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Suzuki Manuals
Motorcycle
AN650K3 2002
Service manual
Suzuki AN650K3 2002 Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
General Information 1
Table of Contents
Warning/ Caution/ Note
General Precautions
Suzuki An650K3 ('03-Model)
Serial Number Location
Fuel, Oil and Engine Coolant Recommendation
Fuel (for Usa and Canada)
Fuel (for Other Countries)
Anti-Freeze/Engine Coolant
Water for Mixing
Engine Coolant
Brake Fluid
Front Fork Oil
Final Gear Oil
Engine Oil and Transmission Oil (for Other Countries)
Engine Oil and Transmission Oil (for Usa)
Liquid Amount of Water/Engine Coolant
BREAK-Ln PROCEDURES
Cylinder Identification
Information Labels
Specifications
Electrical
Country and Area Codes
Periodic Maintenance Chart
Periodic Maintenance Schedule
Lubrication Points
Air Cleaner
Maintenance and Tune-Up Procedures
Spark Plug
Tappet Clearance
Engine Oil and Oil Filter
Fuel Hose
Final Gear Oil
Transmission Oil
Cvt Filter
Engine Idle Speed
Throttle Cable Play
Pair (Air Supply) System
Throttle Valve Synchronization
Cooling System
Brake
Tire
Front Fork
Steering
Exhaust Pipe Bolt and Muffler Mounting Bolt
Rear Suspension
Chassis Bolt and Nut
Compression Pressure Check
Compression Test Procedure
Oil Pressure Check
Oil Pressure Test Procedure
Automatic Clutch Inspection
Clutch "Lock-Up" Inspection
Initial Engagement Inspection
Brake-Lock Inspection
Engine
Engine Components Removable with the Engine in Place
Engine Removal
Engine Removal and Remounting
Engine Remounting
Engine Disassembly
Cylinder Head Cover
Engine Component Inspection and Service
Camshaft
Cam Chain Guide
Cam Chain Tension Adjuster
Cam Chain Tensioner
Cylinder Head
Cylinder
Piston and Piston Ring
Clutch
Starter Clutch
Oil Pressure Regulator/Oil Sump Filter
Oil Pump
Starter Torque Limiter
Crank Balancer
Driveshaft
Conrod/Crankshaft
Oil Jet
Crankcase
Engine Reassembly
Drive Train
Construction
Drive Train
Removal and Disassembly
Inspection and Replacement
Reassembly and Remounting
Cvt Assembly Removal and Installation/Cvt Disassembly and Reassembly
Cvt Assembly Removal
Cvt Assembly Removal and Installation
Cvt Assembly Installation
Cvt Disassembly and Reassembly
Cvt Disassembly
Cvt Inspection
Cvt Primary Pulley Shims Adjustment
Cvt Reassembly
Fi System/ Cvt System
Electrical Parts
Precautions in Servicing
Electrical Circuit Inspection Procedure
Using Testers
Fi System Technical Features
Injection Time (Injection Volume)
Compensation of Injection Time (Volume)
Injection Stop Control
Fi System Parts Location
Fi System Wiring Diagram
Cvt System Technical Features
Cvt System Parts Location
Self-Diagnosis Function
User Mode
Dealer Mode
Tps Adjustment
Fail-Safe Function
Customer Complaint Analysis
Fi System/ Cvt System Troubleshooting
Self-Diagnosis Reset Procedure
Self-Diagnostic Procedures
Battery
Malfunction Code and Defective Condition
C11" Cmp Sensor Circuit Malfunction
C12" Ckp Sensor Circuit Malfunction
C13" Iap Sensor Circuit Malfunction
C14" Tp Sensor Circuit Malfunction
C15" Ect Sensor Circuit Malfunction
C16" Speed Sensor Circuit Malfunction
C21" Iat Sensor Circuit Malfunction
C22" Ap Sensor Circuit Malfunction
C23" to Sensor Circuit Malfunction
C24" or "C25" IGNITION SYSTEM MALFUNCTION
C32" or "C33" FUEL INJECTOR CIRCUIT MALFUNCTION
C40" Iac Valve Circuit Malfunction
C41" Fp Relay Circuit Malfunction
C42" Ig Switch Circuit Malfunction
C44" Ho2 Sensor (Ho2S) Circuit Malfunction (E-02, 19)
C50" Cvt Serial Communication Circuit Malfunction
C51" Cvt Motor Circuit Malfunction
C52" Cvt Pulley Position Sensor (Pps) Circuit Malfunction
C53" Cvt Speed Sensor Circuit Malfunction
C54" Cvt Secondary Pulley Revolution Sensor Circuit Malfunction
C55" Cvt Engine Revolution Signal Circuit Malfunction
C56" Cvt Throttle Position Signal Circuit Malfunction
C58" Cvt Reduction Ratio Disagreement
Sensors
Fuel System and Throttle Body
Fuel System
Fuel Tank Components
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Pressure Control (Ftpc) Valve Inspection
Fuel Pressure Inspection
Fuel Pump Inspection
Fuel Pump Relay Inspection
Fuel Pump Components
Fuel Pump/Fuel Level Gauge Removal and Disassembly
Fuel Level Gauge Inspection
