Suzuki AN650/A Supplementary Service Manual Download Page 1

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9 9 5 0 1 - 3 6 1 6 0 - 0 1 E

AN650

USE THIS MANUAL WITH:
AN650 SERVICE MANUAL (99500-36113-01E)

Summary of Contents for AN650/A

Page 1: ...9 9 5 0 1 3 6 1 6 0 0 1 E AN650 A USE THIS MANUAL WITH AN650 SERVICE MANUAL 99500 36113 01E...

Page 2: ...5 SDS CHECK 7 FI SYSTEM WIRING DIAGRAM 11 ECM PCM TERMINAL 12 FAIL SAFE FUNCTION 14 MALFUNCTION CODE AND DEFECTIVE CONDITION 15 C40 P0505 or P0506 and P0507 ISC VALVE CIRCUIT MALFUNCTION 16 C41 P2505...

Page 3: ...Except for california E U Australia Canada California U S A JS1BU111200100524 JS1BU111200 100001 JS1BU111100114140 JS1BU121300100404 JS1BU111200 100001 JS1BU111200 100001 AN650A E 02 E 03 E 19 E 24 E...

Page 4: ...el 100 mm 3 9 in Caster 26 10 Trail 106 mm 4 17 in Steering angle 41 right and left Turning radius 2 7 m 8 9 ft Front brake Disc brake twin Rear brake Disc brake Front tire size 120 70R15M C 56H tubel...

Page 5: ...2 7 2 3 US Imp qt with filter change 2 900 ml 3 1 2 6 US Imp qt overhaul 3 400 ml 3 6 3 0 US Imp qt Transmission oil oil change 360 ml 12 2 12 7US Imp oz overhaul 400 ml 13 5 14 1US Imp oz Final gear...

Page 6: ...el 100 mm 3 9 in Caster 26 10 Trail 106 mm 4 17 in Steering angle 41 right and left Turning radius 2 7 m 8 9 ft Front brake Disc brake twin Rear brake Disc brake Front tire size 120 70R15M C 56H tubel...

Page 7: ...2 7 2 3 US Imp qt with filter change 2 900 ml 3 1 2 6 US Imp qt overhaul 3 400 ml 3 6 3 0 US Imp qt Transmission oil oil change 360 ml 12 2 12 7US Imp oz overhaul 400 ml 13 5 14 1US Imp oz Final gear...

Page 8: ...se of a customer vehicle which is not periodically brought in for service with no past data value having been saved if the data value of a good vehicle condition have been already saved as a master ST...

Page 9: ...pressure operation at the time of cold starting Approx 3 000 r min Check the manifold absolute pressure XX kPa Check the engine coolant temperature XX C Check the engine r min XXXX r min Check the ma...

Page 10: ...nifold absolute pressure operation at the time of hot starting Check the engine coolant temperature Approx 100 C Check the manifold absolute pressure XX kPa Check the manifold absolute pressure XX kPa...

Page 11: ...hen you may determine how changes have occurred with the pass of time and identify what problem is currently occurring With DTC not output if the value of engine coolant temperature is found to be low...

Page 12: ...stand relay EVAP system purge control solenoid valve Shift down switch Mode switch Power switch Center stand switch Brake light switch 1 For E 02 19 24 2 For E 03 28 33 3 For E 33 only Pulley positio...

Page 13: ...purge control solenoid valve E 33 only 7 Speed sensor SPD 8 PAIR control solenoid valve PAIR 9 Fuel pump relay FP 0 Ignition coil IG1 A Cooling fan relay FRL B Power switch POWER C Mode switch MODE D...

Page 14: ...njector power voltage VM c CKP sensor N d CMP sensor G e HO2 sensor OX f Secondary pulley revolution sensor SPR g Secondary pulley revolution sensor SPR h Sensor power Vcc i TP sensor VTA j IAT sensor...

Page 15: ...plete providing only emergency help by fail safe circuit In this case it is nec essary to bring the motorcycle to the workshop for complete repair ITEM FAIL SAFE MODE STARTING ABILITY RUNNING ABILITY...

Page 16: ...ignal No voltage is applied to the ECM although the ignition switch is turned ON Lead wire coupler connection of ECM terminal to fuel fuse fuel fuse battery voltage to ECM BATT shorted to ground or op...

Page 17: ...e clogged ISC valve is fixed ISC valve pre set position is incorrect C40 P0507 Idle speed is higher than the desired idle speed ISC valve is fixed ISC valve pre set position is incorrect P W ECM ISC 1...

Page 18: ...airing the trouble clear the DTC using SDS tool Refer to the SDS operation manual for further details Step 2 1 Remove the front box AN650K3 9 18 2 Measure the resistance between terminals A and B term...

