor circuit malfunction 210
C54 cvt secondary pulley revolution sensor circuit mal function 212
C55 cvt engine revolution signal circuit malfunction 214
I i i i i i i i 214
I i i i i i i________ i 214
C56 cvt throttle position signal circuit malfunction 215
C58 cvt reduction ratio disagreement 216
Sensors 217
Fuel system and throttle body 220
2 fuel system and throttle body 221
Fuel system 221
Fuel tank components 221
Fuel tank removal 222
Fuel tank installation 223
Fuel tank pressure control ftpc valve inspection 223
Fuel pressure inspection 224
Fuel pump inspection 225
Fuel pump relay inspection 225
Fuel pump components 226
Fuel pump fuel level gauge removal and disassembly 226
Fuel level gauge inspection 229
Fuel mesh filter inspection and cleaning 229
Cautio 230
Fuel pump fuel level gauge reassembly and installation 230
14 fuel system and throttle body 233
Throttle body 233
Throttle body components 233
Throttle body removal 234
Cautio 235
_______________________________ 235
Throttle body disassembly 236
Cautio 237
________________ 237
Cautio 238
Throttle body cleaning and inspection 238
Cautio 239
Iac valve inspection 239
Throttle body reassembly 239
_________________________________ 239
Throttle body installation 241
Fuel injector inspection 242
Fuel injector installation 242
Fuel injector removal 242
Throttle cable adjustment 242
Tp sensor adjustment 242
Throttle valve synchronization 243
Cooling and lubrication system 244
Cooling circuit 245
Cooling system 245
Description 245
Oil cooler 245
Cautio 246
Engine coolant 246
_________________________ _______ 246
Cooling circuit inspection 247
Radiator and hoses 247
Radiator cap inspection 247
Radiator inspection 247
Radiator hose inspection 248
Radiator removal 249
Radiator remounting 250
Radiator reservoir tank 250
Cooling fan 251
Inspection 251
Removal 251
Remounting 252
Cooling fan thermo switch 253
Removal 253
Inspection 254
Installation 254
Coupler 3 255
Engine coolant temperature sensor 255
Removal 255
Remove the engine coolant temperature sensor 255
Remove the footboard e t9 18 disconnect the engine coolant temperature sensor lead wire 255
The following circuit diagram shows the electrical wiring for the thermometer the major components ar temperature sensor in contact with coolant and temperature indicator engine coolant temperature meter 255
Cautio 256
Inspection 256
Instalation 256
___________ ________ ____________ 256
Inspection 257
Removal 257
Thermostat 257
Installation 258
16 cooling and lubrication system 259
Construction ________________________ ______________ 259
Water pump 259
Removal and disassembly 260
Cautio 262
I ___________ _________ 262
Inspection 262
Reassembly and installation 264
Lubrication system 268
28 cooling and lubrication system 271
To a from a 271
Chassis 272
Construction 274
Exterior parts 274
6 chassis 278
Location of exterior components 278
Removal 278
Remove the seat lock remove the trunk box screws 293
Remove the trunk box 293
Remounting 295
Chassis 9 25 297
Construction 297
Front wheel 297
Item n m kgf m ib ft 297
Removal 298
Inspection and disassembly 299
Reassembly and remounting 301
Construction 304
Front fork 304
Item n m kgf m ib ft 304
Removal and disassembly 305
Inspection 307
Reassembly and remounting 308
Construction 312
Item n m kgf m ib ft 312
Mo chassis 312
Steering and handlebars 312
Removal 313
Inspection and disassembly 315
Reassembly and remounting 315
Steering tension adjustment 318
Chassis 9 47 319
Construction 319
Item nm kgf m ib ft 319
Rear wheel 319
Cautio 320
Removal 320
Inspection and disassembly 322
Cautio 323
______ __________ ____ 323
52 chassis 324
Reassemble and remount the rear wheel in the reverse order of removal and disassembly pay attention to 324
Reassembly and remounting 324
The following points 324
Construction 329
Item n m kgf m ib ft 329
Place the motorcycle on the center stand remove the rear shock absorber mounting nut d 329
Rear shock absorber 329
Removal 329
Remove the rear shock absorber mounting bolt remove the rear shock absorber 329
