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Suzuki AN650, Manual

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Suzuki AN650 Manual Download Page 111

7-2

TROUBLESHOOTING

This troubleshooting guide is provided
to help you find the cause of some
common complaints.

IGNITION SYSTEM CHECK

1. Remove the spark plugs and reat-

tach them to the spark plug leads.

2. While holding a spark plug firmly

against the engine, crank the
engine with the ignition switch in
the “ON” position. If the ignition
system is operating properly, a
blue spark should jump across the
spark plug gap. If there is no
spark, consult your Suzuki dealer
for repairs.

ENGINE STALLING

1. Check the fuel supply in the fuel

tank.

2. Check the ignition system for

intermittent spark.

3. Check the idle speed.

NOTICE

Improper repairs or adjustments
may damage the motorcycle
instead of fixing it. Such damage
may not be covered under war-
ranty.

If you are not sure about the
proper action, consult your Suzuki
dealer about the problem.

WARNING

Performing the spark test improp-
erly can be hazardous. You could
get a high voltage electrical shock
if you are not familiar with this
procedure.

Do not perform this check if you
are not familiar with the proce-
dure. Do not point the spark plug
near the spark plug hole during
this test. Do not perform this test
if you have a heart condition or
wear a pacemaker.

Summary of Contents for AN650

Page 1: ...emain with the motorcycle when resold or otherwise transferred to a new owner or operator The manual contains important safety information and instructions which should be read carefully before operating the motorcycle Top 3rd cover 2nd cover Black 4 1 5 mm AN650 Z 99011 26J54 01A ...

Page 2: ...ant that you avoid operating the engine in a manner which could expose the engine parts to excessive heat Please refer to the BREAK IN RUN NING IN section for specific break in recommendations WARNING CAUTION NOTICE NOTE Please read this manual and follow its instructions carefully To emphasize special information the symbol and the words WARNING CAUTION NOTICE and NOTE have special meanings Pay p...

Page 3: ...nsure a long trouble free operating life for your motorcycle Your autho rized Suzuki dealer has experienced technicians that are trained to provide your machine with the best possible service with the right tools and equip ment All information illustrations and speci fications contained in this manual are based on the latest product informa tion available at the time of publica tion Due to improve...

Page 4: ...NSUMER INFORMATION CONTROLS FUEL ENGINE OIL AND COOLANT RECOMMENDATIONS BREAK IN RUNNING IN AND INSPECTION BEFORE RIDING RIDING TIPS INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND MOTORCYCLE CLEANING SPECIFICATIONS INDEX ...

Page 5: ......

Page 6: ...1 1 1 CONSUMER INFORMATION ACCESSORY USE AND MOTORCYCLE LOADING 1 2 SAFE RIDING RECOMMENDATIONS FOR MOTORCYCLE RIDERS 1 4 LABELS 1 6 SERIAL NUMBER LOCATION 1 6 ...

Page 7: ...lity problems The extra weight will cause the motor cycle to be less responsive to your steering control The weight may also cause oscillations in the front end and lead to instability prob lems Accessories added to the handlebars or front fork of the machine should be as light as possible and kept to a minimum Certain accessories displace the rider from his or her normal riding position This limi...

Page 8: ...orks or rear fender Do not install a luggage carrier or a luggage box protruding over the tail end of the motorcycle Do not carry any items that pro trude over the tail end of the motorcycle Check that both tires are properly inflated to the specified tire pres sure for your loading conditions Refer to page 6 33 Improperly loading your motorcy cle can reduce your ability to bal ance and steer the ...

Page 9: ... Motorcycle safety equipment starts with a quality helmet One of the most serious injuries that can happen is a head injury ALWAYS wear a properly approved helmet You should also wear suitable eye protection RIDING APPAREL Loose fancy clothing can be uncom fortable and unsafe when riding your motorcycle Choose good quality motorcycle riding apparel when riding your motorcycle INSPECTION BEFORE RID...

Page 10: ...wet ones requires extra cau tion Braking distances double on a rainy day Stay off of the painted sur face marks manhole covers and greasy appearing areas as they can be especially slippery Use extreme caution at railway crossings and on metal gratings and bridges Whenever in doubt about road conditions slow down RIDE DEFENSIVELY The most common type of motorcycle accident occurs when a car traveli...

Page 11: ...ER LOCATION The frame and or engine serial num bers are used to register the motorcy cle They are also used to assist your dealer when ordering parts or refer ring to special service information The frame number 1 is stamped on the frame The engine serial number 2 is stamped on the engine Please write down the numbers here for your reference Frame No Engine No ...

