🏷️ Basic Information

Make:

Suzuki

Model:

Burgman 650

Internal Model Code:

AN650

Model Years Covered:

2003, 2004, 2005, 2006

Manual Edition Year:

2003

Chassis Code Range:

AN650K3, AN650K4, AN650K5, AN650K6

👋 Introduction

Segment:

Maxi-scooter / Grand Tourer Scooter

Description:

The Suzuki Burgman 650 (AN650) is positioned as a premium, comfortable, and capable maxi-scooter, designed for both urban commuting and longer-distance touring.

Key Competitors:

Yamaha TMAX 500, Honda Silver Wing 600, Gilera GP 800, Aprilia Atlantic 500.

Powertrain:

650cc liquid-cooled four-stroke parallel-twin engine with advanced CVT transmission.

Comfort:

Spacious seating, generous legroom, ample storage capacity, and advanced aerodynamic fairing for rider comfort.

Technology:

Electronically controlled CVT with manual shifting mode (Sport/Standard) and automatic clutch.

Storage:

Large under-seat storage compartment with ample space for two helmets, plus glove compartments.

📋 Manual Details

Scope:

Comprehensive service and repair for Suzuki Burgman 650 (AN650) models from 2003 to 2006.

Total Pages:

463

Type:

Factory Service Repair Manual

Primary Language:

English (ENG)

File Type:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed procedures for engine disassembly, inspection, repair, and reassembly. Includes cylinder head, valves, piston, crankshaft, connecting rods, oil pump, timing chain, and cooling system.

Fuel System:

Comprehensive coverage of the fuel injection system, fuel pump, fuel filter, throttle body, and fuel tank.

Ignition System:

Ignition coil, spark plug, ignition control module, and troubleshooting.

Transmission Cvt:

In-depth coverage of the Continuously Variable Transmission (CVT) system, including clutch, drive pulleys, driven pulleys, V-belt, gearbox, and lubrication.

Electrical System:

Complete electrical system diagnostics, including battery, charging system (alternator/stator, regulator/rectifier), starting system (starter motor), lighting, indicators, horn, and sensors.

Wiring Diagrams:

Hundreds of detailed wiring diagrams illustrating all electrical circuits, component locations, and wire colors for accurate troubleshooting.

Brakes:

Front and rear brake system maintenance, repair, and bleeding. Includes brake calipers, master cylinders, brake pads, brake discs, and hydraulic lines.

Suspension:

Front fork and rear shock absorber maintenance, repair, and adjustment. Includes fork seals, oil changes, and linkage components.

Steering:

Handlebar, steering stem, and steering bearings maintenance and adjustment.

Bodywork Chassis:

Body panel removal and installation, seat, fairings, storage compartments, and chassis components.

Cooling System:

Radiator, cooling fan, coolant hoses, and coolant fluid specifications.

Exhaust System:

Exhaust pipe, muffler, and related components.

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, coolant checks, brake fluid checks, drive belt inspection.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and uncommon problems across all vehicle systems.

Disassembly Reassembly:

Complete step-by-step instructions for taking apart and putting back together all major and minor components and systems.

Inspections:

Detailed inspection points and procedures for all critical vehicle components to ensure safety and longevity.

Adjustments:

Procedures for adjusting critical settings such as throttle cable, brake levers, and suspension preload.

Part Replacement:

Guidance on replacing worn or damaged parts with correct procedures and specifications.

Depth:

Advanced diagnostics, complete engine and transmission rebuilds, complex electrical system troubleshooting.

Illustrations Diagrams:

Hundreds of detailed illustrations, exploded views, and clear wiring diagrams.

Specifications Tolerances:

Precise technical specifications, torque values, clearances, and wear limits for all components.

📊 Manual Specifications

Format:

PDF

Searchability:

Searchable text content within the PDF for quick information retrieval.

Quality:

LOW QUALITY & FULLY PRINTABLE. Content is clear and legible for printing purposes.

Print Recommendation:

Designed for full printability, allowing users to create a physical copy for workshop use.

Binding:

N/A (Digital Format - PDF)

Paper Recommendation:

Suitable for printing on standard A4 or Letter size paper.

Software Requirement:

Adobe Reader 8 or later

⚙️ Engine Specifications

Engine Type:

4-stroke, 2-cylinder, liquid-cooled, DOHC, 8-valve

Displacement:

638 cc (39.0 cu. in.)

Bore X Stroke:

75.5 mm x 73.0 mm (2.97 in. x 2.87 in.)

Compression Ratio:

9.3:1

Fuel Delivery:

Fuel Injection, Suzuki DP (Dual Throttle Valve) system

Horsepower Hp:

Approx. 50 HP @ 6,500 RPM (Manufacturer figures may vary slightly)

Torque Ft Lb:

Approx. 44.3 ft-lb @ 5,000 RPM (Manufacturer figures may vary slightly)

Fuel Type:

Unleaded gasoline, Octane rating 87 or higher.

