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AN650 2002
Suzuki AN650 2002 User Manual
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SE
RVI
CING
IN
FOR
MA
TIO
N 11-
29
S
PEC
IAL T
O
OL
S
09900-06107
Snap ring plier
s
09900-06108
Snap ring
pliers
09900-09004
Impact driver set
09900-18710
Hexagon so
cket
12 mm
09900-20102
Vernier calipers
09900-20202
Micrometer
(25
–
50 mm)
09900-20204
Micrometer
(75
–
100 mm)
09900-20205
Micrometer
(0
–
25 mm)
09900-20508
Cylinder
gauge set
09900-20602
Dial gauge
(1/1000 mm, 1 mm)
09900-20605
Dial gauge
09900-20607
Dial gauge
(1/100 mm, 10 mm)
09900-20701
Magnetic stand
09900-20803
09900-20806
Thickness gauge
09900-20805
Tire depth gaug
e
09900-21304
V-block (100
mm)
09900-22301
09900-22302
Plastigauge
09900-22401
Small bore gauge
(10
–
18 mm)
09900-25008
Mu
lti circuit te
ster
set
09910-32812
Crankshaft installer
09910-32850
Crankshaft installer
attachment
09913-50121
Oil seal remover
09913-60210
09913-60230
Journal bearing
remover/installer
09913-60241
Journal bear
ing
hol
de
r
09913-60912 or
09913-61110 or
09913-61510
Bearing pu
ller
432
434
Table of Contents
General Information 1
8
Table of Contents
8
Warning/ Caution/ Note
9
General Precautions
9
Suzuki An650K3 ('03-Model)
11
Serial Number Location
11
Fuel, Oil and Engine Coolant Recommendation
11
Fuel (for Usa and Canada)
11
Fuel (for Other Countries)
11
Anti-Freeze/Engine Coolant
12
Water for Mixing
12
Engine Coolant
12
Brake Fluid
12
Front Fork Oil
12
Final Gear Oil
12
Engine Oil and Transmission Oil (for Other Countries)
12
Engine Oil and Transmission Oil (for Usa)
12
Liquid Amount of Water/Engine Coolant
13
BREAK-Ln PROCEDURES
14
Cylinder Identification
14
Information Labels
15
Specifications
16
Electrical
17
Country and Area Codes
18
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
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
Brake
40
Tire
43
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
Clutch "Lock-Up" Inspection
50
Initial Engagement Inspection
50
Brake-Lock Inspection
51
Engine
52
Engine Components Removable with the Engine in Place
53
Engine Removal
54
Engine Removal and Remounting
54
Engine Remounting
61
Engine Disassembly
63
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
Cylinder
85
Piston and Piston Ring
87
Clutch
89
Starter Clutch
94
Oil Pressure Regulator/Oil Sump Filter
95
Oil Pump
95
Starter Torque Limiter
95
Crank Balancer
96
Driveshaft
96
Conrod/Crankshaft
98
Oil Jet
106
Crankcase
107
Engine Reassembly
110
Drive Train
127
Construction
128
Drive Train
128
Removal and Disassembly
129
Inspection and Replacement
130
Reassembly and Remounting
133
Cvt Assembly Removal and Installation/Cvt Disassembly and Reassembly
135
Cvt Assembly Removal
136
Cvt Assembly Removal and Installation
136
Cvt Assembly Installation
138
Cvt Disassembly and Reassembly
139
Cvt Disassembly
140
Cvt Inspection
145
Cvt Primary Pulley Shims Adjustment
150
Cvt Reassembly
153
Fi System/ Cvt System
162
Electrical Parts
163
Precautions in Servicing
163
Electrical Circuit Inspection Procedure
166
Using Testers
169
Fi System Technical Features
170
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
Customer Complaint Analysis
183
Fi System/ Cvt System Troubleshooting
183
Self-Diagnosis Reset Procedure
185
Self-Diagnostic Procedures
185
Battery
186
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
Sensors
217
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 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
Fuel Pump/Fuel Level Gauge Reassembly and Installation
230
Throttle Body
233
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
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
Engine Coolant
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
Main Fuse
253
Removal
253
Inspection
254
Installation
254
Engine Coolant Temperature Sensor
255
Removal
255
Inspection
256
Instalation
256
Inspection
257
Removal
257
Thermostat
257
Installation
258
Construction
