2003–2006 Suzuki Burgman 650 AN650 Service Manual OEM (P/N 99500-36110-01E)

• Covers the 2003 Suzuki AN650K3 ('03 model) in E-02 UK, E-03 U.S. (except California), E-19 EU, E-24 Australia, E-28 Canada, and E-33 California configurations; the 463-page, 13-section PDF bears Suzuki cover code 99500-36110-01E and copyright 2002.
• Provides engine removal and remounting, complete disassembly, component inspection, and reassembly for the cylinder head and valve train, cam chain, pistons, clutch, starter clutch, crank balancer, drive shaft, crankshaft, and crankcase.
• Details final-drive and mechanical CVT repair, including assembly removal and installation, internal disassembly, pulley and belt inspection, bearing replacement, primary-pulley shim adjustment, and reassembly.
• Maps FI and electronic CVT diagnostics through user and dealer modes, self-diagnosis and reset, fail-safe operation, TPS adjustment, circuit testing, and C11-C58 fault isolation.
• Handles fuel-tank and pump service, fuel-pressure inspection, throttle-body disassembly and cleaning, throttle-valve synchronization, radiator testing, thermostat service, and water-pump overhaul.
• Walks through wheel, fork, steering, swingarm, brake, brake-lock, charging, starter, ignition, combination-meter, relay, switch, and battery repair.
• Supplies the periodic-maintenance schedule and tune-up procedures, regional full-machine and FI wiring diagrams, charging and starter troubleshooting charts, cooling and lubrication schematics, routing views, special-tool listings, torque tables, inspection limits, fluid data, and electrical test specifications.

AN650K3 Coverage and Skill Level

This Suzuki service manual is centered on the 2003 AN650K3 and its 638 cc, four-stroke, liquid-cooled DOHC twin. It covers the fuel-injected engine, wet multi-plate automatic centrifugal clutch, variable-ratio belt CVT with automatic and manual shift modes, and gear final drive as one integrated powertrain. Suzuki expressly states that the manual is written for people who already have sufficient motorcycle-service knowledge, skills, and tools, including special tools; it assumes general workshop fundamentals rather than teaching them from scratch.

Coverage is tied to the K3 model and the listed market codes. The chassis material addresses twin front discs, the rear disc, and the mechanical brake-lock system; this edition does not contain an ABS service chapter. Region-specific details include lighting and switch differences, California maintenance items, and heated oxygen sensor coverage identified for E-02 and E-19 machines.

Engine and CVT Workshop Depth

The engine chapter identifies components that can be serviced with the engine still in the frame, then moves into removal, teardown, inspection, and assembly. Internal repair coverage includes camshaft timing, cylinder-head and valve inspection, piston and ring measurement, automatic clutch service, starter clutch and torque-limiter work, oil-pump and pressure-regulator inspection, crank-balancer timing, and bearing selection for the connecting rods and crankshaft. Exploded assembly views carry the related torque, lubricant, sealant, and thread-lock callouts.

The CVT is not treated as a sealed replacement unit. A separate mechanical chapter covers primary and secondary pulley work, belt inspection, bearings, the CVT motor gear, shim selection, and assembly setup, while the control-system chapter explains how the CVT control unit uses pulley-position, vehicle-speed, engine-speed, and throttle-position inputs. CVT-specific tools listed in the manual include primary pulley shaft holder 09920-31010, secondary pulley shaft holder 09920-31030, primary pulley shaft adapter 09920-31040, and CVT guide 09920-31050.

FI, Electrical, and Fault Diagnosis

The diagnostic material goes well beyond a code list. It explains injection-time control, compensation inputs, FI and CVT component locations, connector and circuit testing, dealer-mode operation, reset procedures, and fail-safe responses. Fault paths cover the engine-management sensors