Suzuki AN650 2002 Bedienungsanleitung

GROUP INDEX

GENERAL INFORMATION 1

PERIODIC MAINTENANCE 2

ENGINE 3

DRIVE TRAIN 4

CVT 5

FI SYSTEM/ CVT SYSTEM 6

FUEL SYSTEM AND THROTTLE

BODY 7

COOLING AND LUBRICATION

SYSTEM 8

CHASSIS 9

ELECTRICAL SYSTEM 10

SERVICING INFORMATION 11

EMISSION CONTROL

INFORMATION 12

WIRING DIAGRAM 13

FOREWORD

This manual contains an introductory description on

the SUZUKI AN650 and procedures for its inspec-

tion/service and overhaul of its main components.

Other information considered as generally known is

not included.

Read the GENERAL INFORMATION section to

familiarize yourself with the motorcycle and its main-

tenance. Use this section as well as other sections

to use as a guide for proper inspection and service.

This manual will help you know the motorcycle bet-

ter so that you can assure your customers of fast

and reliable service.

* This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent of this manual and the actual motorcycle.

* Illustrations in this manual are used to show

the basic principles of operation and work

procedures. They may not represent the

actual motorcycle exactly in detail.

* This manual is written for persons who have

enough knowledge, skills and tools, including

special tools, for servicing SUZUKI motorcy-

cles. If you do not have the proper knowledge

and tools, ask your authorized SUZUKI

motorcycle dealer to help you.

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

services described in this manual.

Improper repair may result in injury to the

mechanic and may render the motorcycle

unsafe for the rider and passenger.

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right will allow you to find

the first page of the section easily.

4. The contents are listed on the first page of each section to

help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service information

such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front wheel

Brake disc

Coller

Dust seal

Bearing

Front tire

Front wheel

Spacer

Tire valve

Disc bolt

Front axle

ITEM N·m kgf-m lb-ft

23 2.3 16.5

65 6.5 47.0

FWD

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servic-

ing. The meaning of each symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Use engine coolant.

99000-99032-11X

Apply oil. Use engine oil unless other-

wise specified.

Use fork oil.

99000-99044-10G

Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKl

MOLY PASTE in a ratio of 1 : 1)

Apply or use brake fluid.

Apply SUZUKI SUPER GREASE “A”.

99000-25010 Measure in voltage range.

Apply SUZUKI MOLY PASTE.

99000-25140 Measure in current range.

Apply SUZUKI BOND “1207B”

99104-31140 (USA) Measure in resistance range.

Apply SUZUKI BOND “1215”.

99000-31110 (Except USA) Measure in diode test range.

Apply SUZUKI BOND “1216B”.

99000-31230 Measure in continuity test range.

Apply THREAD LOCK SUPER “1303”.

99000-32030 Use special tool.

Apply THREAD LOCK “1342”.

99000-32050 Indication of service data.

Apply THREAD LOCK SUPER “1360”.

99000-32130

1216B

ABBREVIATIONS USED IN THIS

MANUAL

ABDC : After Bottom Dead Center

AC : Alternating Current

ACL : Air Cleaner, Air Cleaner Box

API : American Petroleum Institute

ATDC : After Top Dead Center

ATM Pressure: Atmospheric Pressure

Atmospheric Pressure Sensor

(APS)

A/F : Air Fuel Mixture

BBDC : Before Bottom Dead Center

BTDC : Before Top Dead Center

B+ : Battery Positive Voltage

CKP Sensor : Crankshaft Position Sensor

(CKPS)

CKT : Circuit

CLP Switch : Clutch Lever Position Switch

(Clutch Switch)

CMP Sensor : Camshaft Position Sensor

(CMPS)

CO : Carbon Monoxide

CPU : Central Processing Unit

CVT Control

Unit : Continuously Variable

Transmission Control Unit

DC : Direct Current

DMC : Dealer Mode Coupler

DOHC : Double Over Head Camshaft

DRL : Daytime Running Light

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

EVAP : Evaporative Emission

EVAP

Canister

: Evaporative Emission

Canister (Canister)

FI : Fuel Injection, Fuel Injector

FP : Fuel Pump

FPR : Fuel Pressure Regulator

FP Relay : Fuel Pump Relay

FTPC Valve : Fuel Tank Pressure Control Valve

GEN : Generator

GND : Ground

GP Switch : Gear Position Switch

HC : Hydrocarbons

HO2S : Heated Oxygen Sensor

IAC Valve : Idle Air Control Valve

IAP Sensor : Intake Air Pressure Sensor (IAPS)

IAT Sensor : Intake Air Temperature Sensor

(IATS)

IG : Ignition

LCD : Liquid Crystal Display

LED : Light Emitting Diode

(Malfunction Indicator Lamp)

LH : Left Hand

MAL-Code : Malfunction Code

(Diagnostic Code)

Max : Maximum

MIL : Malfunction Indicator Lamp

(LED)

Min : Minimum

NOx : Nitrogen Oxides

OHC : Over Head Camshaft

OLS : Oil Level Switch

OPS : Oil Pressure Switch

PCV : Positive Crankcase

Ventilation (Crankcase Breather)

RH : Right Hand

ROM : Read Only Memory

SAE : Society of Automotive Engineers

TO Sensor : Tip Over Sensor (TOS)

TP Sensor : Throttle Position Sensor (TPS)

