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

This Suzuki service manual covers the 2003 AN650K3 ('03 model), sold as the Burgman 650, in the listed market configurations. The original Suzuki publication, P/N 99500-36110-01E, carries copyright 2002 and contains 13 sections covering maintenance, diagnosis, and major-component repair.

PDF Search, Diagram Viewing, and Page Count

Search and diagram access: PDF text search and embedded bookmarks are not available. Small wiring labels require zooming, and some diagram pages need rotation. Wide wiring diagrams are spread across separate pages.

The ZIP download contains one printable, 463-page English PDF. This total includes 453 section pages, six introductory pages, front and rear covers, and two spine images.

Engine Overhaul, CVT Repair, and Fault Diagnosis

The following selected coverage highlights outline the main workshop areas rather than reproduce the full contents. Other topics include fuel-tank pressure-control valve inspection and oil-change indicator settings.

• Engine repair: Step-by-step engine removal, disassembly, inspection, and reassembly, including cylinder-head, valve-train, piston, clutch, crankshaft, and crankcase work.

• CVT and final drive: Assembly removal and installation, belt and pulley inspection, bearing replacement, primary-pulley shim adjustment, and final-drive gear service.

• FI and CVT controls: User and dealer modes, self-diagnosis, reset procedures, fail-safe operation, TPS adjustment, and circuit-based fault isolation.

• Fuel and throttle body: Fuel-pressure and pump-delivery checks, injector testing, throttle-body disassembly and cleaning, IAC valve inspection, and throttle-valve synchronization.

• Cooling and lubrication: Radiator and cap testing, thermostat and fan checks, water-pump overhaul, oil-pressure testing, and lubrication-circuit diagrams.

• Chassis and brakes: Wheel, fork, steering, and swingarm service; caliper and master-cylinder repair; brake bleeding; and mechanical brake-lock adjustment.

• Electrical and service references: Charging, starter, ignition, meter, relay, switch, and battery tests, with wiring diagrams, routing views, torque tables, and inspection limits.

Suzuki states that this 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.

Market Differences and Brake-System Scope

Regional details include lighting and switch differences, California maintenance items, and heated oxygen sensor coverage for E-02 and E-19 machines.

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. AN650L appears in wiring diagrams and switch references; those references do not extend the entire repair coverage to that variant.

Engine Inspection and Internal Repair

The engine chapter identifies components that can be serviced with the engine still in the frame. Internal service extends to valve-guide replacement, valve-seat cutting, piston and ring measurement, camshaft timing, and crank-balancer timing.

Clutch and crankshaft work: Coverage includes the wet multi-plate automatic centrifugal clutch, starter clutch, starter torque limiter, drive shaft, and connecting-rod and crankshaft bearing selection. Exploded assembly views carry torque, lubricant, sealant, and thread-lock callouts.

Oil-pump and pressure-regulator inspection are included, but the oil pump is replaced as an assembly rather than internally overhauled.

Mechanical CVT Service and Setup

The mechanical chapter treats the CVT as a serviceable assembly, with separate instructions for belt replacement, secondary-pulley bearing work, CVT motor gear replacement, and reassembly checks. Primary-pulley shim selection is required when the primary pulley, casing, or cover is replaced.

CVT-specific tools include primary pulley shaft holder 09920-31010, secondary pulley shaft holder 09920-31030, primary pulley shaft adaptor remover 09920-31040, and CVT guide 09920-31050.

The CVT chapter warns that contact between the pulleys during removal can scratch their working faces.

FI and Electronic CVT Troubleshooting

The control-system material explains injection-time calculation, compensation inputs, component locations, and the listed C11–C58 faults. Test paths distinguish sensor faults, wiring problems, poor connector contact, and control-unit faults.

Ratio-disagreement diagnosis: The C58 chart considers both a sticking pulley-position sensor and contamination inside the CVT. This gives the technician electrical and mechanical checks for the same reported fault, rather than treating the code as an automatic instruction to replace a control unit.

The CVT operating explanation relates pulley-position, vehicle-speed, engine-speed, and throttle-position inputs to actual and target transmission ratios.

Fuel, Cooling, and Emission Controls

Fuel-system procedures cover tank and pump removal, mesh-filter cleaning, fuel-level gauge testing, and throttle-body reassembly. The throttle-body section warns that letting the throttle snap shut with the cables disconnected can damage the throttle valve and body.

Cooling-system service extends to water-pump bearings, oil and mechanical seals, and impeller inspection. Emission-control material explains the PCV and PAIR systems and includes PAIR reed-valve, solenoid, and hose checks.

Chassis, Electrical Tests, and Diagrams

Fork work includes internal disassembly and oil-level setup; steering service includes bearing replacement and steering-tension adjustment. Rear shock absorbers receive inspection, replacement, and spring-preload adjustment coverage, rather than internal overhaul.

The brake-lock section explains the automatic adjuster and its relationship to the rear caliper piston. Brake work requires the specified bleeding and leak checks, while engine removal requires secure support.

Electrical coverage includes starter-motor repair, side-stand/ignition interlock testing, ignition peak-voltage checks, combination-meter tests, and battery charging.

The FI System Wiring Diagram, charging and starter troubleshooting charts, Cooling Circuit, Engine Lubrication System Chart, and Wiring Harness Routing views support fault tracing and reassembly. The wiring section includes pages labeled E-02/19, AN650L, and E-24.

Selected Valve-Clearance and Sensor-Test Specifications

The tappet-clearance section specifies cold clearances of 0.10–0.20 mm for intake valves and 0.20–0.30 mm for exhaust valves, with shim-selection tables supporting adjustment.

Electrical test examples include injector resistance of 11–13 Ω across the injector terminals at 20°C and CVT secondary-pulley revolution sensor resistance of 400–600 Ω between the yellow and white terminals. These values accompany component-specific diagnostic procedures.