Page 12: ...UMENT PANEL 2 8 LEFT HANDLEBAR 2 20 RIGHT HANDLEBAR 2 24 BRAKE LOCK LEVER 2 26 FUEL TANK CAP 2 27 FRONT TRUNK 2 29 FRONT SMALL BOX 2 30 TRUNK 2 30 HELMET HOLDER 2 31 BACKREST ADJUSTMENT 2 31 TRUNK BOX LIGHT SWITCH 2 32 STAND 2 32 REAR SUSPENSION 2 33 OUTPUT TERMINAL 2 34 ...

Page 13: ...ear brake fluid reservoir 4 Instrument panel 5 Front brake fluid reservoir 6 Right handlebar switches 7 Throttle grip 8 Front brake lever 9 Grip heater switch AN650Z 0 Front small box A Air cleaner Fuses B Ignition switch C Seat heater switch AN650Z D Front trunk E Output terminal AN650 ...

Page 14: ...p N Spark plugs O Engine coolant reservoir P Engine oil filler cap Q Engine oil filter R Engine oil drain plug S Side stand T Engine oil inspection window U Transmission oil drain plug V Center stand W Transmission oil level plug X Transmission oil filler plug Y Final gear oil drain plug Z Final gear oil level plug AN650 ...

Page 15: ...2 4 AN650Z Main fuse CVT fuse CVT filter AN650 ...

Page 16: ...r identification code is programmed into the key There fore a key made by an ordinary locksmith will not work Ask your Suzuki dealer if you need to make a spare key If you lose the key ask your Suzuki dealer to have the lost one deactivated If you own other vehicles with immobilizer keys keep those keys away from the ignition switch when using your motorcycle or they may interfere with your motorc...

Page 17: ...ne can now be started The key cannot be removed from the igni tion switch NOTE Start the engine promptly after turning the key to the ON position or the battery will lose power due to consumption by the headlight and tail light LOCK Position To lock the steering turn the handle bar all the way to the left Push the key in and turn it to the LOCK posi tion and remove the key All electrical circuits ...

Page 18: ...rn off the seat heater switch when the engine is not running WARNING Turning the ignition switch to the P PARKING or LOCK posi tion while the motorcycle is mov ing can be hazardous Moving the motorcycle while the steering is locked can be hazardous You could lose your balance and fall or you could drop the motorcycle Stop the motorcycle and place it on the side stand if equipped before locking the...

Page 19: ... for 4 seconds TURN SIGNAL INDICATOR LIGHT 2 When the turn signals are being oper ated either to the right or to the left the indicator light will blink intermit tently NOTE If a turn signal light is not operating properly due to bulb fila ment or circuit failure the indicator will blink quickly to warn the rider of the existence of a problem BRAKE LOCK INDICATOR LIGHT 3 This light comes on when t...

Page 20: ...on and the coolant tem perature mark blinks stop the engine wait until the engine is cooled and check the coolant level NOTICE Riding the motorcycle with the oil pressure indicator light lit can damage the engine and transmis sion If the oil pressure indicator light comes on indicating low oil pres sure stop the engine immediately Check the oil level and add oil if necessary If there is a proper a...

Page 21: ...ST button H to return to original reading When the ambient air temperature is above 5 C 41 F the display will return to original reading automatically NOTE The thermometer will not indicate the actual ambient air temperature when riding at low speed or when stopped The thermometer displays Lo when the ambient air temperature is below 10 C 14 F The ther mometer displays HI when the ambient air temp...

Page 22: ...UK model is fixed to Imperial gal lon To change the km L and L 100 km Except for UK Push the SELECT button G for 2 sec onds to change km L mode to L 100 km mode Gear Position Indicator MANUAL mode only The gear position indicator display indicates gear position when the MANUAL mode is selected km L mode L 100km mode WARNING Changing the display while riding can be hazardous Removing a hand from th...

Page 23: ... when the motorcycle is placed on the side stand Turn the ignition switch to the ON position when the motorcycle is held upright FREEZE INDICATOR LIGHT 8 The freeze indicator light 8 starts blinking when the ambient tempera ture falls below 3 C 38 F The freeze indicator light keeps flashing for 30 seconds and then remains lit until the ambient temperature rises above 5 C 41 F Freeze indicator ligh...

