Sign In
Upload
Manuals
Brands
Suzuki Manuals
Motorcycle
AN650
Suzuki AN650 Manuals
Manuals and User Guides for Suzuki AN650. We have
4
Suzuki AN650 manuals available for free PDF download: Service Manual, Manual, Technische Tekeningen Manual
Suzuki AN650 Service Manual (464 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 29 MB
Table of Contents
Foreword
2
Group Index
2
How to Use this Manual
3
Component Parts and Work to be Done
3
Symbol
4
Abbreviations Used in this Manual
5
Wire Color
7
General Information
8
Contents
8
Warning/Caution/Note
9
Suzuki AN650K3 ('03-Model) View
11
Serial Number Location
11
Fuel, Oil and Engine Coolant Recommendation Fuel
11
Engine Oil and Transmission Oil
12
Final Gear Oil
12
Brake Fluid
12
Anti-Freeze/Engine Coolant
12
Liquid Amount of Water/Engine Coolant
13
Break-In Procedures
14
Cylinder Identification
14
Information Labels
15
Specifications
16
Dimensions and Dry Mass
16
Engine/Drive Train
16
Electrical
17
Capacities
17
Country and Area Codes
18
Periodic Maintenance
19
Periodic Maintenance Schedule
20
Periodic Maintenance Chart
20
Lubrication Points
21
Maintenance and Tune-Up Procedures
22
Air Cleaner
22
Spark Plug Removal
24
Heat Range
24
Carbon Deposits
25
Spark Plug Gap/Installation
25
Electrodes Condition
25
Tappet Clearance
25
Tappet Clearance Adjustment
27
Intake Side
29
Tappet Shim Selection Table
29
Exhaust Side
30
Fuel Hose
31
Engine Oil and Oil Filter
31
Engine Oil Replacement
31
Oil Filter Replacement
32
Transmission Oil Replacement
33
Final Gear Oil Replacement
33
CVF Filter
34
Engine Idle Speed
36
Throttle Cable Play
36
Minor Adjustment
36
Major Adjustment
37
Cooling System
38
Engine Coolant Level Check
38
Engine Coolant Change
38
Air Bleeding the Cooling Circuit
39
Radiator Hoses
40
Brake Fluid Level Check
40
Brake Pads
41
Air Bleeding the Brake Fluid Circuit
42
Tire Tread Condition
43
Tire Pressure
44
Steering
44
Front Fork
44
Rear Suspension
45
Exhaust Pipe Bolt and Muffler Mounting Bolt
45
Chassis Bolts and Nuts
46
Compression Pressure Check
48
Compression Pressure Specification
48
Compression Test Procedure
48
Oil Pressure Check
49
Oil Pressure Specification
49
Oil Pressure Test Procedure
49
Automatic Clutch Inspection
50
Initial Engagement Inspection
50
Clutch "Lock-Up" Inspection
50
Brake-Lock Inspection
51
Engine
52
Engine Components Removable with Engine in Place
53
Center of Engine
53
Right Side of Engine
53
Left Side of Engine
53
Engine Removal and Remounting
54
External Parts
54
Engine Remounting
61
Muffler
62
Engine Disassembly
63
Starter Motor
63
Oil Pressure/Level Switch
63
Cylinder Head Cover
63
Cylinder Head, and Cylinder
64
Piston
65
Oil Hose
65
Generator Cover
65
Generator
66
Starter Clutch
67
Cam Chain
68
Water Pump
68
Oil Filter
68
Separation of Crankcase
69
Drive Shaft
70
Balancer Shaft
70
Oil Pump
71
Oil Pressure Regulator
71
Piston Cooling Nozzle
71
Crankshaft
72
Primary Driven Gear
72
Return Oil Pump
72
Engine Component Inspection and Service
73
Cam Position Sensor
74
Cam Face
74
Camshaft Runout
74
Camshaft Journal Wear
75
Cam Chain Tension Adjuster
76
Cam Chain Guide
76
Valve and Valve Spring Diassembly
77
Cylinder Head Distortion
77
Valve Stem Deflection
78
Valve Stem Wear
78
Valve Stem Runout
78
Valve Head Radial Runout
78
Valve Face Wear
79
Valve Sprign
79
Valve Guide Servicing
80
Valve Seat Width Inspection
81
Valve Seat Servicing
81
Initial Seat Cut
82
Top Narrowing Cut
82
Bottom Narrowing Cut
83
Final Seat Cut
83
Valve and Valve Spring Reassembly
84
Intake Pipe
85
Cylinder Distortion
85
Cylinder Bore
86
Piston and Piston Ring
87
Piston Diameter
87
Piston to Cylinder Clearance
87
Piston Pins and Pin Bore
87
Piston Ring to Groove Clearance
88
Piston Ring Free End Gap and Piston Ring End Gap
88
Clutch
89
Clutch Drive Plates/Clutch Driven Plates No.2 Inspection
90
Clutch Driven Plate No.2 Inspection
91
Clutch Spring Free Height
91
Clutch Plate Concaved Washer Inspection
91
Starter Clutch View
94
Starter Torque Limiter
95
Oil Pump Inspection
95
Oil Pressure Regulator/Oil Sump Filter
95
Crank Balancer
96
Drive Shaft Disassembly
96
Conrod/Crankshaft
98
Conrod Small End I.D.