Cautio 330
Inspection 330
Remounting 330
Suspension setting 330
______________ __________________ 330
Construction 331
Place the motorcycle on the center stand remove the exhaust muffler c7 3 7 remove the rear wheel dz 9 48 remove the rear brake hose guide 3 331
Rear swingarm 331
Removal 331
Inspection 332
Remounting 333
Caution___________________________________________________________ __________________ 335
Construction 335
Different types of fluid such as silicone based or petroleum based 335
Do not use any brake fluid taken from old used or unsealed containers never reuse brake 335
Fluid left over from the last servicing or stored for long periods 335
Front brake 335
Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will damage then severly 335
Pads and clean the disc with high quality brake cleaner or neutral detergent 335
This brake system is filled with an ethylene glycol based dot 4 brake fluid do not use mix 335
Warning 335
When storing the brake fluid seal the container completely and keep away from children when replenishing brake fluid take care not to get dust into fluid when washing brake components use fresh brake fluid never use cleaning solvent a contaminated brake disc or brake pad reduces braking performance discard contaminated 335
Brake pad replacement 336
Brake fluid replacement 337
Caliper removal and disassembly 338
Cautio 338
________ _________________ ______ 338
Caliper inspection 339
Caliper reassembly and remounting 340
Cautio 340
_________________________________ 340
Brake disc inspection 342
Cautio 342
Master cylinder removal and disas sembly 342
________________________ 342
Cautio 343
Master cylinder inspection 343
Master cylinder reassembly and remounting 343
__________ ________ _____________ 343
And clean the disc with high quality brake cleaner or neutral detergent 345
Caution _______________________________________________________________________ 345
Construction 345
Do not use any brake fluid taken from old used or unsealed containers never reuse brake fluid 345
Ferent types of fluid such as silicone based or petroleum based 345
Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will damage them severly 345
Left over from the last servicing or stored for long periods 345
Rear brake 345
This brake system is filled with an ethylene glycol based dot 4 brake fluid do not use or mix dif 345
Warning 345
When storing the brake fluid seal the container completely and keep away from children when replenishing brake fluid take care not to get dust into fluid when washing brake components use fresh brake fluid never use cleaning solvent a contaminated brake disc or brake pad reduces braking performance discard contaminated pads 345
Brake pad replacement 346
Cautio 346
____________________ __________ 346
Brake fluid replacement 348
Caliper removal and disassembly 348
Cautio 348
_____________________________ 348
Cautio 349
_____________________ ___ 349
Caliper inspection 350
Cautio 350
______ __________________________ 350
Caliper reassembly and remounting 351
Cautio 353
__________ _______ 353
Brake disc inspection 355
Master cylinder inspection 355
Master cylinder reassembly and remounting 355
Master cylinder removal and disassembly 355
Brake lock adjustment 356
Brake lock cable replacement 357
Brake lock system 359
Inspection 363
Tire and wheel 363
Tire removal 363
Cautio 364
Tire installation 364
Valve installation 364
Balancer weight installation 365
Contents 366
Electrical system 366
Cautions in servicing 367
Clamps 367
Connectors 367
Couplers 367
Semi conductor equipped parts 367
Battery 368
Connecting the battery 368
Using the multi circuit tester 368
Wiring procedure 368
4 electrical system 369
Location of electrical components 369
Electrical system 10 5 370
Charging system 371
Inspection 373
Starter system 376
Troubleshooting 376
Starter motor removal and disassembly 377
Starter motor inspection 378
Starter motor reassembly 379
Starter relay inspection 380
Side stand ignit1on interlock system parts inspection 381
