Suzuki AN650/A Supplementary Service Manual
Suzuki AN650/A Supplementary Service Manual

Suzuki AN650/A Supplementary Service Manual

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AN650 / A
USE THIS MANUAL WITH:
AN650 SERVICE MANUAL (99500-36113-01E)
9 9 5 0 1 - 3 6 1 6 0 - 0 1 E

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Summary of Contents for Suzuki AN650/A

  • Page 1 AN650 / A USE THIS MANUAL WITH: AN650 SERVICE MANUAL (99500-36113-01E) 9 9 5 0 1 - 3 6 1 6 0 - 0 1 E...
  • Page 2: Table Of Contents

    WIRING HARNESS, CABLE AND HOSE ROUTING ........33 WIRING HARNESS ROUTING ..............33 THROTTLE BODY INSTALLATION AND HOSE ROUTING ....34 SPECIAL TOOLS ....................35 TIGHTENING TORQUE CHART............... 35 SERVICE DATA (AN650K7) ................36 SERVICE DATA (AN650AK7)................45 WIRING DIAGRAM..................... 55 © COPYRIGHT SUZUKI MOTOR CORPORATION 2007...
  • Page 3: An650/Ak7 ('07-Model

    AN650/AK7 (’07-MODEL) AN650/AK7 (’07-MODEL) COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). MODEL CODE COUNTRY or AREA EFFECTIVE FRAME NO. E-02 U.K. JS1BU111200100524 – E-03 U.S.A. (Except for california) JS1BU111200 100001 – E-19 E.U. JS1BU111100114140 –...
  • Page 4: Specifications (An650K7)

    AN650/AK7 (’07-MODEL) SPECIFICATIONS (AN650K7) DIMENSIONS AND DRY MASS Overall length ..................2 260 mm (89.0 in) Overall width..................810 mm (31.9 in) Overall height ..................1 435 mm (56.5 in) Wheelbase ..................1 595 mm (62.8 in) Ground clearance ................130 mm ( 5.1 in) Seat height ..................
  • Page 5 AN650A/K7 (’07-MODEL) CAPACITIES Fuel tank, including reserve ............... 15.0 L (4.0/3.3 US/Imp gal) Engine oil, oil change ................. 2 600 ml (2.7/2.3 US/Imp qt) with filter change .............. 2 900 ml (3.1/2.6 US/Imp qt) overhaul................3 400 ml (3.6/3.0 US/Imp qt) Transmission oil, oil change ..............
  • Page 6: Specifications (An650Ak7)

    AN650/AK7 (’07-MODEL) SPECIFICATIONS (AN650AK7) DIMENSIONS AND DRY MASS Overall length ..................2 260 mm (89.0 in) Overall width..................810 mm (31.9 in) Overall height ..................1 435 mm (56.5 in) Wheelbase ..................1 595 mm (62.8 in) Ground clearance ................130 mm ( 5.1 in) Seat height ..................
  • Page 7 AN650A/K7 (’07-MODEL) CAPACITIES Fuel tank, including reserve ............... 15.0 L (4.0/3.3 US/Imp gal) Engine oil, oil change ................. 2 600 ml (2.7/2.3 US/Imp qt) with filter change .............. 2 900 ml (3.1/2.6 US/Imp qt) overhaul................3 400 ml (3.6/3.0 US/Imp qt) Transmission oil, oil change ..............
  • Page 8: Sds Check

    AN650/AK7 (’07-MODEL) SDS CHECK Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time.
  • Page 9 AN650A/K7 (’07-MODEL) Data at 3 000 r/min under no load Approx. 3 000 r/min Check the manifold absolute pressure. XX kPa Check the engine coolant temperature. XX ˚C Data of manifold absolute pressure operation at the time of cold starting Check the engine r/min.
  • Page 10 AN650/AK7 (’07-MODEL) Data of intake negative pressure during idling (100 °C) Check the manifold absolute pressure. XX kPa Check the engine coolant temperature. Approx. 100 ˚C Data of manifold absolute pressure operation at the time of hot starting Check the engine r/min. XXXX r/min Check the manifold absolute pressure.
  • Page 11 AN650A/K7 (’07-MODEL) Example of trouble Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in compar- ison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the pass of time and identify what problem is currently occurring.
  • Page 12: Fi System Wiring Diagram

    AN650/AK7 (’07-MODEL) FI SYSTEM WIRING DIAGRAM Fuel injector #1 Fuel injector #2 Combination Br/W O/Bl meter Fuel pump Gr/W Gr/B Ignition coil #2 Ignition coil #1 Crankshaft position sensor(CKPS) Camshaft position sensor (CMPS) W/Bl Y/Bl G/Bl Intake air pressure sensor (IAPS) Fuel pump relay PAIR control...
  • Page 13: Ecm/Pcm Terminal

