Suzuki Burgman 650 AN650 2002–2003 Service Manual (P/N 99500-36110-01E)

This Suzuki Burgman 650 AN650 service manual, P/N 99500-36110-01E, covers the 2003 AN650K3 ('03-model'), with inspection, service and overhaul procedures for its main components.

PDF Viewing and Included Pages

Text search and diagram viewing: PDF text search and embedded bookmarks are not available. Small wiring labels require zooming, and some diagram pages are rotated or upside down.

One printable, English-language PDF with 463 pages, including seven cover/front-matter pages, one back cover and two additional spine-image pages.

Engine Overhaul, CVT Repair and System Diagnostics

The selected topics below outline the main workshop coverage. Additional references include lubrication-point diagrams and an exterior-component removal flowchart.

• Maintenance and condition checks: Service schedules, valve-clearance adjustment, compression and oil-pressure tests, and automatic-clutch engagement and lock-up inspections.

• Engine repair: Step-by-step engine removal, teardown and reassembly, cylinder-head and valve service, cam timing, selective-fit bearings, automatic-clutch and starter-clutch repair.

• CVT overhaul: Assembly removal, case separation, primary- and secondary-pulley inspection, belt inspection, shim selection, bearing and seal replacement, reassembly and operating checks.

• FI and CVT diagnostics: User- and dealer-mode self-diagnosis, fail-safe operation, reset procedures, open- and short-circuit testing, TPS adjustment, and sensor and actuator fault isolation.

• Fuel and cooling systems: Fuel-pressure and pump tests, throttle-body and injector service, synchronization, radiator and cap checks, thermostat and water-pump repair, and cooling-system bleeding.

• Chassis service: Body-panel removal, wheel and fork service, steering, swingarm and rear suspension, front and rear brake overhaul, hydraulic bleeding and brake-lock adjustment.

• Electrical troubleshooting: Charging, starting and ignition tests, combination-meter checks, harness routing and wiring diagrams.

This manual suits trained technicians and experienced owners who already have the service knowledge, practical skills and tools, including special tools, specified by Suzuki.

Cylinder-Head and Lower-End Repair

Valve gear: Cylinder-head coverage includes valve-guide replacement, valve-seat cutting, camshaft journal checks, tappet-shim selection and camshaft/sprocket positioning. An unlubricated valve-guide bore can leave both the guide and cylinder head damaged during installation.

Internal engine work: Procedures cover pistons and rings, connecting rods, crankshaft journals, crankcase bearings and the crank balancer. Oil pumps, the pressure regulator, sump filter, oil jets and piston-cooling nozzles are also covered.

The automatic centrifugal clutch and starter clutch receive separate disassembly, inspection and reassembly instructions.

CVT Measurements and Final-Gear Service

The transmission material is split between final-gear drive repair, mechanical CVT overhaul and electronic CVT control. Having both hardware inspections and control-system tests available supports diagnosis of drive complaints before choosing the repair work.

Primary-pulley shim selection uses cover-depth and pulley-height measurements after replacement of the primary pulley, CVT casing or cover. Reassembly coverage includes case sealing and smooth-rotation checks; separating the CVT requires a new case oil seal.

Grease contamination can make the CVT belt unserviceable, while damaged pulley faces require replacement. The final-gear section covers gearcase removal, gear and bearing inspection, oil-seal replacement and reassembly.

Fault Codes, Fuel Controls and Regional Wiring

Dealer-mode diagnosis covers cam and crank sensors, fuel injectors and IAC circuits, followed by CVT serial communication, motor, pulley-position, speed, secondary-pulley revolution, engine-speed and throttle-position faults. The C58 reduction-ratio disagreement procedure connects pulley-position checks with inspection for contamination inside the CVT.

Symptom-based troubleshooting tables cover engine, CVT, cooling, chassis, brake, electrical and battery complaints.

IAC service limit: The manual includes resistance and heat-response tests for the idle air control valve. Suzuki specifies replacement as a complete assembly rather than internal disassembly.

Regional references distinguish E-02 (UK), E-03 (US except California), E-19 (EU), E-24 (Australia), E-28 (Canada) and E-33 (California). Heated-oxygen-sensor circuit diagnosis is identified for E-02/E-19; AN650L electrical material includes switch inspection tables and a separately labeled wiring layout.

Visual references include the FI System Wiring Diagram, CVT System Parts Location view, Cooling Circuit schematic, Engine Lubrication System Chart, Wiring Harness Routing views and regional main wiring diagrams.

Factory Reference Data and Workshop Tools

Reference tables provide component-specific tightening torques, fluid capacities and approved lubricants, inspection limits, bearing selections, valve and clutch wear data, suspension settings and electrical test specifications.

Diagnostic tools: Dealer-mode procedures identify mode select switch 09930-82720, while the TP-adjustment section lists 09930-82710. Other callouts include multi-circuit tester 09900-25008 and vacuum balancer gauge 09913-13121.

Mechanical tools: The manual identifies crankcase separator 09920-13120 and CVT primary-pulley shaft holder 09920-31010 with extension handle 09920-31020.

Fuel-pressure testing, brake hydraulic service, hot cooling-system work, and engine or CVT removal carry serious risks. Use the specified tools, support equipment, ventilation, and shop procedures for these jobs.

Selected PAIR and Oxygen-Sensor Test Values

The PAIR control solenoid valve has a specified resistance of 20–24 Ω at 20°C (68°F), alongside airflow checks for valve operation.

For E-02/E-19 models, the heated oxygen sensor’s white-to-white circuit is specified at 4–5 Ω at 23°C (73.4°F). The inspection section relates this measurement to sensor-heater temperature.