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

• Exact coverage: Factory Suzuki service publication for the 2003 AN650K3 ('03-model') only, with market references for E-02, E-03, E-19, E-24, E-28, and E-33. Supplied as a 463-page PDF; Suzuki cover number 99500-36110-01E.
• Engine and final drive: Covers engine removal and installation, complete disassembly and reassembly, cylinder-head and valve service, cam timing, crankshaft and connecting-rod bearing selection, the automatic centrifugal clutch, starter clutch, balancer, and final-gear case repair.
• CVT overhaul: Details CVT assembly removal, case separation, primary- and secondary-pulley inspection, belt inspection, primary-pulley shim selection, bearing and seal work, reassembly, and operating checks.
• FI and CVT diagnostics: Provides user- and dealer-mode self-diagnosis, fail-safe information, reset procedures, open- and short-circuit testing, TPS adjustment, and fault isolation for ECM sensors, injectors, the CVT motor, and pulley-speed and position sensors.
• Fuel, cooling, and lubrication systems: Includes fuel-pressure and pump tests, throttle-body and injector service, throttle synchronization, radiator and cap pressure checks, thermostat and water-pump repair, cooling-system air bleeding, and lubrication-circuit information.
• Chassis and electrical work: Documents body-panel removal, wheel and fork service, steering, swingarm and rear suspension, front and rear brake overhaul, brake-lock adjustment, charging, starting, ignition, combination-meter tests, harness routing, and full wiring diagrams.

The manual is built around the 638 cc, liquid-cooled DOHC twin and its electronically controlled CVT, not just routine maintenance. Suzuki states that it is written for people who already have the knowledge, skills, and tools - including special tools - required to service Suzuki motorcycles. That makes it appropriate for trained technicians and genuinely experienced owners with a properly equipped shop, not first-time mechanics.

AN650K3 Engine, Clutch, and CVT Repair Depth

The engine chapter takes the AN650K3 from removal through complete teardown, inspection, selective-fit bearing work, and reassembly. Cylinder-head coverage reaches into valve-guide replacement, valve-seat cutting, camshaft journal checks, tappet-shim selection, and camshaft/sprocket positioning. Lower-end repair information covers pistons and rings, connecting rods, crankshaft journals, crankcase bearings, the crank balancer, oil pumps, pressure regulator, sump filter, oil jets, and piston-cooling nozzles. The wet multi-plate automatic centrifugal clutch and starter clutch receive their own disassembly, inspection, and reassembly procedures.

The transmission material is split between the final-gear drive, the mechanical CVT chapter, and the electronic CVT-control chapter. That separation matters: the PDF covers both the pulley-and-belt hardware and the control system used to command it. Workshop procedures include primary-pulley depth and height measurement, shim selection after pulley or housing replacement, CVT case sealing, and final smooth-rotation checks. The final-gear section covers gearcase removal, gear and bearing inspection, oil-seal replacement, and reassembly.

Dealer-Mode Diagnostics and Regional Electrical Coverage

Dealer-mode troubleshooting identifies malfunction codes from the cam and crank sensors through fuel-injector and IAC circuits, then continues into CVT serial communication, motor, pulley-position, speed, secondary-pulley revolution, engine-speed, and throttle-position faults. Symptom tables in the servicing-information section separately cover engine, CVT, cooling, chassis, brake, electrical, and battery complaints.

Regional callouts distinguish E-02 (UK), E-03 (US except California), E-19 (EU), E-24 (Australia), E-28 (Canada), and E-33 (California). The E-02/E-19 heated-oxygen-sensor circuit and its fault checks are identified separately. Useful 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 the market-specific main wiring diagrams, including E-02/E-19 and the separately labeled AN650L layout.

Factory Data, Special Tools, and Damage Risks

Factory reference data covers component-specific tightening torques, fluid capacities and approved lubricants, inspection limits, bearing selections, valve and clutch wear data, suspension settings, and electrical test specifications. Named tool callouts include the 09930-82710 mode select switch, 09913-13121 vacuum balancer gauge, 09920-13120 crankcase separator, 09920-31010 CVT primary-pulley shaft holder with 09920-31020 extension handle, and 09900-25008 multi-circuit tester.

Opening the CVT requires a new case oil seal, and the manual treats grease on the belt or scratches on the pulley faces as conditions that can leave those drive surfaces unserviceable. Replacing the primary pulley, CVT casing, or CVT cover also requires the specified shim-selection procedure. During cylinder-head repair, installing a valve guide without first lubricating the guide bore can damage both the guide and the head.

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.