Segment:
Premium Maxi-Scooter
Target Audience:
Commuters, touring riders, riders seeking comfort and practicality in a scooter form factor
Key Competitors:
Yamaha TMAX, Honda Silver Wing, BMW C600 Sport/C650 GT (later models)
Unique Selling Points:
Advanced CVT transmission (Seamlessly variable), electric power-adjustable windscreen, large under-seat storage, rider comfort ergonomics
Engine System:
Complete coverage: diagnosis, disassembly, assembly, tuning, specifications
Transmission System:
CVT (Continuously Variable Transmission) including drive and driven pulleys, belt, clutch, and gearbox
Fuel System:
Fuel injection system, fuel pump, injectors, sensors, evaporative emission control
Cooling System:
Radiator, fan, water pump, thermostat, coolant specifications
Exhaust System:
Muffler, catalytic converter, exhaust pipe routing, emissions control
Electrical System:
Ignition system, starting system, charging system, lighting, indicators, horn, battery
Control Systems:
Throttle control, brake control, ABS (if equipped), electronic control unit (ECU) functions
Suspension System:
Front fork (telescopic), rear shock absorber, linkage, adjustments
Braking System:
Front and rear disc brakes, brake fluid specifications, hydraulic system, ABS operation (if applicable)
Wheel And Tire System:
Wheel specifications, tire sizes, inflation pressures, bearing maintenance
Frame And Bodywork:
Chassis, fairings, seating, storage compartments, structural components
Instrumentation And Controls:
Dashboard layout, indicators, switches, diagnostic codes
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, brake pad replacement, chain adjustment (if applicable, though AN650 is belt-driven), fluid checks
Repair Procedures:
Engine overhaul, transmission repair, electrical component replacement, suspension rebuild, brake system bleeding
Troubleshooting Guides:
Diagnostic charts, symptom-based fault finding, common problem resolutions
Component Location:
Detailed diagrams and descriptions for all major components
Wiring Diagrams:
Complete electrical schematics for all circuits and components
Depth Level:
Factory level detail, suitable for professional technicians and experienced DIY mechanics
Diagnostic Capabilities:
Includes procedures for using diagnostic tools and interpreting fault codes
Rebuild Instructions:
Detailed instructions for complete engine and transmission rebuilds
Engine Type:
4-stroke, DOHC, 2-cylinder, parallel-twin
Displacement:
638 cc (39.0 cu. in.)
Bore X Stroke:
75.5 mm x 71.3 mm (2.97 in. x 2.81 in.)
Cooling System:
Liquid-cooled
Horsepower Approx:
50 HP (approximate, depending on market tuning)
Torque Approx:
55 Nm (approximate, depending on market tuning)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Tank Capacity:
15.0 L (3.96 US gal)
Instrument Cluster:
Digital LCD display with analog tachometer, speed, fuel level, coolant temperature, gear indicator (in manual mode), clock, and various warning lights.
ABS Availability:
Optional Anti-lock Braking System (ABS) was available on some 2003 models, enhancing braking safety.
Diagnostic Port:
On-board diagnostics system with connectors for diagnostic tools (details and connector pinouts should be in the manual).
Engine Oil Change:
Every 6,000 km (3,700 miles) or 6 months
Oil Filter Replacement:
Every 12,000 km (7,500 miles) or 12 months
Air Filter Inspection:
Every 6,000 km (3,700 miles)
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or as specified by ignition system diagnostics
Brake Fluid Replacement:
Every 24,000 km (15,000 miles) or 24 months
Engine Oil Type:
Suzuki recommends Suzuki Performance Oil 10W-40 SE, SF, or SG, API SG or higher, JASO MA
Engine Oil Capacity:
3.3 L (3.5 US qt) without filter change; 3.5 L (3.7 US qt) with filter change
Coolant Type:
Permanent antifreeze (ethylene glycol based), 50% solution with distilled water
Gear Oil Type:
Suzuki Gear Oil SAE 80 API GL-4
Gear Oil Capacity:
150 ml (0.16 US qt)
Cvt Belt Wear:
While robust, CVT belts have a finite lifespan and require periodic inspection and replacement. The manual covers inspection procedures.
Electrical Gremlins:
Like many modern vehicles, occasional minor electrical issues can arise, often related to connections or sensors. The wiring diagrams are crucial here.
Suspension Bushings:
Over time, suspension bushings can wear, leading to a less precise feel. The manual details replacement procedures.
