🏷️ Basic Information

Make:

Suzuki

Model:

AN650 Burgman

Year:

2003

Type:

Maxi-Scooter

Generation Code:

First Generation

Chassis Code:

CP51A

👋 Introduction

Segment Description:

The Suzuki AN650 Burgman 2003 entered the maxi-scooter market as a premium, comfortable, and technologically advanced offering, aiming to compete with established European and Japanese brands in the touring and commuting segments.

Key Competitors:

Yamaha TMAX, Honda Silver Wing, Kymco Xciting series, Aprilia Scarabeo.

Unique Selling Points:

Advanced Suzuki Automatic V-belt Transmission (S-A&V) with power mode, extensive under-seat storage, comfortable riding position, and robust engine performance for its class.

Manual Value Proposition:

Provides essential technical information for maintaining the Burgman's complex S-A&V transmission and advanced features, enabling cost-effective repairs and maximizing vehicle longevity.

📋 Manual Details

Areas Covered:

Full coverage of all maintenance, repair, and diagnostic procedures for the 2003 Suzuki AN650 Burgman.

Page Count:

Approximately 400+ pages (estimated based on typical factory service manuals for this class of vehicle).

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of engine components including cylinders, pistons, crankshaft, valves, and timing systems.

Engine Fuel System:

Fuel injection system diagnostics, injector cleaning, fuel pump testing, pressure regulation, and sensor troubleshooting (TPS, MAP, IAT, O2).

Engine Cooling System:

Radiator, water pump, thermostat, coolant flow, bleeding procedures, and fan operation.

Transmission Cvt:

Detailed procedures for the Suzuki Automatic V-belt Transmission (S-A&V), including variator disassembly, roller inspection, belt replacement, clutch operation, and oil maintenance.

Electrical System:

Wiring diagrams, component testing (starter motor, alternator, ignition coils, lighting), battery management, fuses, relays, and switches.

Brakes:

Hydraulic brake system diagnosis, master cylinder overhaul, caliper service, pad replacement, brake fluid flush, and ABS system (if equipped on specific models/regions) troubleshooting.

Suspension:

Front fork disassembly, seal replacement, oil levels, rear shock absorber inspection and replacement, and linkage lubrication.

Steering:

Handlebar assembly, steering stem bearings inspection and adjustment, and lubrication.

Chassis And Bodywork:

Frame inspection, body panel removal and installation, seat mechanisms, storage compartments, and fairing components.

Diagnostics:

Troubleshooting guides, symptom-to-cause diagnosis, and fault code interpretation (if applicable).

Maintenance Procedures:

Oil changes, filter replacements (oil, air), spark plug service, valve clearance adjustment, coolant flushes, brake fluid replacement, and CVT belt inspection/replacement.

Repair Procedures:

Complete engine rebuilds, CVT system overhauls, suspension overhauls, electrical component replacement, brake system repairs, and bodywork repairs.

Disassembly Assembly:

Step-by-step instructions for removing and reinstalling all major components and sub-assemblies.

Troubleshooting Guides:

Systematic approaches to identify and resolve common and uncommon problems.

Torque Specifications:

Precise torque values for all critical fasteners and bolts.

Depth Of Coverage:

Comprehensive, covering basic owner maintenance to advanced mechanical and electrical diagnostics and repairs. Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Yes, the digital format allows for text searching of keywords and procedures.

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Four-stroke, DOHC, 4-valve, liquid-cooled, 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)

Compression Ratio:

9.4:1

Horsepower:

Approximately 50 HP @ 7000 RPM (manufacturer figures may vary slightly)

Torque:

Approximately 57 Nm (42 lb-ft) @ 5000 RPM (manufacturer figures may vary slightly)

Fuel Delivery:

Fuel Injection (SDTV - Suzuki Dual Throttle Valve)

Fuel Type:

Unleaded gasoline, minimum 87 octane

Ignition System:

Electronic ignition (CDI)

🔧 Transmission

Transmission Type:

Suzuki Automatic V-belt Transmission (S-A&V) - Continuously Variable Transmission (CVT)

Drive System:

Automatic, belt drive to rear wheel

Power Mode:

Yes, selectable Power Mode for enhanced acceleration.