Page 24: ...tely and the red indicator light comes on and remains lit keep the engine run ning and bring your motorcycle to an authorized Suzuki dealer If the engine stalls try restarting the engine after turning the ignition switch off and on When the display J indicates CHEC make sure that the engine stop switch is in the position If the display still indicates CHEC after above procedure inspect the ignitio...

Page 25: ...th the engine running after riding the motorcycle and racing the engine the ABS indicator light can come on In such a case check if the ABS indicator light comes on by turning off and on the ignition switch After that check if the ABS indicator light goes out after the motorcycle speed exceeds 5 km h 3 mph If the ABS indicator light does not go out you should have the sys tem checked by an authori...

Page 26: ...tons simultaneously for 2 seconds to return to the clock mode NOTE When the button is pressed and held display will increase continu ously The clock can be adjusted when the ignition switch is in the ON position This clock is powered by the bat tery of the motorcycle If your motorcycle is to be left unused more than two months remove the battery from the motorcycle DRIVE MODE INDICATOR B Drive mod...

Page 27: ...INDICATOR D if equipped The immobilizer indicator blinks two times when the ignition switch is turned on Then indicator comes on two seconds and goes off Immobilizer system is designed to help prevent motorcycle theft by elec tronically disabling the engine starting system The engine can be started only with your original keys which have an electronic identification code programmed into it The key...

Page 28: ... OIL CHANGE indicator E blinks 3 times and goes off To preset the oil change interval 1 Set the meter to odometer then press and hold the ADJUST but ton H for 2 seconds until the INTERVAL F and OIL CHANGE E indicators blink 2 Push the SELECT button G to decrease the interval from 6000 km 3600 miles to 500 km 300 miles in 500 km 300 mile steps 3 Push the ADJUST button H to increase the interval fro...

Page 29: ... the specified range NOTE The engine oil level in the crankcase changes while riding Quick acceleration hard braking and hill climbing will change engine oil level This oil level change can trigger the engine oil level indicator The indi cator will also come on it the motorcy cle tips over These cases are not oil level indicator malfunction ODOMETER TRIP METER J The display has two functions odom ...

Page 30: ...ive Indicator light located on the instrument panel will come on when the motorcycle is operated in a fuel efficient manner and may help riders learn techniques to improve their fuel economy The Eco Drive Indicator is active when the AN650 Z is operated in the Drive mode but disabled when in the Manual mode The system monitors the motorcycle s real time fuel con sumption rate and illuminates the E...

Page 31: ...n the adjuster to the desired position When changing the brake lever posi tion always be sure the adjuster stops in the proper position a projec tion of the brake lever pivot should fit into the depression of the adjuster This motorcycle is delivered from the factory with its adjuster set on posi tion 3 WARNING Adjusting the rear brake lever position while riding can be haz ardous Removing a hand ...

Page 32: ...itch will shift down the transmission The transmis sion will be shifted down automati cally when the motorcycle speed is decreased NOTE Gear position indicator blinks 3 times when the shift change is not acceptable due to the desired gear being out of transmission speed range WARNING Riding the motorcycle with the rear view mirrors folded will be hazardous Extend both right and left rear view mirr...

Page 33: ...ing The grip heater switch will be turned off when the ignition switch is turned off The grip heater temperature can be adjusted in five steps by pushing the switch Pushing the switch changes temperature as follows NOTICE Sticking tape or placing objects in front of the headlight can obstruct headlight heat radiation This can result in headlight damage Do not stick tape on the headlight or place o...

Page 34: ...ill also flash intermittently Push in the switch to cancel the turn signal operation WARNING Improperly using the grip heater can be hazardous Rider can suf fer burns even if the heating tem perature is fairly low when the rider is wearing no gloves and leaves the heater on for long peri ods Damaged grip can suffer burns or get an electrical shock Be sure to wear gloves to avoid burns Replace the ...

Page 35: ... ignition circuit is off The engine cannot start or run position The ignition circuit is on and the engine can run HAZARD WARNING SWITCH 2 All four turn signal lights and indica tors will flash simultaneously when the switch is turned on with the igni tion switch in the ON or P position Use the hazard warning lights to warn other traffic during emergency park ing or when your vehicle could other w...

Page 36: ...e starter motor NOTE If the brake lever is not squeezed the starter motor will not operate NOTE This motorcycle is equipped with an interlock system for the igni tion circuit and the starter circuit The engine can only be started if the side stand is fully up NOTE The headlight will go off when the electric starter switch is pushed WARNING Adjusting the front brake lever position while riding can ...