259
Water Pump
259
Removal and Disassembly
260
Inspection
262
Reassembly and Installation
264
Lubrication System
268
Oil Cooler
268
Oil Filter
268
Oil Level Switch
268
Oil Pressure
268
Oil Pressure Regulator
268
Oil Pressure Switch
268
Oil Pump
268
Oil Return Pump
268
Oil Sump Filter
268
Engine Lubrication System Chart
269
Engine Lubrication System
270
Chassis
272
Construction
274
Exterior Parts
274
Removal
278
Remounting
295
Construction
297
Front Wheel
297
Removal
298
Inspection and Disassembly
299
Reassembly and Remounting
301
Construction
304
Front Fork
304
Removal and Disassembly
305
Inspection
307
Reassembly and Remounting
308
Construction
312
Steering and Handlebars
312
Removal
313
Inspection and Disassembly
315
Reassembly and Remounting
315
Steering Tension Adjustment
318
Construction
319
Rear Wheel
319
Removal
320
Inspection and Disassembly
322
Reassembly and Remounting
324
Construction
329
Rear Shock Absorber
329
Removal
329
Inspection
330
Remounting
330
Suspension Setting
330
Construction
331
Rear Swingarm
331
Removal
331
Inspection
332
Remounting
333
Construction
335
Front Brake
335
Brake Pad Replacement
336
Brake Fluid Replacement
337
Caliper Removal and Disassembly
338
Caliper Inspection
339
Caliper Reassembly and Remounting
340
Brake Disc Inspection
342
Master Cylinder Removal and Disassembly
342
Master Cylinder Inspection
343
Master Cylinder Reassembly and Remounting
343
Construction
345
Rear Brake
345
Brake Pad Replacement
346
Brake Fluid Replacement
348
Caliper Removal and Disassembly
348
Caliper Inspection
350
Caliper Reassembly and Remounting
351
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
Tire Installation
364
Valve Installation
364
Balancer Weight Installation
365
Electrical System
366
Cautions in Servicing
367
Clamps
367
Connectors
367
Couplers
367
Fuses
367
Semi-Conductor Equipped Parts
367
Battery
368
Connecting the Battery
368
Using the Multi Circuit Tester
368
Wiring Procedure
368
Location of Electrical Components
369
Charging System
371
Troubleshooting
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/Ignition Interlock System Parts Inspection
381
Ignition System
383
Troubleshooting
383
Inspection
385
Combination Meter
388
Parts Names
388
Removal and Disassembly
388
Operating Procedure
389
Inspection
391
Headlight
396
Lamp
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 Light
399
Turn Signal Relay
399
Battery
402
Initial Charging
402
Specifications
402
Recharging Operation
404
Servicing
404
Servicing Information
405
Fi System/ Cvt System Malfunction Code and Defective Condition
406
Troubleshooting
406
Engine
408
Cvt
413
Radiator (Cooling System)
413
Chassis
414
Brakes
415
Electrical
416
Battery
417
Wiring Harness Routing
418
Wiring Harness, Cable and Hose Routing
418
Cable Routing
422
Throttle Body Installation/Hose Routing
424
Fuel Tank Mounting
425
Fuel Tank Hose Routing
427
Radiator Hose Routing
429
Front Brake Hose Routing
430
Rear Brake Hose Routing
431
Center Stand Set-Up
432
Side-Stand Set-Up
432
Special Tools
433
Engine
437
Tightening Torque
437
Chassis
438
Cvt
438
Tightening Torque Chart
439
Service Data
440
Brake Light/Taillight
446
Brake Lock Indicator Light
446
Drive Indicator Light
446
Gear Position Indicator Light
446
High Beam Indicator Light
446
License Light
446
Oil Pressure Indicator Light
446
Power Mode Indicator Light
446
Turn Signal Indicator Light
446
Emission Control Systems
450
Fuel Injection System
450
Crankcase Emission Control System
451
Exhaust Emission Control System (Pair System)
452
Noise Emission Control System
453
Hose
454
Pair (Air Supply) System Inspection
454
Pair Control Solenoid Valve
454
Pair Reed Valve
454
Pair (Air Supply) System Hose Routing
456
Heated Oxgen Sensor (Ho2S) Inspection
457
5
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Suzuki AN650 2002 Specifications
General
Brand
Suzuki
Model
AN650 2002
Category
Motorcycle
Language
English
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