Transmission Fluid Type:

Suzuki High Performance Gear Oil (or equivalent API GL-4 SAE 80W-90 or SAE 85W-90 gear oil for the final drive)

Transmission Fluid Capacity:

Approximately 280 mL (0.3 US qt, 0.25 UK qt) for the final drive.

📐 Dimensions

Length:

2,260 mm (89.0 in)

Width:

795 mm (31.3 in)

Height:

1,435 mm (56.5 in)

Wheelbase:

1,555 mm (61.2 in)

Ground Clearance:

135 mm (5.3 in)

Dry Weight:

235 kg (518 lbs)

Curb Weight:

252 kg (555.6 lbs) (approximate)

Gross Vehicle Weight Rating Gvwr:

Not explicitly stated, but typically around 400-450 kg for this class.

Fuel Tank Capacity:

15.0 L (3.9 US gal)

🛡️ Safety Features

Crash Test Results:

Not applicable for motorcycles/scooters in the same way as cars. Focus is on design and engineering for rider safety.

Braking System:

Hydraulic disc brakes front and rear. Optional ABS was available on some markets/trims.

Lighting:

Dual Halogen headlights, LED taillight, integrated turn signals.

Frame Construction:

Steel frame for rigidity and rider protection.

Rider Ergonomics:

Designed for comfort and stability with a low center of gravity.

💡 Technology Features

Dashboard Features:

Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meter, engine diagnostic indicator, and power mode indicator.

Storage Features:

Large, lockable under-seat storage compartment with ample space for helmets and luggage. Glove box compartment in the front fairing.

ABS Availability:

Anti-lock Braking System (ABS) was an optional feature on some models and markets, significantly enhancing braking safety.

Charging Port:

Optional 12V power outlet for charging accessories like GPS units or mobile phones (availability may vary).

🔧 Maintenance

Engine Oil Change:

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

Oil Filter Replacement:

At every engine oil change (6,000 km / 3,700 miles).

Air Filter Cleaning Replacement:

Inspect every 6,000 km (3,700 miles), clean or replace as needed. Replace every 12,000 km (7,500 miles).

Spark Plug Replacement:

Inspect every 12,000 km (7,500 miles), replace as needed. Recommended replacement at 24,000 km (15,000 miles).

Cv Belt Inspection Replacement:

Inspect every 6,000 km (3,700 miles). Recommended replacement between 20,000 km - 30,000 km (12,500 - 18,500 miles), or earlier if wear is evident.

Coolant Replacement:

Every 2 years.

Brake Fluid Replacement:

Every 2 years.

Engine Oil Grade:

10W-40 API SG or higher (Synthetic recommended for optimal performance and protection).

Engine Oil Capacity:

3.1 L (3.3 US qt) with filter change.

Coolant Type:

Suzuki Super Long Life Coolant (or equivalent ethylene glycol-based antifreeze with a 50/50 mix with distilled water).

Brake Fluid Type:

DOT 4.

Common Wear Items:

CVT belt, front fork seals, brake pads, steering head bearings, battery.

Potential Electrical Issues:

While generally reliable, occasional issues with regulator/rectifier or stator can occur, particularly with higher mileage units. This manual will detail testing procedures.

Cv System Considerations:

The S-A&V system requires precise maintenance. Irregular servicing of the CVT belt and rollers can lead to premature wear or performance degradation. The manual provides critical inspection points.

📚 Vehicle History

Suzuki Motorcycle History:

Suzuki has a long and storied history in motorcycle manufacturing, known for innovation and performance across various segments, including sportbikes, cruisers, and scooters.

Burgman Lineage:

The AN650 Burgman, introduced in 2003, was Suzuki's flagship maxi-scooter, designed to offer car-like comfort and features in a two-wheeled package. It represented a significant step up in technology and comfort for the Burgman series.

Manufacturing Location:

Japan

Production Years:

2002-2019 (with significant updates in 2006 and 2013, but the 2003 model represents the initial generation).

🏆 Awards & Recognition

Industry Acclaim:

While specific awards for the 2003 model year may not be widely documented, the Burgman series has consistently been recognized for its comfort, practicality, and innovative features in the maxi-scooter segment by motorcycle publications and riders alike.