Fuel Mesh Filter Inspection and Cleaning
Fuel Pump/Fuel Level Gauge Reassembly and Installation
Throttle Body
Throttle Body Components
Throttle Body Removal
Throttle Body Disassembly
Throttle Body Cleaning and Inspection
Iac Valve Inspection
Throttle Body Reassembly
Throttle Body Installation
Fuel Injector Inspection
Fuel Injector Installation
Fuel Injector Removal
Throttle Cable Adjustment
Tp Sensor Adjustment
Throttle Valve Synchronization
Cooling and Lubrication System
Cooling Circuit
Cooling System
Description
Oil Cooler
Engine Coolant
Cooling Circuit Inspection
Radiator and Hoses
Radiator Cap Inspection
Radiator Inspection
Radiator Hose Inspection
Radiator Removal
Radiator Remounting
Radiator Reservoir Tank
Cooling Fan
Inspection
Removal
Remounting
Cooling Fan Thermo-Switch
Main Fuse
Removal
Inspection
Installation
Engine Coolant Temperature Sensor
Removal
Inspection
Instalation
Inspection
Removal
Thermostat
Installation
Construction
Water Pump
Removal and Disassembly
Inspection
Reassembly and Installation
Lubrication System
Oil Cooler
Oil Filter
Oil Level Switch
Oil Pressure
Oil Pressure Regulator
Oil Pressure Switch
Oil Pump
Oil Return Pump
Oil Sump Filter
Engine Lubrication System Chart
Engine Lubrication System
Chassis
Construction
Exterior Parts
Removal
Remounting
Construction
Front Wheel
Removal
Inspection and Disassembly
Reassembly and Remounting
Construction
Front Fork
Removal and Disassembly
Inspection
Reassembly and Remounting
Construction
Steering and Handlebars
Removal
Inspection and Disassembly
Reassembly and Remounting
Steering Tension Adjustment
Construction
Rear Wheel
Removal
Inspection and Disassembly
Reassembly and Remounting
Construction
Rear Shock Absorber
Removal
Inspection
Remounting
Suspension Setting
Construction
Rear Swingarm
Removal
Inspection
Remounting
Construction
Front Brake
Brake Pad Replacement
Brake Fluid Replacement
Caliper Removal and Disassembly
Caliper Inspection
Caliper Reassembly and Remounting
Brake Disc Inspection
Master Cylinder Removal and Disassembly
Master Cylinder Inspection
Master Cylinder Reassembly and Remounting
Construction
Rear Brake
Brake Pad Replacement
Brake Fluid Replacement
Caliper Removal and Disassembly
Caliper Inspection
Caliper Reassembly and Remounting
Brake Disc Inspection
Master Cylinder Inspection
Master Cylinder Reassembly and Remounting
Master Cylinder Removal and Disassembly
Brake-Lock Adjustment
Brake-Lock Cable Replacement
Brake-Lock System
Inspection
Tire and Wheel
Tire Removal
Tire Installation
Valve Installation
Balancer Weight Installation
Electrical System
Cautions in Servicing
Clamps
Connectors
Couplers
Fuses
Semi-Conductor Equipped Parts
Battery
Connecting the Battery
Using the Multi Circuit Tester
Wiring Procedure
Location of Electrical Components
Charging System
Troubleshooting
Inspection
Starter System
Troubleshooting
Starter Motor Removal and Disassembly
Starter Motor Inspection
Starter Motor Reassembly
Starter Relay Inspection
Side-Stand/Ignition Interlock System Parts Inspection
Ignition System
Troubleshooting
Inspection
Combination Meter
Parts Names
Removal and Disassembly
Operating Procedure
Inspection
Headlight
Lamp
Brake Light/ Taillight, Turn Signal Light and License Light
Cooling Fan Motor Relay
Fuel Pump Relay
Ignition Switch Removal
Relays
Side-Stand Relay
Starter Relay
Switches
Turn Signal Light
Turn Signal Relay
Battery
Initial Charging
Specifications
Recharging Operation
Servicing
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Table of
Contents
Previous
Page
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Page
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2
3
4
5
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Chapters
General Information 1
8
Electrical
17
Engine
52
Drive Train
127
Cvt Assembly Removal and Installation/Cvt Disassembly and Reassembly
135
Fi System/ Cvt System
162
Fuel System and Throttle Body
220
Cooling and Lubrication System
244
Chassis
272
Electrical System
366
Servicing Information
405
Table of Contents
Troubleshooting
FI SYSTEM/ CVT SYSTEM TROUBLESHOOTING
183
CHARGING SYSTEM
371
STARTER SYSTEM
376
IGNITION SYSTEM
383
TROUBLESHOOTING
406
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