Suzuki BURGMAN AN650 Master Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: Burgman AN650 Product Type: Master Service Repair Manual Codes Chassis Code: AN650 Generation Generation Identifier: First Generation 👋 Introduction Market Position Vehicle Segment:...

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Type: Motorcycle

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Sku: 355164

Tags: BURGMAN AN650 Burgman Series Motorcycle Motorcycles Suzuki

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Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Burgman AN650

Product Type:

Master Service Repair Manual

Codes

Chassis Code:

AN650

Generation

Generation Identifier:

First Generation

👋 Introduction

Market Position

Vehicle Segment:

Maxi-scooter, commuter-oriented, touring capability.

Target Audience Manual:

Professional motorcycle technicians, experienced DIY mechanics, fleet maintenance personnel.

Competitive Analysis

Key Competitors Era:

Yamaha TMAX, Honda Silver Wing, Gilera Nexus.

Key Features Vehicle

Unique Selling Proposition:

Advanced automatic transmission (SECC), comfort, large storage capacity, aerodynamic design for touring.

Key Features Manual

Value Proposition:

Authoritative technical resource for accurate diagnosis and repair, minimizing downtime and ensuring longevity.

📋 Manual Details

Coverage Areas

Model Years Covered:

2002, 2003

Region Of Origin Primary:

Japan (for manufacturing and technical development)

Page Count

Estimated Page Count:

350-450 (typical for a comprehensive master service manual)

Manual Type

Manual Type:

Master Service Repair Manual

Purpose:

Professional technician-level diagnostic, repair, and maintenance procedures.

Language

Language:

English

Format

Format:

Digital (likely PDF, potentially with hyperlinking for navigation)

📖 Manual Coverage

Systems Covered

Engine:

Full coverage: disassembly, inspection, assembly, troubleshooting, tuning.

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, fuel pressure, evaporative emissions control (EVAP).

Cooling System:

Radiator, fan, thermostat, water pump, coolant specifications, troubleshooting.

Exhaust System:

Catalytic converter, mufflers, pipes, emission control components.

Transmission:

Automatic transmission (Suzuki's SECC - Suzuki Electronic Controlled Clutch Transmission), CVT components, hydraulic control, troubleshooting, fluid specifications.

Drive System:

Final drive, gears, drive shaft, bearings, lubrication.

Brakes:

Front and rear disc brakes, hydraulic system, ABS (if applicable), brake fluid specifications, bleeding procedures, component replacement.

Suspension:

Front telescopic forks, rear swingarm, shock absorbers, linkages, bearings, lubrication, adjustments.

Steering:

Handlebars, steering column, headstock bearings, lubrication, alignment.

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), ignition system (CDI, spark plugs), lighting, starter motor, fuses, relays.

Electronic Control Unit ECU:

ECU functions, sensor inputs/outputs, diagnostic trouble codes (DTCs), troubleshooting.

Body And Frame:

Chassis, fairings, seat, storage compartments, body panel removal and installation, fasteners.

Wheels And Tires:

Wheel specifications, tire types, pressures, replacement, balancing.

Procedures Included

Preventive Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment (if applicable - though AN650 is shaft drive), lubrication points.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon problems, symptom-based troubleshooting charts.

Engine Repair:

Full engine rebuilds, cylinder head service, piston/ring replacement, valve adjustments (if applicable).

Transmission Repair:

CVT belt inspection/replacement, clutch operation, gearbox overhaul (if separable).

Brake System Service:

Pad/disc replacement, caliper service, fluid flush and replacement.

Electrical Diagnostics:

Component testing (stator output, rectifier function), wiring harness checks, circuit diagnostics.

Suspension And Steering Service:

Fork seal replacement, bearing service, shock absorber replacement.

Special Tools:

Identification and usage instructions for specialized tools required for specific procedures.

Technical Depth

Depth:

Comprehensive: Covers everything from basic fluid changes to complete engine and transmission overhauls.

Diagnostic Level:

Advanced diagnostics, including electrical system analysis and ECU troubleshooting.

Repair Scope:

Full disassembly, repair, and reassembly of all major mechanical and electrical systems.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format) - commonly used for service manuals.

Searchability:

Likely text-searchable, allowing quick access to specific information.

Print Quality:

Designed for digital viewing and printing; high-resolution diagrams and text.

Binding Type

Binding:

N/A (for digital format)

Paper Type

Paper Type:

N/A (for digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, 8-valve, liquid-cooled, parallel-twin.