Fuel Tank Capacity:

15 Liters (3.96 US gal.)

🔧 Transmission

Transmission Type:

Automatic Continuously Variable Transmission (Suzuki EPPTM - Electronically Controlled Patented Powertrain)

Manual Modes:

Yes, includes 'Standard' and 'Power' modes, selectable via handlebar switch.

Clutch Type:

Automatic centrifugal clutch

Drive:

Belt drive to rear wheel

Transmission Fluid Type:

Suzuki Genuine Gear Oil SAE 80 API GL-4 (Specific part number recommended in manual)

📐 Dimensions

Overall Length:

2,260 mm (89.0 in.)

Overall Width:

810 mm (31.9 in.)

Overall Height:

1,400 mm (55.1 in.)

Wheelbase:

1,585 mm (62.4 in.)

Ground Clearance:

125 mm (4.9 in.)

Curb Weight:

235 kg (518 lbs)

Front Tire Size:

120/70-15M/C 56P

Rear Tire Size:

160/60-15M/C 67P

Wheel Bolt Pattern:

N/A (Scooter specific wheel mounting)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycle and scooter safety ratings are typically not standardized like automobiles).

Brakes:

Front: Dual hydraulic disc brakes. Rear: Single hydraulic disc brake. ABS may have been an option on some models/markets, check specific vehicle.

Lighting:

Halogen headlights, LED taillight, turn signals.

Frame:

Steel tube frame construction for rigidity and stability.

Mirrors:

Large, adjustable rearview mirrors for enhanced visibility.

💡 Technology Features

Display:

Digital instrument cluster with analogue tachometer, digital speedometer, fuel gauge, clock, and various indicator lights.

Features:

Electric adjustable windscreen (on some variants/markets), heated grips (optional).

ABS:

Anti-lock Braking System (ABS) was an optional feature available on certain models and markets.

Charging Port:

12V accessory socket for charging electronic devices.

🔧 Maintenance

Engine Oil Change:

Every 4,000 km (2,500 miles) or 6 months, whichever comes first. (Refer to manual for precise interval).

Oil Filter Replacement:

Every 8,000 km (5,000 miles) or 12 months. (Refer to manual for precise interval).

Air Filter Inspection/Cleaning:

Every 4,000 km (2,500 miles).

Spark Plug Replacement:

Every 8,000 km (5,000 miles). (Refer to manual for specific plug type and gap).

Transmission Fluid Change:

Every 12,000 km (7,500 miles) or 24 months. (Refer to manual for precise interval).

Coolant Replacement:

Initial replacement at 4 years, then every 2 years thereafter. (Refer to manual for coolant type).

Engine Oil Type:

SAE 10W-40 API SG, SH, SJ or higher. (Refer to manual for exact specification and capacity).

Coolant Type:

Suzuki Long Life Coolant or equivalent ethylene glycol-based antifreeze mixture (50% coolant, 50% deionized water). (Refer to manual for specific part numbers).

Brake Fluid Type:

DOT 4 (Refer to manual for specific recommendations and bleeding procedures).

Starter Clutch:

Some models may experience wear on the starter clutch mechanism, leading to a grinding noise during starting.

Cvt Belt Wear:

The CVT drive belt requires periodic inspection and replacement, typically around 20,000-30,000 km, though this varies with riding style. Symptoms of wear include slipping or poor acceleration.

Voltage Regulator:

While not exclusively a Suzuki issue, early voltage regulators can sometimes fail, leading to battery charging problems. This manual will help diagnose such issues.

Throttle Position Sensor Issues:

Erratic throttle response or check engine light can sometimes be attributed to a faulty throttle position sensor.

📚 Vehicle History

Manufacturer:

Suzuki Motor Corporation, a renowned Japanese manufacturer of automobiles, motorcycles, marine engines, and ATVs.

Introduction Year:

The Burgman 650 was first introduced in 2002 for the 2003 model year in most markets.

Design Philosophy:

Designed to blend the practicality of a scooter with the performance and comfort of a motorcycle, creating a 'Grand Tourer' experience.

Updates 2003-2006:

This specific manual covers the initial generation. Minor cosmetic and feature updates were implemented in subsequent model years, but the core mechanics remained consistent until a more significant redesign later in its production life.

Manufacturing Location:

Typically manufactured in Japan.

🏆 Awards & Recognition

Industry Acclaim:

The Suzuki Burgman 650 has consistently received praise for its comfort, performance, and practicality in the maxi-scooter segment, often cited as a benchmark for long-distance touring capability among scooters.

Rider Reviews:

Generally high ratings for comfort, power delivery, and touring suitability in rider and professional reviews from the period.

Manual Certification:

Genuine Factory Service Repair Manual, reflecting official manufacturer procedures and data.