    AN650A/K7 (’07-MODEL) ECM/PCM TERMINAL ECM TERMINAL CIRCUIT ← Ignition coil (IG2) ← Fuel injector (#1) ← Fuel injector (#2) ← Shift up switch (UP) ← Pulley position sensor (PPS) PTVC heater (PTC) EVAP system purge control solenoid valve (E-33 only) ←...
  • Page 14 AN650/AK7 (’07-MODEL) CIRCUIT ECM TERMINAL — — ← Battery (BATT) — — ← Ground (E1) ← CKP sensor (N-) ← CMP sensor (G+) ← HO2 sensor heater (OXH) ← Immobilizer (TXCK) (For E-02, 19, 24) ← Immobilizer (RXCK) (For E-02, 19, 24) Immobilizer LED (Meter) (For E-02, 19, 24) ←...
  • Page 15: Fail-Safe Function

    AN650A/K7 (’07-MODEL) FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY HO2 sensor Feedback compensation is inhibited.
  • Page 16: Malfunction Code And Defective Condition

    AN650/AK7 (’07-MODEL) MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– ISC valve ISC valve circuit open or shorted Although current is flowing though the to ground C40 (P0505) ISC valve motor, the current detection is not possible.
  • Page 17: C40" (P0505 Or P0506 And P0507) Isc Valve Circuit Malfunction

    AN650A/K7 (’07-MODEL) “C40” (P0505 or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Although current is flowing though the • ISC valve circuit open or shorted to ground (P0505) ISC valve motor, the current detection is • Power source circuit open not possible.
  • Page 18 AN650/AK7 (’07-MODEL) 4) Remove the front panel. (#AN650K3 9-8) 5) Disconnect the ISC valve coupler and ECM couplers. 6) Check the continuity between terminals A (B/Lg) and m, ter- minals B (P/W) and t, terminals C (G) and s, terminals D (W/B) and r.
  • Page 19 AN650A/K7 (’07-MODEL) ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Place the motorcycle on the center stand. 2) Pull the parking brake lever and make sure that the rear wheel is locked. 3) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 4) Check that the engine is running.
  • Page 20 AN650/AK7 (’07-MODEL) Check 2 1) Click the button 1 and decrease the “Spec” 2 to 1 050 rpm slowly. 2) Check that the “Desired idle speed” 3 is nearly equal to the “Spec” 2. At the same time, check that the number of steps 4 in the ISC valve position decreases NOTE: It takes a few seconds for “Desired idle speed”...
  • Page 21 AN650A/K7 (’07-MODEL) Check 4 1) Increase the “Spec” 1 to 1 500 rpm. 2) Check that the “Desired idle speed” 2 is approx. 1 500 rpm. 3) Check that the “Engine speed” 3 is close to 1 500 rpm. NOTE: Be careful not to increase the “Spec”...
  • Page 22: C41" (P2505) Ecm/Pcm Power Input Circuit Malfunction

    AN650/AK7 (’07-MODEL) “C41” (P2505) ECM/PCM POWER INPUT CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to the ECM, • Lead wire/coupler connection of ECM terminal to although the ignition switch is turned (P2505) fuel fuse • Fuel fuse •...
  • Page 23 AN650A/K7 (’07-MODEL) Is the voltage OK? • Fuel pump related circuit malfunction. • R/Bl wire open or shorted or poor terminal W connection. • Battery voltage to ECM (BATT) shorted to ground or open. • If the wire and connection are OK, intermittent trouble or faulty ECM.
  • Page 24: C44" (P0130/P0135) Ho2 Sensor (Ho2S) Circuit Malfunction

    AN650/AK7 (’07-MODEL) “C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input • HO2 sensor circuit open to ECM during engine operation and (P0130) running condition. (Sensor voltage < 1.0 V) In other than the above value, C44 (P0130) is indicated.
  • Page 25 AN650A/K7 (’07-MODEL) 7) Remove the front panel. (#AN650K3 9-8) 8) Disconnect the ECM coupler. 9) Check the continuity between B/G wire A and terminal e. 10)Also, check the continuity between B/Br wire B and terminal $ HO2S lead wire continuity: Continuity (%) ! 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set ECM coupler (Harness side)
  • Page 26 AN650/AK7 (’07-MODEL) Is the voltage OK? ECM coupler (Harness side) • B/G wire or B/Br wire open or shorted to ground, or poor e or n connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM. •...
  • Page 27 AN650A/K7 (’07-MODEL) Step 2 (When indicating C44/P0135:) 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probe to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between B (O/W) wire and ground. 4) If the tester voltage indicates the battery voltage, it is good condition.
  • Page 28: C49" (P1656) Pair Control Solenoid Valve Circuit Malfunction