98
Conrod Big End Side Clearance
98
Conrod-Crank Pin Bearing Inspection
98
Conrod-Crank Pin Bearing Selection
99
Conrod I.D.
100
Crank Pin O.D.
100
Bearing Thickness
100
Bearing Assembly
100
Crankcase-Crankshaft Bearing Inspection
101
Crankcase-Crankshaft Bearing Selection
101
Crankshaft Journal Bearing Replacement
102
Crankshaft Thrust Clearance
105
Oil Jet
106
Crankcase
107
Oil Pressure Switch
107
Bearing Disassembly
107
Bearing Inspection
108
Bearing Reassembly
108
Oil Seal Disassembly
108
Oil Seal Reassembly
109
Engine Reassembly
110
Primary Driven Gear/Crankshaft
110
Oil Sump Filter
111
Oil Pump/Oil Pressure Regulator
111
Crank Balancer Shaft
112
Piston Ring
120
Cam Shaft
123
Position of Camshafts and Sprockets
124
Oil Level Switch
126
Drive Train
127
Drive Train Construction
128
Removal and Disassembly
129
Inspection and Replacement
130
Gears
130
Oil Seals
130
Bearings
131
Final Driven Gear Hub
132
Reassembly and Remounting
133
Cvt
135
CVT Assembly Removal and Installation
136
CVT Assembly Installation
138
CVT Disassembly and Reassembly
139
CVT Disassembly
140
CVT Casing/Cover
140
Secondary Pulley Assembly
143
CVT Belt
144
Primary Pulley
144
CVT Inspection
145
Primary Pulley Inspection
145
Secondary Pulley Inspection
145
Secondary Pulley Disassembly
146
CVT Motor
146
Secondary Pulley Reassembly
147
CVT Bely Inspection
147
CVT Casing/Cover Inspection
148
CVT Casing/Cover Disassembly
148
CVT Casing/Cover Reassembly
149
Primary Slide Pulley Idle Gear Inspection
150
CVT Primary Pulley Shims Adjustment
150
CVT Cover Depth Measurement
150
Primary Pulley Height Measurement
150
Shim Selection Table
152
CVT Reassembly
153
Primary Pulley Assembly
153
CVT Belt Installation
154
CVT Belt Brake-In Procedures
161
Clamp Location
161
FI System/ CVT System
162
Precautions in Servicing
163
Electrical Parts
163
Connector/Coupler
163
Fude
164
ECM/CVT Control Unit/Various Sensors
164
Electrical Circuit Inspection Procedure
166
Open Circuit Check
166
Continuity Check
167
Voltage Check
167
Short Circuit Check (Wire Harness to Ground)
168
Using the Tester
169
FI System Technical Features Injection Time (Injection Volume)
170
Compensation of Injection Time (Volume)
171
Injection Stop Control
171
FI System Parts Location
172
FI System Wiring Diagram
174
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
FI System/Cvt System Troubleshooting Customer Complaint Analysis
183
Self-Diagnostic Procedures
185
Self-Diagnosis Reset Procedure
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
"C16" Speed Sensor Circuit Malfunction
195
"C21" IAT Sensor Circuit Malfunction
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" HO2 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 Malfunction
212
"C55" CVT Engine Revolution Signal Circuit Malfunction
214
"C56" CVT Throttle Position Signal Circuit Malfunction
215
"C58" CVT Reduction Ratio Disagreement
216
Throttle Position Sensor (TPS) Setting
217
CMP/CKP Sensor
217
IAP Sensor
217
TP Sensor
218
ECT Sensor
218
Speed Sensor
218
IAT/AP Sensor
218
To Sensor
219
H02 Sensor (E-02,19)
219
CVT Pulley Position Sensor
219
CVT Secondary Pulley Revolution Sensor
219