Page 37: ...ll come on when the brake lock lever is engaged To release the brake lock lever pull the lever and release it WARNING Operating power windshield on someone s hands or fingers can cause serious injury Make sure nobody is touching windshield before operating the power windshield switch SCREEN WARNING Riding the motorcycle with the brake lock lever engaged is haz ardous The rear brake will over heat ...

Page 38: ...uel tank cap guide pins Push down the fuel tank cap until the locking pins click into position The key must be in the cap lock before installing the cap WARNING Operating the brake lock lever while riding can be hazardous Removing a hand from the handle bars can reduce your ability to control the motorcycle Operating the brake lock lever while riding can cause rear wheel skid and loss of control A...

Page 39: ...g hold the tip of fuel nozzle against crossbar in fuel inlet as illustration Stop filling the fuel tank after the fuel nozzle automatically clicks off Do not try to top off the fuel tank Leave some room for the fuel to expand from temperature increase WARNING Failure to follow safety precau tions when refueling could result in a fire or cause you to breathe toxic fumes Refuel in a well ventilated ...

Page 40: ...to lock the latch lever 3 Remove the key 4 Pull the latch lever and check that the box lid is locked The box load capacity is 1 5 kg 3 0 lbs WARNING If the box lid is not locked it may open while riding Make sure the box lid is closed and locked securely WARNING Opening the box lid while riding can be hazardous Removing a hand from the handlebars can reduce your ability to control the motorcycle A...

Page 41: ...unk when leaving the motorcycle unattended Do not put valuable items in the trunk because the trunk is not watertight Push down the rear end of the seat if the seat does not unlock with key operation Place helmets as shown or seat may not be completely locked WARNING Opening the box lid while riding can be hazardous Removing a hand from the handlebars can reduce your ability to control the motorcy...

Page 42: ...ENT The backrest adjustment lever is located under the seat To adjust the backrest position move the adjust ment lever and slide the backrest for ward or rearward Try to move the backrest forward and rearward to ensure that it is securely latched NOTE Return the adjustment lever by hand to lock the backrest BACKREST ADJUST ...

Page 43: ...senger hand rail with your right hand while steadying the handlebars with your left hand NOTE The transmission cannot shift when the motorcycle is placed on the center stand Ride and move the motorcycle to inspect shift operation SIDE STAND 2 An interlock system is provided to cut off the ignition circuit when the side stand is down The side stand ignition interlock sys tem works as follows If the...

Page 44: ...t when you turn left Check operation of the side stand ignition interlock system before riding Always retract the side stand completely before starting off NOTICE Park the motorcycle on firm level ground to help prevent it from fall ing over If you must park on an incline aim the front of the motorcycle uphill and apply the brake lock to reduce the possibility of rolling off the side stand For bet...

Page 45: ...e before attaching accessories to the output terminal NOTE The trunk lid may not latch closed if a long type plug is inserted into the output terminal NOTICE Using improper electrical acces sories can damage your motorcy cle Exceeding 36W or using other than a 12V accessory can seri ously damage the electrical sys tem and accessory Check voltage and wattage before connecting electrical accessories...

Page 46: ...3 1 3 FUEL ENGINE OIL AND COOLANT RECOMMENDATIONS FUEL OCTANE RATING 3 2 OXYGENATED FUEL RECOMMENDATION 3 2 ENGINE OIL 3 4 TRANSMISSION OIL 3 5 FINAL GEAR OIL 3 5 ENGINE COOLANT SOLUTION 3 6 ...

Page 47: ...da and EU Oxygenated fuels which meet the minimum octane requirement and the requirements described below may be used in your motorcycle without jeopardizing the New Vehicle Limited Warranty or the Emission Control System Warranty NOTE Oxygenated fuels are fuels which contain oxygen carrying addi tives such as MTBE or alcohol Gasoline Containing MTBE Unleaded gasoline containing MTBE Methyl Tertia...

Page 48: ...ated fuels Be sure that any oxygenated fuel you use has recommended octane ratings If you are not satisfied with the drivability of your motorcycle when you are using an oxygen ated fuel or if engine pinging is experienced substitute another brand as there are differences between brands NOTICE Spilled gasoline containing alco hol can damage the painted sur faces of your motorcycle Be careful not t...

