![Suzuki BURGMAN AN650 (2003) [315/463] Inspection and disassembly](/img/pdf.png)
Suzuki BURGMAN AN650 (2003) [315/463] Inspection and disassembly
![Suzuki BURGMAN AN650 (2003) [315/463] Inspection and disassembly](/views2/1121328/page315/bg13b.png)
Содержание
- 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
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CHAS INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities Handlebars distriction Race wear and brinelling Bearing wear or damage Abnormal bearing noise Distortion of the steering stem If any abnormal points are found replace defective parts with the new ones Remove the steering stem lower bearing and dust seal using a chisel CAUTION ________ __________________________________ The removed bearing inner race and dust seal must be replaced with the new ones Drive out the steering stem upper and lower bearing races using the special tools 09941 54911 Bearing outer race remover 09941 74911 Steering bearing installer REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem in the reverse order of removal and disassembly Pay attention to the following points BEARING RACES Press in the upper and lower outer races using the special tool 09941 34513 Steering outer race installer BEARINGS Press in the lower bearing and dust seal using the special tool 09941 18011 Steering bearing installer
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