Page 19: ...make sure that the rear wheel is locked 3 Set up the SDS tool Refer to the SDS operation manual for further details 4 Check that the engine is running 5 Click the Engine and Transmission 1 6 Click th...

Page 20: ...r Desired idle speed to catch up with the changed value of Spec 3 Click the button 5 and increase the Spec 2 slowly 4 Check that the Desired idle speed 3 is nearly equal to the Spec 2 Also check that...

Page 21: ...peed 2 is approx 1 500 rpm 3 Check that the Engine speed 3 is close to 1 500 rpm NOTE Be careful not to increase the Spec to more than 1 600 rpm or the Engine speed may reach the upper limit If the IS...

Page 22: ...pointed probe set Tester knob indication Voltage DETECTED CONDITION POSSIBLE CAUSE C41 P2505 No voltage is applied to the ECM although the ignition switch is turned ON Lead wire coupler connection of...

Page 23: ...circuit malfunction R Bl wire open or shorted or poor terminal W connection Battery voltage to ECM BATT shorted to ground or open If the wire and connection are OK intermittent trouble or faulty ECM R...

Page 24: ...ob indication Continuity test DETECTED CONDITION POSSIBLE CAUSE C44 P0130 HO2 sensor output voltage is not input to ECM during engine operation and running condition Sensor voltage 1 0 V In other than...

Page 25: ...0130 1 Connect the ECM couplers and HO2 sensor coupler 2 Warm up the engine enough 3 Measure the HO2 sensor output voltage between B G wire and B Br wire when idling condition HO2 sensor output voltag...

Page 26: ...or affects resistance value largely Make sure that the sensor heater is at atmospheric tempera ture 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the voltage OK 5 After rep...

Page 27: ...rcuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool Refer to the SDS operation manual for...

Page 28: ...ance 20 24 at 20 C 68 F Terminal Terminal 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK 6 After repairing the trouble clear the DTC using SDS tool Refer t...

Page 29: ...he SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click PAIR Sol operating control 1 4 Click each button 2 At this time if an operation sound is heard f...

Page 30: ...ge 16 ISC VALVE INSTALLATION Install the ISC valve in the reverse order of removal Be careful not to disconnect the ISC valve coupler at least 5 seconds after ignition switch is turned OFF If the ECM...

Page 31: ...the SDS operation manual for further details 3 Click Active control 4 Click ISC learned value reset 1 5 Click Reset button 2 to clear the ISC learned value NOTE The learned value of the ISC valve is s...

Page 32: ...K3 9 18 Disconnect the respective vacuum hoses 1 from vacuum nip ples Disconnect the IAP sensor coupler 2 Connect the respective vacuum tester hoses to the nipples on the throttle body Step 2 Set up t...

Page 33: ...ing speed NOTE Always set the engine rpm at idle rpm If the adjustment is not yet correct remove each air screw and clean them with a spray type carburetor cleaner and blow dry with a compressed air A...

Page 34: ...sensor HO2 sensor CVT revolution sensor Center stand switch Parking brake switch Wiring harness Clamp CVT control unit Position light LH Headlight LH Wiring harness Throttle cable Position light RH H...

Page 35: ...se Throttle cables B top side top side B top side B top side IA IAC hose C hose ISC hose A left side left side A left side VIEW OF A AP sensor IAT sensor 18 N m 1 8 kgf m 13 0 lb ft TP sensor Vacuum h...

Page 36: ...et 09904 41010 SDS set tool 09930 82720 Mode select switch 99565 01010 010 CD ROM Ver 10 Bolt Diameter A mm Conventional or 4 marked bolt 7 marked bolt N m kgf m lb ft N m kgf m lb ft 4 1 5 0 15 1 0 2...

Page 37: ...0 0 0012 0 0024 Valve guide I D IN EX 4 500 4 515 0 1772 0 1778 Valve stem O D IN 4 475 4 490 0 1762 0 1768 EX 4 455 4 470 0 1754 0 1760 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX...

Page 38: ...00 1 900 kPa 15 0 19 0 kgf cm2 213 270 psi 1 200 kPa 12 kgf cm2 171 psi Compression pressure difference 200 kPa 2 0 kgf cm2 28 psi Piston to cylinder clearance 0 045 0 055 0 0018 0 0022 0 120 0 0047 C...

Page 39: ...012 Conrod big end width 19 950 20 000 0 7854 0 7874 Crank pin width 20 100 20 150 0 7913 0 7933 Conrod big end oil clearance 0 032 0 056 0 0013 0 0022 0 080 0 0031 Crank pin O D 44 976 45 000 1 7707...

Page 40: ...mp qt For 30 sec at 300 kPa 3 0 kgf cm2 43 psi Fuel pressure regulator operating set pressure Approx 300 kPa 3 0 kgf cm2 43 psi ITEM SPECIFICATION NOTE CMP sensor resistance 0 9 1 7 k CMP sensor peak...