Fuel System and Throttle Body
220
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 Discharge Amount Inspection
225
Fuel Pump Relay Inspection
225
Fuel Pump Components
226
Fuel Pump/Fuel Level Gauge Removal and Disassembly
226
Fuel Mesh Filter Inspection and Cleaning
229
Fuel Level Gauge Inspection
229
Fuel Meter Inspection
229
Fuel Pump/Fuel Level Gauge Reassembly and Installation
230
Throttle Body Components
233
Throttle Body Removal
234
Throttle Body Disassembly
236
Throttle Body Cleaning and Inspection
238
IAC Valve Inspection
239
Throttle Body Reassembly
239
Throttle Body Installation
241
Throttle Body Clamp Position
241
Throttle Cable Adjustment
242
Fuel Injector Removal
242
Fuel Injector Inspection
242
Fuel Injector Installation
242
Throttle Valve Synchronization
243
Cooling and Lubrication System
244
Cooling System Description
245
Cooling Circuit
245
Oil Cooler
245
Engine Coolant
246
Radiator and Hoses
247
Cooling Circuit Inspection
247
Radiator Cap Inspection
247
Radiator Hose Inspection
248
Radiator Removal
249
Radiator Reservoir Tank Removal/Remounting
250
Cooling Fan
251
Inspection
251
Removal
251
Remounting
252
Cooling Fan Thermo-Switch
253
Engine Coolant Temperature Sensor
255
Thermostat
257
Water Pump Construction
259
Mechanical Seal
262
Oil Seal
263
Bearing Case/Mechanical Case
263
Impeller
263
Reassembly and Installation
264
Engine Lubrication System Chart
269
Engine Lubrication System
270
Chassis
272
Exterior Parts Construction
274
Front Box
277
Foot Board Assembly
277
Location of Exterior Components
278
Removal Procedure Flow Chart
278
Wind Screen
279
Handlebar Cover
280
Front Panel
280
Rear View Mirror
281
Lower Leg Shield
282
Right Leg Side Cover
284
Left Leg Side Cover
284
Maintenance Lid
285
Seat
285
Seat Damper
286
Pillon Rider Handle
287
Trunk Box Cover
288
Frame Cover
288
Foot Board
290
Rear Fender
292
Trunk Box
292
Leg Shield Brace
294
Seat Rail
295
Front Wheel Construction
297
Dust Seal
299
Front Axle
299
Wheel
299
Wheel Bearing
300
Brake Disc
302
Brake Caliper
303
Front Fork Construction
304
Inner and Outer Tubes
307
Fork Spring
307
Cylinder
308
Metals and Seals
308
Cylinder Bolt
309
Fork Oil
310
Front Fork Cap Bolt
311
Steering and Handlebars Construction
312
Handlebars
313
Steering Stem
313
Bearing Races
315
Steering Tension Adjustment
318
Rear Wheel Construction
319
Rear Axle
322
Rear Hub Damper
322
Rear Hub Driven Joint
322
Rear Shock Absorber Construction
329
Suspension Setting
330
Spring Rpe-Load Adjustment
330
Rear Swingarm Construction
331
Swingarm Bearing
332
Bushing
333
Front Brake Construction
335
Brake Pad Replacement
336
Brake Fluid Replacement
337
Caliper Removal and Disassembly
338
Caliper Inspection
339
Brake Caliper Piston
339
Caliper Holder
339
Rubber Parts
340
Caliper Reassembly and Remounting
340
Piston Seal
340
Master Cylinder Removal and Disassembly
342
Master Cylinder Inspection
343
Master Cylinder Reassembly and Remounting
343
Rear Brake Construction
345
Boot
351
Caliper Reassembly Ans Remounting
351
Caliper
353
Brake Lock
353
Brake Disc Inspection
355
Brake Lock Adjustment
356
Brake Lock Cable Replacement
357
Brake-Lock System