Page 49: ...rganization SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available select an alternative according to the following chart JASO T903 The JASO T903 standard is an index to select engine oils for 4 stroke motorcycle and ATV engines Motor cycle and ATV engines lubricate clutch and transmission gears with engine oil JASO T903 specifies per ...

Page 50: ...affect engine life and clutch performance API SG SH SJ or SL Recommended API SH SJ or SL Not recommended TRANSMISSION OIL Use a good quality SAE 10W 40 multi grade motor oil FINAL GEAR OIL Use an SAE90 hypoid gear oil which is rated GL 5 under the API classifica tion system If you operate the motor cycle where ambient temperature is below 0 C 32 F use an SAE80 hypoid gear oil A PI SERVICE S J SAE ...

Page 51: ... is pre mixed to the proper ratio Add only SUZUKI SUPER LONG LIFE COOLANT if coolant level drops It is not necessary to dilute SUZUKI SUPER LONG LIFE COOL ANT when replacing coolant WARNING Engine coolant is harmful or fatal if swallowed or inhaled Solution can be poisonous to animals Do not drink antifreeze or coolant solution If swallowed do not induce vomiting Immediately con tact a poison cont...

Page 52: ...pacity total 1600 ml 1 7 1 4 US Imp qt NOTE This 50 mixture will protect the cooling system from freezing at temperatures above 31 C 24 F If the motorcycle is to be exposed to tem perature below 31 C 24 F this mix ing ratio should be increased up to 55 40 C 40 F or 60 55 C 67 F coolant The mixing ratio should not exceed 60 coolant 50 Water 800 ml 0 8 0 6 US Imp qt Coolant 800 ml 0 8 0 6 US Imp qt ...

Page 53: ......

Page 54: ...4 1 4 BREAK IN RUNNING IN AND INSPECTION BEFORE RIDING INSPECTION BEFORE RIDING 4 3 ...

Page 55: ...eak in to assure maximum performance just as the engine does Wear in the tread surface by gradually increasing your cornering lean angles over the first 160 km 100 miles before attempting maximum performance Avoid hard acceleration hard cornering and hard braking for the first 160 km 100 miles AVOID CONSTANT LOW SPEED Operating the engine at constant low speed light load can cause parts to glaze a...

Page 56: ... The 1000 km 600 miles ser vice should be performed as outlined in the Maintenance Schedule section of this Owner s Manual Pay particular attention to the caution and warning messages in MAINTENANCE SCHEDULE section INSPECTION BEFORE RIDING WARNING Failure to inspect your motorcy cle before riding and to properly maintain your motorcycle increases the chances of an acci dent or equipment damage Al...

Page 57: ...le WHAT TO CHECK CHECK FOR Steering Smoothness No restriction of movement No play or looseness Brakes 2 20 2 24 2 26 6 29 Proper lever operation Fluid level in the reservoir to be above LOWER line No fluid leakage Brake pads not worn down to the limit line Correct lever play No sponginess No dragging Brake lock operation Tires 6 32 Proper pressure Adequate tread depth No cracks or cuts Fuel 2 12 E...

Page 58: ...5 1 5 RIDING TIPS STARTING THE ENGINE 5 2 STARTING OFF 5 3 RIDING ON HILLS MANUAL mode 5 4 STOPPING AND PARKING 5 5 ...

Page 59: ...y and push the electric starter switch 3 After the engine starts let the engine run until the engine suffi ciently warms up When the Engine is Warm 1 Squeeze the front or rear brake lever 2 Close the throttle completely and push the electric starter switch 3 After the engine starts let the engine run until the engine suffi ciently warms up When a Warm Engine is Hard to Start 1 Squeeze the front or...

Page 60: ...t begin your ride promptly WARNING Riding at excessive speeds increases your chances of losing control of the motorcycle which can result in an accident Always ride at a speed that is proper for the terrain visibility and operating conditions and your skills and experience WARNING If you remove even one hand or foot from the motorcycle you can reduce your ability to control the motorcycle This cou...

Page 61: ...ou should shift to a lower gear so that the engine will again be operating in its normal power range Shift rapidly to pre vent the motorcycle from losing momentum When descending a long steep slope use the engine compres sion to assist the brakes by shift ing to a lower gear Continuous brake application can overheat the brakes and reduce their effective ness Be careful however not to allow the eng...

Page 62: ...or weather conditions You must still ride sensibly and alertly On regular paved roads some riders may be able to obtain slightly shorter stopping distances with conventional brake systems than with ABS NOTE In some situations a motorcy cle with ABS may require a longer stopping distance to stop on loose or uneven surfaces than an equivalent motorcycle without ABS WARNING Inexperienced riders tend ...