Page 41: ...rox 1 3 V 5th 3 000 r min Approx 0 5 V CVT secondary pulley revolution sensor resistance 400 600 CVT secondary pulley revolution sensor peak voltage More than 5 V at idle speed Y W ITEM SPECIFICATION...

Page 42: ...1 atm CKP sensor peak voltage More than 2 0 V Bl G Ignition coil resistance Primary 0 8 2 5 Secondary 8 18 k Ignition coil primary peak voltage More than 80 V 1 W Bl Ground 2 B Y Ground Generator coi...

Page 43: ...Drive indicator light 1 4 Gear position indicator light 1 4 5 Trunk light 5 Immobilizer indicator light LED E 24 Only Over drive indicator light 1 4 ITEM STANDARD LIMIT Brake disc thickness Front 4 5...

Page 44: ...il Front fork oil capacity each leg 458 ml Front fork oil level 151 5 9 Front fork inner tube diam 41 1 61 Rear wheel travel 100 3 9 Rear shock absorber spring adjuster 2nd ITEM STANDARD LIMIT Cold in...

Page 45: ...tank capacity Including reserve 15 0 L 4 0 3 3 US lmp gal Fuel meter mark flickering Approx 3 0 L 0 79 0 66 US lmp gal Fuel meter mark and LCD flickering Approx 1 5 L 0 40 0 33 US lmp gal Engine oil...

Page 46: ...0 0 0012 0 0024 Valve guide I D IN EX 4 500 4 515 0 1772 0 1778 Valve stem O D IN 4 475 4 490 0 1762 0 1768 EX 4 455 4 470 0 1754 0 1760 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX...

Page 47: ...00 1 900 kPa 15 0 19 0 kgf cm2 213 270 psi 1 200 kPa 12 kgf cm2 171 psi Compression pressure difference 200 kPa 2 0 kgf cm2 28 psi Piston to cylinder clearance 0 045 0 055 0 0018 0 0022 0 120 0 0047 C...

Page 48: ...012 Conrod big end width 19 950 20 000 0 7854 0 7874 Crank pin width 20 100 20 150 0 7913 0 7933 Conrod big end oil clearance 0 032 0 056 0 0013 0 0022 0 080 0 0031 Crank pin O D 44 976 45 000 1 7707...

Page 49: ...mp qt For 30 sec at 300 kPa 3 0 kgf cm2 43 psi Fuel pressure regulator operating set pressure Approx 300 kPa 3 0 kgf cm2 43 psi ITEM SPECIFICATION NOTE CMP sensor resistance 0 9 1 7 k CMP sensor peak...

Page 50: ...rox 1 3 V 5th 3 000 r min Approx 0 5 V CVT secondary pulley revolution sensor resistance 400 600 CVT secondary pulley revolution sensor peak voltage More than 5 V at idle speed Y W ITEM SPECIFICATION...

Page 51: ...CKP sensor peak voltage More than 2 0 V Bl G Ignition coil resistance Primary 0 8 2 5 Secondary 8 18 k Ignition coil primary peak voltage More than 80 V 1 W Bl Ground 2 B Y Ground Generator coil resi...

Page 52: ...light 1 4 Gear position indicator light 1 4 5 ABS warning indicator light 1 4 Trunk light 5 Immobilizer indicator light LED E 24 Only Over drive indicator light 1 4 ITEM STANDARD LIMIT Brake disc thi...

Page 53: ...il Front fork oil capacity each leg 458 ml Front fork oil level 151 5 9 Front fork inner tube diam 41 1 61 Rear wheel travel 100 3 9 Rear shock absorber spring adjuster 2nd ITEM STANDARD LIMIT Cold in...

Page 54: ...ing Approx 1 5 L 0 40 0 33 US lmp gal Engine oil and transmission oil type SAE 10W 40 API SF SG or SJ SH with JASO MA Engine oil capacity Oil change 2 6 L 2 7 2 3 US lmp qt Filter change 2 9 L 3 1 2 6...

Page 55: ...WIRING DIAGRAM AN650K7 E 02 19 SAMPLE...

Page 56: ...AN650K7 E 24 SAMPLE...

Page 57: ...AN650K7 E 03 28 33 SAMPLE...

Page 58: ...AN650AK7 E 02 19 51 SAMPLE...

Page 59: ...AN650AK7 E 24 SAMPLE...

Page 60: ...AN650AK7 E 03 28 33 SAMPLE...

Page 61: ...Prepared by February 2007 Part No 99501 36160 01E Printed in Japan 56 SAMPLE...

Page 62: ...Printed in Japan K7...

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