359
Brake-Lock Operation
359
Automatic Brake-Lock Adjuster System
360
Over-Adjust Prevention Mechanism
362
Tire and Wheel
363
Tire Removal
363
Valve Installation
364
Tire Installation
364
Balancer Weight Installation
365
Electrical System
366
Cautions in Servicing
367
Location of Electrical Components
369
Charging System
371
Battery Current Leakage
373
Regulated Voltage
374
Generator Coil Resistance
374
Generator No-Load Performance
375
Regulator/Rectifier
375
Starter System
376
Starter Motor Removal and Disassembly
377
Starter Motor Inspection
378
Carbon Brushes
378
Commutator
378
Armature Coil Inspection
378
Oil Seal Inspection
379
Starter Motor Reassembly
379
Starter Relay Inspection
380
Side Stand/Ignition Interlock System Parts Inspection
381
Side-Stand Switch
381
Side-Stand Relay
381
Starter Relay Diode Inspection
382
Ignition System
383
Ignition Coil Primary Peak Voltage
385
Ignition Coil/Plug Cap Resistance
386
CKP Sensor Peak Voltage
386
CKP Sensor Resistance
387
Combination Meter Parts Names
388
Operating Procedure
389
Initial Display
389
Change the Display Mode
389
Tripmeter
389
To Reset the Oil Change Indicator
390
To Vary the Preset Interval of Oil Change Indicator
390
Example of Oil Change Indicator Setting
390
Engine Coolant Temperature Meter and Indicator Light
391
Fuel Meter
392
Fuel Gauge
392
Fuel Pump Relay
393
Oil Pressure Indicator
393
Engine Oil Level Indicator
394
Engine Oil Level Switch
394
Speedometer
394
Speedometer Sensor
395
Lamp
396
Headlight Bulb Replacement
396
Headlight Beam Adjustment
396
Brake Light/Taillight, Turn Signal Light and License Light
397
Bulb Replacement
397
Front Turn Signal Light
397
Rear Turn Signal Light
398
Brake Light/Taillight
398
License Light
398
Turn Signal Relays
399
Cooling Fan Motor Relay
399
Battery Specifications
402
Initial Charging
402
Filling Electrolyte
402
Servicing
404
Recharging Operation
404
Servicing Information
405
Troubleshooting
406
FI System/Cvt System Malfunction Code and Defective Condition
406
Engine Servicing Information
408
CVT Servicing Information
413
Radiator (Cooling System) Servicing Information
413
Chassis Servicing Information
414
Brakes Servicing Information
415
Electrical Servicing Information
416
Battery Servicing Information
417
Wiring Harness, Cable and Hose Routing
418
Cable Routing
422
Throttle Body Installation/Hose Routing
424
Fuel Tank Mounting
425
Fuel Tank Hose Routing
426
Radiator Hose Routing
427
Front Brake Hose Routing
428
Rear Brake Hose Routing
429
Side-Stand Set-Up
430
Center Stand Set-Up
430
Special Tools
431
Tightening Torque Engine
435
Tightening Torque Chart
437
Service Data
438
Valve + Guide
438
Camshaft + Cylinder Head
439
Cylinder + Piston + Piston Ring
439
Conrod + Crankshaft
440
Injector + Fuel Pump + Fuel Pressure Regulator
441
FI/CVT-Sensors
441
Throttle Body
442
Thermostat + Radiator + Fan + Coolant
442
Wattage
443
Brake + Wheel
444
Suspension
444
Tire
445
Fuel + Oil
445
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 Hose
451
Pair Reed Valve
451
Pair Control Solenoid Valve
451
Pair (Air Supply) System Hose Routing
453
Heated Oxgen Sensor (HO2S) Inspection
