2003–2009 Suzuki Burgman 650 AN650/AN650A Service & Repair Manual PDF (P/N 99500-36116-03E)

This Suzuki service manual covers 2003–2009 AN650 and AN650A Burgman 650 scooters with the 638cc DOHC twin-cylinder engine and electronic CVT. Publication 99500-36116-03E brings together the base manual and K4–K9 supplements for standard and ABS-equipped variants.

Supplied as one 653-page PDF in English, with the supplements and wiring diagrams included in that total.

• Engine repair: Engine removal and installation, cylinder-head and crankshaft inspection, camshaft timing, and wet multi-plate clutch disassembly and reassembly.

• CVT and final drive: CVT removal, belt and pulley inspection, primary-pulley shim adjustment, and final-drive bearing and oil-seal service.

• FI and CVT diagnosis: Dealer-mode malfunction codes, reset procedures, fail-safe operation, sensor-circuit tests, and ECM/CVT control-unit connector references.

• SDS and idle control: Sampled-data checks, Diagnostic Trouble Codes (DTC), Idle Speed Control (ISC) active-control tests, learned-value reset, and throttle valve synchronization.

• Cooling and lubrication: Cooling-circuit pressure tests, radiator-cap and thermostat inspection, water-pump repair, oil-cooler service, and engine oil-pressure checks.

• Brakes and chassis: Front and rear disc-brake service, brake-lock adjustment, ABS wheel-speed-sensor troubleshooting, telescopic fork overhaul, and rear swingarm inspection.

Written for people with the knowledge, skills, and tools—including special tools—needed to service Suzuki motorcycles; general workshop knowledge is assumed.

Engine, Clutch and CVT Repair

The engine chapters cover internal overhaul, valve-seat service, crankshaft bearing selection, and crankcase reassembly, with exploded assembly views. Periodic maintenance procedures are supported by tappet shim selection tables and component-specific inspection limits.

Torque charts and service data include tappet and piston-to-cylinder clearances, transmission ratios, cylinder-head tightening sequences, transmission oil-level-plug torque, and fluid capacities.

CVT hardware: The K5 supplement identifies revised primary-pulley shaft hardware and holder 09924-51010. CVT assembly notes address the risk of scratching the belt against the casing and damaging an oil seal with the secondary pulley shaft.

FI/CVT Fault Tracing and SDS Checks

Dealer-mode procedures specify mode-select switch 09930-82720. Circuit tests provide electrical test values for the throttle position sensor (TPS), engine coolant temperature sensor (ECT), intake air pressure sensor (IAPS), heated oxygen sensor (HO2S), and CVT secondary pulley revolution sensor.

FI system wiring diagrams, including CVT circuits, and ECM connector views distinguish the K4 ECM/CVT control-unit connections from the K5 arrangement. These references help match a fault test to the correct connector and separate wiring problems from sensor faults before replacement decisions.

The K7 supplement adds Suzuki Diagnostic System (SDS) data comparisons and active-control checks for ISC and PAIR operation. It documents ISC valve pre-set and learned-value reset, with 09904-41010 identified as the SDS set tool; setup details refer to the separate SDS operation manual.

Cooling, Emissions and Market-Specific Equipment

Engine lubrication system charts and coolant density/freezing-point curves accompany the cooling and oil-system procedures.

Pulsed Secondary Air Injection (PAIR) inspections cover the reed valve and control solenoid. Evaporative Emission Control System (EVAP) inspection and canister hose-routing diagrams apply to E-33 California configurations.

The K5 supplement explains immobilizer anti-theft operation for E-02, E-19 and 000 markets. It also covers the AN650AK5 power wind screen for those markets and ambient air temperature (AAT) sensor testing.

Brake-Lock Service and ABS Coverage

The automatic brake-lock adjuster mechanism is explained alongside cable replacement and adjustment. AN650AK5 ABS coverage includes front and rear wheel-speed-sensor signal and open-circuit troubleshooting for codes 41, 42, 44 and 45.

The K9 rear-brake update covers pad replacement, caliper removal and installation, and brake-lock work. It refers to the AN650/A/AZK8 service manual for caliper disassembly and assembly; that full manual is not included here.

Review the factory safety precautions before working on electrical circuits or pressurized brake systems.

PDF Navigation and Wiring-Diagram Readability

The file contains 466 pages of base-manual material, including front matter and blank pages, plus 180 pages of K4–K9 supplements and seven wiring-diagram pages. Embedded bookmarks cover the main sections and supplements; most text is searchable, but search is limited in the K9 supplement and does not cover the labels in the final two wiring diagrams. Small wiring labels require zooming.