Displacement:

638 cc (cubic centimeters)

Bore X Stroke:

75.5 mm x 71.2 mm

Compression Ratio:

10.5:1

Fuel Delivery:

Fuel Injection (EFI) with dual throttle bodies.

Performance

Horsepower Approx:

55 PS (Pferdestärke) / 54.3 hp @ 7,000 rpm (approximate, varies by region/tuning)

Torque Approx:

60 Nm / 44.3 ft-lbs @ 5,000 rpm (approximate)

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

15.0 liters (3.96 US gallons)

🔧 Transmission

Standard

Transmission Type:

Suzuki Electronic Controlled Clutch Transmission (SECC) - Automatic with manual override (5-speed simulated mode).

Transmission Fluid Type:

Suzuki Genuine Oil SAE 10W-40 API SE, SF, SG, SH, SJ, SL or equivalent (check specific manual for exact spec).

Features

Drive Mode:

Full Automatic (CVT behavior) and 5-Speed Manual Mode via handlebar buttons.

Final Drive:

Shaft drive.

📐 Dimensions

Exterior

Overall Length:

2,270 mm (89.4 in)

Overall Width:

805 mm (31.7 in)

Overall Height:

1,485 mm (58.5 in)

Wheelbase:

1,510 mm (59.4 in)

Ground Clearance:

125 mm (4.9 in)

Weights

Curb Weight:

275 kg (606 lbs) - approximate, depending on equipment.

Gross Vehicle Weight Rating Gvwr:

Not typically specified for motorcycles in the same way as cars, but implies total weight capacity including rider and cargo.

🛡️ Safety Features

Ratings

Crash Safety Standards:

N/A (motorcycle safety ratings are different from automotive; focused on rider protection and vehicle stability).

Active Features

Anti Lock Braking System ABS:

Optional or standard depending on market/trim for this generation.

Linked Braking System:

Some models may feature a form of linked braking, where front lever application partially applies rear brake.

Passive Features

Lighting:

Halogen headlamps, LED taillight, turn signals.

Wind Protection:

Full fairing with adjustable windscreen for rider comfort and protection.

💡 Technology Features

Infotainment

Display Type:

Digital instrument cluster with analog tachometer, LCD for speed, fuel, gear indicator, clock, etc.

Audio System:

Optional integrated audio system on some models/markets, with handlebar controls.

Driver Assistance

Anti-lock Braking System (as mentioned in safety).

Connectivity

Charging Port:

12V accessory power outlet for charging devices.

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first (typical for Suzuki).

Oil Filter Replacement Interval:

At every oil change (typical).

Transmission Fluid Change Interval:

Every 12,000 km (7,500 miles) or 12 months (typical, check manual).

Spark Plug Replacement Interval:

Approximately 24,000 km (15,000 miles), depending on plug type and condition.

Air Filter Cleaning Interval:

Every 6,000 km (3,700 miles) or as needed based on operating conditions.

Fluid Specifications

Engine Oil Viscosity:

SAE 10W-40

Engine Oil API Service Category:

API SE, SF, SG, SH, SJ, SL or JASO MA.

Engine Oil Capacity:

3.1 L (3.2 US qt) without filter change; 3.3 L (3.5 US qt) with filter change.

Brake Fluid Type:

DOT 4

Coolant Type:

Ethylene glycol-based antifreeze coolant (50% mixture with distilled water recommended).

Known Issues

Secc Belt Wear:

The CVT belt can wear over time, potentially leading to slipping or reduced acceleration; replacement is a common service item.

Stator Failure:

Some units may experience stator failure leading to charging issues.

Rear Shock ABSorber Leaks:

Rear shock absorbers can develop leaks over time, affecting ride quality.

Electrical Connector Corrosion:

Corrosion in electrical connectors can lead to intermittent issues.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycles:

Suzuki has a long history in motorcycle manufacturing, known for innovation in engine technology and performance.

Model Evolution

Burgman Lineage:

The Burgman line originated in Japan in 1998 (AN400) and evolved into larger displacement models like the AN650, aiming for comfort, practicality, and performance.

An650 Introduction Era:

Introduced to capture the growing maxi-scooter market segment demanding car-like comfort and practicality.

Production

Manufacturing Plant:

Primarily manufactured in Japan.

Production Years An650 First Gen:

2002-2012 (with updates).

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

The Burgman AN650 was generally well-received for its comfort, performance, and practicality in the maxi-scooter segment.

Ratings

Consumer Reviews:

Often praised for long-distance comfort and the convenience of its automatic transmission.