454
Wiring Diagram E-02, 19
455
Wiring Diagram AN650L
458
Advertisement
Suzuki AN650 Manual (125 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 2 MB
Table of Contents
Table of Contents
4
Consumer Information
6
Accessory Use and Motorcycle Loading
7
Safe Riding Recommendations for Motorcycle Riders
9
Labels
11
Serial Number Location
11
Controls
12
Location of Parts
13
Key
16
Ignition Switch
17
Instrument Panel
19
Left Handlebar
31
Right Handlebar
35
Brake Lock Lever
37
Fuel Tank Cap
38
Front Trunk
40
Front Small Box
41
Trunk
41
Helmet Holder
42
Backrest Adjustment
42
Trunk Box Light Switch
43
Stand
43
Rear Suspension
44
Output Terminal
45
Fuel, Engine Oil and Coolant Recommendations
46
Fuel Octane Rating
47
Oxygenated Fuel Recommendation
47
Engine Oil
49
Transmission Oil
50
Final Gear Oil
50
Engine Coolant Solution
51
Break-In (Running-In) and Inspection before Riding
54
Riding Tips
58
Starting the Engine
59
Starting off
60
RIDING on HILLS (MANUAL Mode)
61
Stopping and Parking
62
Inspection and Maintenance
66
Maintenance Schedule
67
Tools
70
Lubrication Points
70
Battery
71
Spark Plug
73
Air Cleaner
77
Engine Idle Speed Inspection
80
Throttle Cable Play
81
Cvt Filter
82
Engine Coolant
84
Engine Oil
86
Transmission Oil and Final Gear Oil
91
Brakes
94
Tires
97
Side Stand/Ignition Interlock System
100
Light Bulb Replacement
101
Fuses
105
Catalytic Converter
107
Diagnostic Connector
109
Troubleshooting
110
Storage Procedure and Motorcycle Cleaning
112
Storage Procedure
113
Procedure for Returning to Service
114
Corrosion Prevention
114
Motorcycle Cleaning
115
Inspection after Cleaning
117
Specifications
119
Suzuki AN650 Service Manual (121 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 7 MB
Advertisement
(German) SUZUKI AN650 Technische Tekeningen Manual (58 pages)
Brand:
SUZUKI
| Category:
Motorcycle
| Size: 3 MB
Table of Contents
Battery
3
Air Cleaner
4
Alternator
5
Cam Chain
6
Cam Shaft + Valve
7
Carburetor Fittings
8
Carburetor
9
Clutch
11
Cooling Fan
12
Cosling Body Installation Parts
13
Cowling Body (Model W)
14
Crankcase Cover
15
Crankcase
16
Crankshaft
17
Electrical
18
Footrest
19
Frame Cover (Model W/X)
20
Frame
21
Front Brake Hose
22
Front Caliper
23
Front Damper
24
Front Fender
25
Front Wheel
26
Fuel Cock
27
Fuel Tank (Model W/X)
28
Gear Shifting
29
Handlebar
30
Handle Lever
31
Handle Switch
32
Cylinder Head Cover
33
Cylinder Head
34
Headlamp
35
Muffler
36
Oil Cooler
37
Oil Pan
38
Oil Pump
39
Rear Caliper
40
Rear Fender
41
Rear Master Cylinder
42
Rear Cushion Lever
43
Rear Wheel
44
Seat (Model W/X)
45
Signal Generator
46
Speedometer (Model W/X)
47
Stand
48
Starter Clutch
49
Starting Motor
50
Steering Stem
51
Rear Swinging Arm
52
Tail Lamp
53
Transmission
54
Turn Signal Lamp
55
Under Cowling
56
Wiring Harness
57
Advertisement
Related Products
Suzuki AS50
Suzuki A50
Suzuki AN650Z
Suzuki AN650 2002
Suzuki AN650L 2002
Suzuki AN650K3 2002
SUZUKI Burgman AN400
Suzuki AN400ZA
Suzuki AN400A
Suzuki AN650/A
Suzuki Categories
Motorcycle
Automobile
Motorcycle Accessories
Outboard Motor
Offroad Vehicle
More Suzuki Manuals
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL