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2003 Suzuki AN650 Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: AN650 Burgman Year: 2003 Codes Chassis Code: CP11 Engine Code: K700 👋 Introduction Market Position Category: Maxi-scooter Target Audience: Commuters, touring riders, urban...
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Type: Motorcycle
Vendor:
Sku: 539021
2003 Suzuki AN650 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
AN650 Burgman
Year:
2003
Codes
Chassis Code:
CP11
Engine Code:
K700
👋 Introduction
Market Position
Category:
Maxi-scooter
Target Audience:
Commuters, touring riders, urban mobility enthusiasts seeking comfort and practicality.
Competitive Analysis
Competitors:
Yamaha TMAX, Honda Silver Wing, Gilera Nexus, Aprilia Atlantic.
Key Features
Features:
Spacious underseat storage, comfortable seating position, advanced CVT transmission, powerful engine for its class, aerodynamic fairing.
📋 Manual Details
Coverage Areas
Coverage Type:
Comprehensive Service and Repair
Page Count
Estimated Pages:
400+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, internal components, lubrication system, cooling system, fuel system (EFI), ignition system, emissions control.
Transmission:
Automatic CVT (Continuously Variable Transmission) operation, maintenance, diagnosis, and repair, including drive belt, variator, and final drive.
Chassis:
Frame inspection, suspension (front fork, rear shock absorber), steering system, wheels, and tires.
Brakes:
Hydraulic brake system (front and rear discs), brake fluid specifications, caliper maintenance, pad replacement, bleeding procedures.
Electrical:
Wiring diagrams, battery, starter, charging system (alternator), lighting, ignition, instrument panel, EFI control unit, sensors.
Bodywork:
Fairing removal and installation, seating, storage compartments, lighting, fasteners, specifications.
Procedures Included
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, spark plug service, drive belt inspection/replacement, brake fluid flush, coolant service.
Troubleshooting:
Diagnostic flowcharts for common problems, fault code identification (if applicable), symptom-based troubleshooting.
Repair:
Step-by-step instructions for component disassembly, reassembly, and adjustment across all covered systems.
Diagnostics:
Engine performance diagnosis, electrical system checks, CVT system testing.
Technical Depth
Depth:
Detailed diagnostic procedures, torque specifications for all fasteners, clearances and adjustments, electrical schematics, component testing methods.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Printability:
Optimized for printing specific sections or the entire manual.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Type:
Four-stroke, DOHC, 4-valve, liquid-cooled, parallel-twin
Displacement:
638 cc
Bore X Stroke:
75.5 mm x 72.0 mm
Compression Ratio:
9.3:1
Performance
Horsepower:
Approx. 55 PS (40 kW) @ 7000 rpm (claimed)
Torque:
Approx. 61 Nm (45 lb-ft) @ 5000 rpm (claimed)
Fuel System
Induction:
Electronic Fuel Injection (EFI) with dual throttle bodies
Fuel Type:
Unleaded gasoline, minimum 87 octane
Lubrication
Oil Type:
Suzuki brand 10W-40 API SG or higher motorcycle oil, or equivalent.
Oil Capacity:
Approx. 3.3 L (3.5 US qt) with filter change.
Cooling System
Coolant Type:
Permanent-type ethylene glycol antifreeze/coolant mixture with distilled water (50/50 ratio).
Ignition
Ignition System:
Digital CDI with electronic spark advance.
Spark Plug Type:
NGK CR9E or DENSO U27ESR-N (check manual for exact spec).
🔧 Transmission
Standard
Type:
Automatic CVT (Continuously Variable Transmission) with torque converter.
Features
Features:
Suzuki's SEletc Drive System (SDS) offering two modes: D (Drive) for general use and PP (Power Plus) for enhanced acceleration.
Fluid Specifications
Transmission Fluid Type:
Suzuki Genuine Scooter Gear Oil or equivalent SAE 80W-90 API GL-5 gear oil.
Fluid Capacities
Final Drive Oil Capacity:
Approx. 0.25 L (0.26 US qt).
📐 Dimensions
Exterior
Length:
2,260 mm (89.0 in)
Width:
790 mm (31.1 in)
Height:
1,425 mm (56.1 in)
Wheelbase:
1,570 mm (61.8 in)
Ground Clearance:
125 mm (4.9 in)
Weights
Dry Weight:
203 kg (447.5 lbs)
Curb Weight:
Approx. 232 kg (511.5 lbs) with all fluids and a full tank.
Cargo
Underseat Storage Capacity:
Large enough for two full-face helmets, with a split compartment and 12V power outlet.
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle safety is typically assessed through independent testing and rider experience, not standardized government ratings like cars).
Active Features
Braking System:
Hydraulic dual-disc front brakes, hydraulic single-disc rear brake. Some markets offered ABS (Anti-lock Braking System) as an option.
Lighting:
Halogen headlights, LED taillight, turn signals.
Passive Features
Chassis Design:
Robust frame construction for stability.
Ergonomics:
Comfortable riding position, good wind protection from fairing.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital speedometer, analog tachometer, fuel gauge, coolant temperature gauge, odometer, trip meter, clock, various indicator lights.
Power Outlet:
12V DC accessory outlet in the glove box for charging devices.
Driver Assistance
ABS:
Optional ABS system available in certain markets for enhanced braking control.
Connectivity
Connectivity Features:
N/A (No Bluetooth or integrated smartphone connectivity).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Interval:
Inspect every 6,000 km (3,700 miles), replace as needed. Clean at 12,000 km (7,500 miles).
Spark Plug Interval:
Inspect every 12,000 km (7,500 miles), replace if necessary. (Check manual for specific replacement intervals).
Drive Belt Interval:
Inspect every 12,000 km (7,500 miles), replace at 24,000 km (15,000 miles) or if signs of wear are evident.
Brake Fluid Interval:
Replace every 2 years, regardless of mileage.
Coolant Interval:
Replace every 2 years, regardless of mileage.
Fluid Specifications
Brake Fluid Type:
DOT 4 brake fluid.
Coolant Capacity:
Approx. 1.7 L (1.8 US qt).
Known Issues
Common Problems:
Occasional CVT judder or hesitation (often related to belt wear or maintenance), potential for exhaust heat buildup, stator failure (less common on early models but a known Suzuki issue).
Preventative Maintenance:
Regular CVT fluid changes, ensuring proper engine oil levels, checking drive belt condition, and keeping cooling system in good order are crucial for longevity.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation, Japan.
Model Evolution
Introduction Year:
First generation introduced in 2002.
2003 Updates:
Minor refinements and color options over the initial model year.
Production
Manufacturing Location:
Primarily Japan.
🏆 Awards & Recognition
Recognitions
Awards:
While specific awards for the 2003 model are not widely documented, the Burgman line is consistently praised for its comfort, practicality, and touring capability in scooter reviews and comparisons.
Ratings
User Satisfaction:
Generally high user satisfaction due to its comfortable ride, storage, and performance for its intended use.
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