Ignition system 383
Troubleshooting 383
Inspection 385
Combination meter 388
Electrical system 10 23 388
Parts names 388
Removal and disassembly 388
Remove the combination meter r 9 22 disassembly the combination meter as shown 388
Operating procedure 389
Continue pushing on the select and reset buttons for two seconds 390
Desired interval with a step of 500 km 300 miles the minimum possible interval is 500 km 300 miles 390
Electrical system 10 25 390
Example of oil change indicator setting 390
Interval with a step of 500 km 300 miles the maximum possible interval is 6 000 km 3 600 miles 390
Note the preset interval can be adjusted after the odometer reading has exceeded 1 000 km 600 miles reset the indicator after engine oil replacement has been performed 390
Oil change counter will be reset to initial and the indicator blinks for three seconds 390
Oil change indicator the oil change indicator warns the driver of engine oil replacement timing the indicator comes on at initial 1 000 km 600 miles and the preset intervals thereafter the preset interval can be varied in the range between 500 km 300 miles to 6 000 km 3 600 miles with a step of 500 km 300 miles reset the indicator after changing engine oil to turn off the display 390
Push the resest button to increase the interval from the minimum of 500 km 300 miles to the desired 390
Push the select and reset buttons together for more than two seconds 390
To reset the oil change indicator 1 turn off the ignition switch 2 hold down the select and reset buttons together and turn the ignition switch to the on position 390
To vary the preset interval of oil change indicator 1 push the select and reset buttons together for two seconds until interval display comes on 2 push the select button to decrease the interval from the maximum of 6 000 km 3 600 miles to the 390
Inspection 391
Headlight 396
Brake light taillight turn signal light and license light 397
Cooling fan motor relay 399
Fuel pump relay 399
Ignition switch removal 399
Relays 399
Side stand relay 399
Starter relay 399
Switches 399
Turn signal relay 399
Inspection 400
____ о 401
Battery 402
Initial charging 402
Specifications 402
Cautio 403
_________________________________ 403
Recharging operation 404
Servicing 404
Servicing information 405
Fl system cvt system malfunction code and defective condition 406
Troubleshooting 406
Engine 408
Radiator cooling system 413
Chassis 414
Brakes 415
Electrical 416
Battery 417
14 servicing information ____________________________________________________ ________ 418
Wiring harness cable and hose routing 418
Wiring harness routing 418
Servicing information 11 15 419
16 servicing information 420
18 servicing information 422
Oo o c 422
Viewb secta a 422
Servicing information 11 19 423
Cd o c 424
O co m 424
View 0f b 424
View of a v 424
View of top 424
Fuel tank hose routing 426
K3l2225 5 426
Ä i __ 426
View a 427
View a 428
View b 428
Sect dd 429
Sect ff sect ee 429
View b view a 429
View g 429
Special tools 431
Note when ordering a special tool please confirm whether it is available or not 434
Engine 435
Tightening torque 435
Chassis 436
Tightening torque chart 437
Service data 438
Valve guide 438
Cylinder head 439
Piston ring 439
Oil pump 440
Fi cvt sensors 441
Injector fuel pump fuel pressure regulator 441
Electrical 442
Thermostat radiator fan doolant 442
Throttle body 442
Wattage 443
Brake wheel 444
Suspension 444
Emission control information 446
Emission control systems 447
Fuel injection system 447
Crankcase emission control system 448
Exhaust emission control system pair system 449
Noise emission control system 450
Pair air supply system inspection 451
Pair control solenoid valve 451
Pair reed valve 451
Pair air supply system hose routing 453
Cautio 454
Heated oxgen sensor ho2s inspection 454
_______________________________ 454
Wiring diagram e 02 19 455
An650l 458
Suzuki motor corporation 461

Suzuki BURGMAN AN650 (2003) Инструкция по эксплуатации онлайн

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