Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair of engine components including cylinder, piston, crankshaft, connecting rod, cylinder head, valves, camshaft, and oil pump.
Fuel System:
Fuel injection system, throttle body, fuel pump, injectors, fuel lines, fuel tank, and emissions control systems.
Cooling System:
Radiator, cooling fan, water pump, thermostat, coolant hoses, and temperature sensor.
Exhaust System:
Exhaust pipes, muffler, catalytic converter (if applicable), and exhaust gaskets.
Transmission Drivetrain:
CVT (Continuously Variable Transmission) operation, disassembly, inspection, adjustment, and reassembly, including drive and driven pulleys, belt, and final drive.
Electrical System:
Ignition system, charging system (alternator, rectifier/regulator), starting system (starter motor, battery), lighting, indicators, horn, and wiring diagrams.
Chassis Frame:
Frame inspection, welding procedures (if applicable), and general structural integrity.
Suspension System:
Front fork (telescopic), rear shock absorber, swingarm, and related components. Includes fork oil specifications and procedures.
Braking System:
Front and rear disc brakes, brake calipers, master cylinders, brake lines, brake fluid specifications, and bleeding procedures.
Steering System:
Handlebars, steering stem, steering bearings, and related components.
Wheels Tires:
Wheel bearings, tire pressure specifications, and wheel removal/installation.
Bodywork Exterior:
Fairings, body panels, seat, storage compartments, and trim. Includes removal and installation procedures.
Instrumentation Controls:
Instrument cluster, switches, levers, cables, and throttle/brake control adjustments.
Maintenance:
Oil change, filter replacement, spark plug replacement, air filter cleaning/replacement, coolant checks, brake fluid checks, tire pressure checks, chain/belt inspection (if applicable).
Troubleshooting:
Diagnostic procedures for common starting issues, engine performance problems, electrical faults, and braking system issues. Includes flowcharts and symptom-based troubleshooting.
Repair Overhaul:
Detailed step-by-step instructions for complete engine rebuilds, transmission overhauls, suspension repairs, brake system servicing, and electrical component replacement.
Adjustments:
Valve clearance adjustment, idle speed adjustment, throttle cable adjustment, brake lever adjustment, and CVT belt tension adjustment (if applicable).
Installation Removal:
Comprehensive guides for removing and installing all major components and sub-assemblies, including engine, transmission, suspension, body panels, and electrical parts.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair and adjustment procedures.
Depth:
Comprehensive, bumper-to-bumper coverage suitable for professional mechanics and advanced DIY enthusiasts. Includes detailed explanations, critical specifications, and diagnostic information.
Engine Type:
4-stroke, DOHC, 2-cylinder, liquid-cooled
Displacement:
638 cc (for the AN650 Burgman)
Bore X Stroke:
75.5 mm x 71.0 mm (typical for the K702 engine)
Horsepower:
Approximately 50-55 HP (varies slightly by year/region)
Torque:
Approximately 60-65 Nm (varies slightly by year/region)
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle bodies
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON + MON / 2)
Fuel Tank Capacity:
Approximately 15 liters (4.0 US gal)
Oil Change Interval:
Typically every 6,000 km (3,700 miles) or 6 months, whichever comes first. Refer to manual for exact specification.
Air Filter Interval:
Inspection every 6,000 km (3,700 miles), cleaning/replacement as needed. Refer to manual for exact specification.
Spark Plug Replacement:
Typically around 12,000 km (7,500 miles) or as per manual recommendation.
Cv Belt Inspection:
Inspection recommended every 12,000 km (7,500 miles) for wear and tension. Replacement interval varies with usage.
Engine Oil Type:
Suzuki recommends SAE 10W-40 API SG or higher, JASO MA.
Engine Oil Capacity:
Approximately 2.0 liters (2.1 US qt) with filter change. Refer to manual for exact capacity.
Coolant Type:
Suzuki Super Long Life Coolant (or equivalent ethylene glycol based coolant with corrosion inhibitors).
Common Wear Items:
CVT belt wear, brake pad wear, fork seals, and battery life are common maintenance items.
Potential Electrical Faults:
Occasionally, issues with charging system components (rectifier/regulator) or starter solenoids can occur, particularly with age.
Cv Transmission Notes:
Proper maintenance of the CVT system, including belt replacement, is crucial for optimal performance and longevity.
Brand Legacy:
Suzuki is a well-established Japanese manufacturer renowned for its motorcycles, automobiles, and marine engines, known for reliability and innovation.
First Generation Launch:
The AN650 Burgman was introduced in 2002, rapidly becoming a benchmark in the maxi-scooter market.
Updates During Coverage Period:
The 1998-2008 period represents the first generation, with minor updates in styling, features, and potentially emissions compliance over the years.
Manufacturing Location:
Primarily manufactured in Japan.
Production Run:
The AN650 Burgman has had a long and successful production run, with continuous evolution.