Page 63: ...ion without pumping either one It is normal for the brake levers to pulsate while the ABS is operating Non recommended tires can affect wheel speed and may confuse the computer ABS does not work at very low speed less than 8 km h 5 mph and does not work with a discharged battery WARNING Failure to use good judgment with ABS can be hazardous ABS can not make up for bad road condi tions bad judgemen...

Page 64: ...while turning may cause wheel skid and loss of con trol Brake before you begin to turn WARNING Hard braking on wet loose rough or other slippery surfaces can cause wheel skid and loss of con trol Brake lightly and with care on slip pery or irregular surfaces WARNING Following another vehicle too closely can lead to a collision As vehicle speeds increase stop ping distance increases progres sively ...

Page 65: ...heft lock such as an U shape lock brake disk lock or chain is used to avoid theft be sure to remove the anti theft lock before moving the motorcycle CAUTION A hot muffler can cause severe burns The muffler will be hot enough to cause burns for some time after stopping the engine Park the motorcycle where pedes trians or children are not likely to touch the muffler NOTICE Direct sunlight magnified ...

Page 66: ...R CLEANER 6 12 ENGINE IDLE SPEED INSPECTION 6 15 THROTTLE CABLE PLAY 6 16 CVT FILTER 6 17 ENGINE COOLANT 6 19 ENGINE OIL 6 21 TRANSMISSION OIL AND FINAL GEAR OIL 6 26 BRAKES 6 29 TIRES 6 32 SIDE STAND IGNITION INTERLOCK SYSTEM 6 35 LIGHT BULB REPLACEMENT 6 36 FUSES 6 40 CATALYTIC CONVERTER 6 42 DIAGNOSTIC CONNECTOR 6 44 ...

Page 67: ...um safety we suggest that you have these items inspected and serviced by your authorized Suzuki dealer or a quali fied service mechanic WARNING Improper maintenance or failure to perform recommended mainte nance can lead to an accident Keep your motorcycle in good condition Ask your Suzuki dealer or a qualified mechanic to perform the maintenance items marked with an asterisk You may per form the ...

Page 68: ... a qualified mechanic NOTICE Servicing electric parts with the ignition switch in the ON posi tion can damage the electric parts when the electric circuit is shorted Turn off the ignition switch before servicing the electric parts to avoid short circuit damage NOTICE Poorly made replacement parts can cause your motorcycle to wear more quickly and may shorten its useful life When replacing parts on...

Page 69: ...ply system I I CVT filter 6 17 I I Radiator hose 6 20 I I I I Replace every 4 years Engine coolant 6 19 SUZUKI SUPER LONG LIFE COOLANT Blue Replace every 4 years or 48000 km 29000 miles SUZUKI LONG LIFE COOLANT Green or an engine coolant other than SUZUKI SUPER LONG LIFE COOLANT Blue R R Fuel hose I I I I Replace every 4 years Engine oil 6 21 R R R R R Engine oil filter 6 21 R R Transmission oil 6...

Page 70: ...to lubricate the motorcycle after a long rough ride and after getting it wet in the rain or after washing it Major lubrication points are indicated below Motor oil Grease 1 Rear brake lever pivot 2 Side stand pivot and spring hook 3 Center stand pivot and spring hook 4 Throttle cable 5 Front brake lever pivot NOTICE Lubricating electrical switches can damage the switches Do not apply grease or oil...

Page 71: ...ic acid from the bat tery can cause blindness or severe burns When working near the battery use proper eye protection and gloves Flush eyes or body with ample water and get medical care immediately if you suffer injury Keep batteries out of reach of chil dren WARNING Batteries produce flammable hydrogen gas which can explode if exposed to flames or sparks Keep flames and sparks away from the batte...

Page 72: ... Recharge the battery once a month if the motorcycle is not used for a long time NOTICE Reversing the battery lead wires can damage the charging system and the battery Always attach the red lead to the positive terminal and the black or black with white tracer lead to the negative terminal WARNING Batteries contain toxic sub stances including sulfuric acid and lead They could cause injury to human...

Page 73: ...mation about disposing or recy cling of the used battery consult your Suzuki dealer SPARK PLUG 0 7 0 8 mm 0 028 0 031 in Remove the carbon deposits from the spark plug with a spark plug cleaning machine Readjust the spark plug gap to 0 7 0 8 mm 0 028 0 031 in by using a spark plug gap thickness gauge The spark plug should be replaced periodically Whenever removing the carbon deposits be sure to ob...