    AN650/AK7 (’07-MODEL) “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short ECM. • PAIR control solenoid valve malfunction • ECM malfunction Engine stop Side-stand Ignition...
  • Page 29 AN650A/K7 (’07-MODEL) Step 2 1) Turn the ignition switch ON. 2) Measure the voltage between O/W wire and ground. $ PAIR control solenoid valve voltage:Battery voltage (+ O/W – - Ground) ! 09900-25008: Multi-circuit tester set ' Tester knob indication: Voltage (() Is the voltage OK? ECM coupler (Harness side) •...
  • Page 30: Isc Valve Removal

    AN650/AK7 (’07-MODEL) ISC VALVE REMOVAL • Remove the front box. (#AN650K3 9-18) • Disconnect the ISC valve coupler 1. " Be careful not to disconnect the ISC valve coupler at least 5 seconds after ignition switch is turned OFF. If the ECM coupler or ISC valve coupler is discon- nected within 5 seconds after ignition switch is turned OFF, there is a possibility of an unusual valve position being written in ECM and causing an error of ISC valve...
  • Page 31: Isc Valve Pre-Set

    AN650A/K7 (’07-MODEL) ISC VALVE PRE-SET When removing or replacing the ISC valve, set the ISC valve in the following procedures: 1) Turn the ignition switch ON. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 3) Click “Active control”.
  • Page 32: Throttle Valve Synchronization

    AN650/AK7 (’07-MODEL) THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization between two cylinders. Step 1 • Remove the front box. (#AN650K3 9-18) • Disconnect the respective vacuum hoses 1 from vacuum nip- ples. • Disconnect the IAP sensor coupler 2. •...
  • Page 33 AN650A/K7 (’07-MODEL) • Click “Active control”. • Click “ISC air volume control” 1. • Click “ON” 2 to fix the ISC air volume of two cylinders. NOTE: When making this synchronization, be sure that the water tem- perature is within 80 – 100 °C (176 – 212 °F). A Engine speed: Approx.
  • Page 34: Wiring Harness, Cable And Hose Routing

    AN650/AK7 (’07-MODEL) WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Clamp CVT control unit Wiring harness Position light (LH) Throttle cable Position light (RH) Headlight (LH) Wiring harness To ECM/PCM Pass the headlight harness inside the wiring harness. Headlight (RH) To headlights Front turn signal light (LH) Front turn signal light (RH)
  • Page 35: Throttle Body Installation And Hose Routing

    AN650A/K7 (’07-MODEL) THROTTLE BODY INSTALLATION AND HOSE ROUTING...
  • Page 36: Special Tools

    AN650/AK7 (’07-MODEL) SPECIAL TOOLS 09900-25008 09900-25009 Multi-circuit tester Needle pointed 09904-41010 09930-82720 99565-01010-010 probe set SDS set tool Mode select switch CD-ROM Ver. 10 NOTE: When order the special tool, please confirm whether it is available or not. TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4”...
  • Page 37: Service Data (An650K7)

    AN650A/K7 (’07-MODEL) SERVICE DATA (AN650K7) VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. 29.5 — (1.16) 25.0 — (0.98) Tappet clearance (when cold) 0.10 – 0.20 — (0.0039 – 0.0079) 0.20 – 0.30 — (0.0079 – 0.0118) Valve guide to valve stem 0.010 –...
  • Page 38 AN650/AK7 (’07-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.38 – 35.43 35.10 (1.393 – 1.395) (1.382) 33.98 – 34.03 33.70 (1.338 – 1.340) (1.327) Camshaft journal oil clearance 0.032– 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 39: Oil Pump

    AN650A/K7 (’07-MODEL) ITEM STANDARD LIMIT Piston ring thickness 0.97 – 0.99 — (0.038 – 0.039) 0.97 – 0.99 — (0.038 – 0.039) Piston pin bore 16.002 – 16.008 16.030 (0.6300 – 0.6302) (0.6311) Piston pin O.D. 15.995 – 16.000 15.980 (0.6297 –...
  • Page 40 AN650/AK7 (’07-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Drive plate thickness 2.92 – 3.08 2.62 (0.115 – 0.121) (0.103) Drive plate claw width 13.85 – 13.96 13.05 (0.545 – 0.550) (0.514) Driven plate No. 2 thickness 2.42 – 2.58 2.27 (0.095 –...
  • Page 41: Throttle Body