WIRE COLOR

B : Black G : Green P : Pink

Bl : Blue Gr : Gray R : Red

Br : Brown Lbl : Light blue V : Violet

Dg : Dark green Lg : Light green W : White

Dgr : Dark gray O : Orange Y : Yellow

B/Bl : Black with Blue tracer

B/G : Black with Green tracer

B/R : Black with Red tracer

B/Y : Black with Yellow tracer

Bl/G : Blue with Green tracer

Bl/W : Blue with White tracer

Br/B : Brown with Black tracer

G/B : Green with Black tracer

G/R : Green with Red tracer

G/Y : Green with Yellow tracer

Gr/R : Gray with Red tracer

Gr/Y : Gray with Yellow tracer

Lg/Y : Light green with Yellow tracer

O/Bl : Orange with Blue tracer

O/R : Orange with Red tracer

O/Y : Orange with Yellow tracer

P/W : Pink with White tracer

R/Bl : Red with Blue tracer

R/W : Red with White tracer

W/B : White with Black tracer

W/G : White with Green tracer

W/Y : White with Yellow tracer

Y/Bl : Yellow with Blue tracer

Y/R : Yellow with Red tracer

B/Br : Black with Brown tracer

B/O : Black with Orange tracer

B/W : Black with White tracer

Bl/B : Blue with Black tracer

Bl/R : Blue with Red tracer

Bl/Y : Blue with Yellow tracer

Br/W : Brown with White tracer

G/Bl : Green with Blue tracer

G/W : Green with White tracer

Gr/B : Gray with Black tracer

Gr/W : Gray with White tracer

Lg/B : Light green with Black tracer

O/B : Orange with Black tracer

O/G : Orange with Green tracer

O/W : Orange with White tracer

P/B : Pink with Black tracer

R/B : Red with Black tracer

R/G : Red with Green tracer

R/Y : Red with Yellow tracer

W/Bl : White with Blue tracer

W/R : White with Red tracer

Y/B : Yellow with Black tracer

Y/G : Yellow with Green tracer

Y/W : Yellow with White tracer

GENERAL INFORMATION 1-1

CONTENTS

GENERAL INFORMATION

WARNING/ CAUTION/ NOTE .............................................................1- 2

GENERAL PRECAUTIONS ................................................................1- 2

SUZUKI AN650K3 (’03-MODEL) ........................................................1- 4

SERIAL NUMBER LOCATION ...........................................................1- 4

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION .............1- 4

FUEL (FOR USA AND CANADA) ...............................................1- 4

FUEL (FOR OTHER COUNTRIES) ..............................................1- 4

ENGINE OIL AND TRANSMISSION OIL (FOR USA) .................1- 5

ENGINE OIL AND TRANSMISSION OIL

(FOR OTHER COUNTRIES) ........................................................1- 5

FINAL GEAR OIL .........................................................................1- 5

BRAKE FLUID .............................................................................1- 5

FRONT FORK OIL .......................................................................1- 5

ENGINE COOLANT .....................................................................1- 5

WATER FOR MIXING ..................................................................1- 5

ANTI-FREEZE/ENGINE COOLANT ............................................1- 5

LIQUID AMOUNT OF WATER/ENGINE COOLANT ...................1- 6

BREAK-lN PROCEDURES .................................................................1- 7

CYLINDER IDENTIFICATION ............................................................1- 7

INFORMATION LABELS ....................................................................1- 8

SPECIFICATIONS ..............................................................................1- 9

COUNTRY AND AREA CODES .........................................................1-11

1-2 GENERAL INFORMATION

WARNING/ CAUTION/ NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol

and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-

sages highlighted by these signal words.

Indicates a potential hazard that could result in death or injury.



Indicates a potential hazard that could result in motorcycle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-

INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you

are unsure about how to perform a particular service operation, ask a more experienced mechanic for

advice.

GENERAL PRECAUTIONS

* Proper service and repair procedures are important for the safety of the service mechanic and

the safety and reliability of the motorcycle.

* When 2 or more persons work together, pay attention to the safety of each other.

* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-

doors.

* When working with toxic or flammable materials, make sure that the area you work in is well-

ventilated and that you follow all of the material manufacturer’s instructions.

* Never use gasoline as a cleaning solvent.

* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system

until they have cooled.

* After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings

related to the system for leaks.

GENERAL INFORMATION 1-3



* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-

lent.

* When removing parts that are to be reused, keep them arranged in an orderly manner so that

they may be reinstalled in the proper order and orientation.

* Be sure to use special tools when instructed.

* Make sure that all parts used in reassembly are clean. Lubricate them when specified.

* Use the specified lubricant, bond, or sealant.

* When removing the battery, disconnect the negative cable first and then the positive cable.

* When reconnecting the battery, connect the positive cable first and then the negative cable,

and replace the terminal cover on the positive terminal.

* When performing service to electrical parts, if the service procedures not require use of bat-

tery power, disconnect the negative cable the battery.

* When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first.

Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci-

fied tightening torque.

* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking

nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with

new ones. Also, before installing these new parts, be sure to remove any left over material

from the mating surfaces.

* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is

completely seated in its groove and securely fitted.

* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a

thread is smeared with them.

* After reassembling, check parts for tightness and proper operation.

* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and

other fluids: batteries, and tires.

* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

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