Page 74: ...may have an incorrect fit or inappropriate heat range for your engine This may cause severe engine damage which may not be covered under warranty Use one of the spark plugs listed or their equivalent Consult your Suzuki dealer if you are not sure which spark plug is correct for your type of usage NGK DENSO REMARKS CR7E U22ESR N If the standard plug is wet in appearance or very dark in color replac...

Page 75: ...from the lower leg shield Unhook the hooks and remove the lower leg shield forward 1 2 Remove the bolt Pull the radiator forward CAUTION A hot radiator and hot engine can burn you Wait until the radiator and engine are cool enough to touch with bare hands before starting this work ...

Page 76: ...s threaded spark plug will damage the alumi num threads of the cylinder head Carefully turn the spark plug by hand into the threads If the spark plug is new tighten it with a wrench about 1 2 turn past finger tight If you are reusing the old spark plug tighten it with a wrench about 1 8 turn past finger tight NOTICE Dirt can damage the moving engine parts of your motorcycle if it enters an open sp...

Page 77: ...n be hazardous A flame can spit back from the engine to the air intake box without the air cleaner ele ment to stop it Severe engine damage can also occur if dirt enters the engine due to running the engine without the air cleaner element Never run the engine without the air cleaner element in place NOTICE Failure to inspect the air cleaner element frequently if the vehicle is used in dusty wet or...

Page 78: ...low the procedure below to remove the air cleaner element 1 Open the front trunk 2 Remove the air cleaner mainte nance lid 3 Remove the screws and air cleaner cap 4 Pull out the air cleaner element with pliers ...

Page 79: ...element NOTE Be careful not to spray water on the air cleaner box when cleaning the motorcycle NOTICE A torn air cleaner element will allow dirt to enter the engine and can damage the engine Replace the air cleaner element with a new one if it is torn Care fully examine the air cleaner ele ment for tears during cleaning NOTICE Failure to position the air cleaner element properly can allow dirt to ...

Page 80: ...nance interval ENGINE IDLE SPEED INSPECTION Inspect the engine idle speed The engine idle speed should be 1100 1300 r min when the engine is warm NOTE If the engine idle speed is not within the specified range ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle ...

Page 81: ...BLE BOOTS The throttle cable has a boots Check that the boots are fit securely Do not apply water directly to the boots when washing Wipe off dirt from the boots with a wet cloth when the boots are dirty WARNING Inadequate throttle cable play can cause engine speed to rise sud denly when you turn the handle bars This can lead to loss of control and an accident Adjust the throttle cable play so tha...

Page 82: ...2 Remove the floor mats 3 Remove the screws 4 Remove the fastener 5 Unhook the hooks and remove the right side rear lower footboard 1 6 Unhook the hooks and remove the right side leg shield 2 NOTE To remove the right side leg shield 2 push the hook 3 located inside the front side of leg shield and pull it towards you ...

Page 83: ...he screws 1 2 Unhook the hooks and move the CVT filter lid 2 3 Remove the bolts and CVT filter cover 3 4 Remove the bolts and CVT filter 4 5 Inspect the CVT filter for damage and dirt If any defects are found the CVT filter must be replaced ...

Page 84: ...through the filler hole until it reaches the F line NOTE Check the coolant level when the engine is cold If the engine coolant reservoir is empty check the radiator coolant level To add specified engine coolant 1 Place the motorcycle on the cen ter stand 2 Remove the fastener Unhook the hooks and remove the mainte nance lid 3 Remove the filler cap and add specified engine coolant through the fille...

Page 85: ...lant leakage If any defects are found ask your Suzuki dealer to replace the radiator hose with a new one WARNING Engine coolant is harmful or fatal if swallowed or inhaled Solution can be poisonous to animals Do not drink antifreeze or coolant solution If swallowed do not induce vomiting Immediately con tact a poison control center or a physician Avoid inhaling mist or hot vapors if inhaled remove...

Page 86: ... stand 2 Start the engine and run it for three minutes 3 Stop the engine and wait three minutes 4 Hold the motorcycle vertically and inspect the engine oil level through the engine oil level inspection window on the left side of the engine NOTICE Operating the motorcycle with too little or too much oil can damage the engine Place the motorcycle on level ground Check the oil level with the engine o...