    AN650A/K7 (’07-MODEL) ITEM SPECIFICATION NOTE TO sensor resistance 19.1 – 19.7 kΩ +: Gr/R TO sensor output voltage Normal 0.4 – 1.4 V -: B/Br +: Gr/R Leaning 3.7 – 4.4 V -: B/Br #1 +: W/Bl Ignition coil primary peak voltage -: Ground More than 80 V (When cranking) #2 +: B/Y...
  • Page 42 AN650/AK7 (’07-MODEL) ITEM STANDARD/SPECIFICATION LIMIT Engine coolant type Use an anti-freeze/coolant compatible with alumi- num radiator, mixed with distilled water only, at the — ratio of 50:50. Engine coolant including reserve Reverse Approx. 250 ml — tank side (0.264/0.220 US/Imp qt) Approx.
  • Page 43 AN650A/K7 (’07-MODEL) WATTAGE Unit: W STD/SPEC. ITEM E-02, 19 E-03, 24, 28, 33 Headlight 60 + 55 60 × 2 55 × 2 Parking or position light 5 × 2 ← Brake light/Taillight 21/5 × 2 ← Turn signal light 21 ×...
  • Page 44 Front fork stroke — (4.3) Front fork spring free length — (13.4) Front fork oil type SUZUKI FORK OIL G-10 (#10) or — an equivalent fork oil Front fork oil capacity (each leg) 458 ml — Front fork oil level —...
  • Page 45 AN650A/K7 (’07-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.
  • Page 46: Service Data (An650Ak7)

    AN650/AK7 (’07-MODEL) SERVICE DATA (AN650AK7) VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. 29.5 — (1.16) 25.0 — (0.98) Tappet clearance (when cold) 0.10 – 0.20 — (0.0039 – 0.0079) 0.20 – 0.30 — (0.0079 – 0.0118) Valve guide to valve stem 0.010 –...
  • Page 47 AN650A/K7 (’07-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.38 – 35.43 35.10 (1.393 – 1.395) (1.382) 33.98 – 34.03 33.70 (1.338 – 1.340) (1.327) Camshaft journal oil clearance 0.032– 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 48 AN650/AK7 (’07-MODEL) ITEM STANDARD LIMIT Piston ring thickness 0.97 – 0.99 — (0.038 – 0.039) 0.97 – 0.99 — (0.038 – 0.039) Piston pin bore 16.002 – 16.008 16.030 (0.6300 – 0.6302) (0.6311) Piston pin O.D. 15.995 – 16.000 15.980 (0.6297 –...
  • Page 49 AN650A/K7 (’07-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Drive plate thickness 2.92 – 3.08 2.62 (0.115 – 0.121) (0.103) Drive plate claw width 13.85 – 13.96 13.05 (0.545 – 0.550) (0.514) Driven plate No. 2 thickness 2.42 – 2.58 2.27 (0.095 –...
  • Page 50 AN650/AK7 (’07-MODEL) ITEM SPECIFICATION NOTE TO sensor resistance 19.1 – 19.7 kΩ +: Gr/R TO sensor output voltage Normal 0.4 – 1.4 V -: B/Br +: Gr/R Leaning 3.7 – 4.4 V -: B/Br #1 +: W/Bl Ignition coil primary peak voltage -: Ground More than 80 V (When cranking) #2 +: B/Y...
  • Page 51 AN650A/K7 (’07-MODEL) ITEM STANDARD/SPECIFICATION LIMIT Engine coolant type Use an anti-freeze/coolant compatible with alumi- num radiator, mixed with distilled water only, at the — ratio of 50:50. Engine coolant including reserve Reverse Approx. 250 ml — tank side (0.264/0.220 US/Imp qt) Approx.
  • Page 52 AN650/AK7 (’07-MODEL) WATTAGE Unit: W STD/SPEC. ITEM E-02, 19, 51 E-03, 24, 28, 33 Headlight 60 + 55 60 × 2 55 × 2 Parking or position light 5 × 2 ← Brake light/Taillight 21/5 × 2 ← Turn signal light 21 ×...
  • Page 53 Front fork stroke — (4.3) Front fork spring free length — (13.4) Front fork oil type SUZUKI FORK OIL G-10 (#10) or — an equivalent fork oil Front fork oil capacity (each leg) 458 ml — Front fork oil level —...
  • Page 54 AN650/AK7 (’07-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. Fuel tank capacity Including 15.0 L (4.0/3.3 US/lmp gal) reserve Fuel meter mark Approx. 3.0 L (0.79/0.66 US/lmp gal) flickering Fuel meter mark and...
  • Page 55: Wiring Diagram

    WIRING DIAGRAM AN650K7 (E-02, 19) –...
  • Page 56 AN650K7 (E-24) –...
  • Page 57 AN650K7 (E-03, 28, 33) –...
  • Page 58 AN650AK7 (E-02, 19, 51) –...
  • Page 59 AN650AK7 (E-24) –...
  • Page 60 AN650AK7 (E-03, 28, 33) –...
  • Page 61 Prepared by February, 2007 Part No. 99501-36160-01E Printed in Japan...
  • Page 62 Printed in Japan...

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