Page 87: ...mainte nance lid 2 Remove the oil filler cap 1 3 Remove the drain plug 2 and gasket 3 from the bottom of the engine and drain the engine oil into a drain pan CAUTION Hot engine oil and exhaust pipes can burn you Wait until the oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil CAUTION A hot muffler can burn you The muffler will be hot enough to burn you f...

Page 88: ...clean rag WARNING Children and pets may be harmed by swallowing new or used oil Repeated prolonged contact with used engine oil may cause skin cancer Brief contact with oil may irritate skin Keep new and used oil and used oil filters away from children and pets To minimize your exposure to used oil wear a long sleeve shirt and moisture proof gloves such as dishwashing gloves when changing oil If o...

Page 89: ...r position on the cap type filter wrench or on the oil filter Use an oil filter wrench to tighten the filter 2 turns or to specified torque Oil filter tightening torque 20 N m 2 0 kgf m 14 5 lbf ft NOTICE Failure to use an oil filter with the correct design and thread specifi cations can damage your motor cycle s engine Be sure to use a genuine Suzuki oil filter or an equivalent one designed for y...

Page 90: ...Start the engine while the motor cycle is outside on level ground and allow it to idle for three min utes 11 Turn the engine off and wait approximately three minutes Recheck the oil level on the engine oil inspection window while holding the motorcycle vertically If it is lower than the L line add oil until the oil level is between the L line and the F line Inspect the area around the drain plug a...

Page 91: ...6 26 TRANSMISSION OIL AND FINAL GEAR OIL LEFT SIDE LEG SHIELD REMOVAL 1 Remove the lower leg shield by referring to the SPARK PLUG sec tion 2 Remove the floor mats 3 Remove the screws ...

Page 92: ...e motorcycle on level ground on the center stand Hold the motorcycle vertically and check the transmission oil 2 Remove the oil filler plug 1 3 Remove the drain plug 2 from the bottom of the engine and drain the transmission oil into a drain pan 4 Reinstall the drain plug 2 Tighten the plug securely with a wrench 5 Remove the oil level plug 3 and inspect the oil level If the level is below the lev...

Page 93: ...inal gear oil can cause the final drive unit to lock up and cause an accident Check for leaks and the correct level of final gear oil before each use Add oil if necessary Tighten the drain plug securely after changing the gear oil WARNING Children and pets may be harmed by swallowing new or used oil Repeated prolonged contact with used engine oil may cause skin cancer Brief contact with oil may ir...

Page 94: ... disk brake pads BRAKE HOSE INSPECTION Inspect the brake hoses and hose joints for cracks damage or brake fluid leakage If any defects are found ask your Suzuki dealer to replace the brake hose with a new one BRAKE FLUID FRONT REAR Check the brake fluid level in both the front and rear brake fluid reservoirs If the level in either reservoir is below the lower mark inspect for brake pad wear and le...

Page 95: ...t Clean filler cap before removing Use only DOT4 brake fluid from a sealed container Never use or mix with different types of brake fluid WARNING Brake fluid is harmful or fatal if swallowed and harmful if it comes in contact with skin or eyes Solu tion can be poisonous to animals If brake fluid is swallowed do not induce vomiting Immediately con tact a poison control center or a physician If brak...

Page 96: ...the grooved wear limit line both front or both rear pads must be replaced with new ones by your authorized Suzuki dealer or a quali fied service mechanic WARNING Failure to inspect and maintain the brake pads and replace them when recommended can increase your chance of having an acci dent If you need to replace brake pads have your Suzuki dealer do this work Inspect and maintain the brake pads as...

Page 97: ... restored WARNING Replacing only one of the two brake pads can result in uneven braking action and can increase your chance of having an acci dent Always replace both pads together WARNING The tires on your motorcycle form the crucial link between your motorcycle and the road Failure to take the precautions below may result in an accident due to tire failure Check tire condition and pres sure befo...

Page 98: ...f vehicle control Tire wear also affects the tire profile changing vehicle handling character istics Check the condition of your tires each day before you ride Replace tires if tires show visual evidence of damage such as cracks or cuts or if tread depth is less than 1 6 mm 0 06 in front 2 0 mm 0 08 in rear NOTE These wear limits will be reached before the wear bars molded into the tire make conta...

Page 99: ...lure to follow the instructions below for tubeless tires may result in an accident due to tire failure Tubeless tires require different service procedures than tube tires Tubeless tires require an air tight seal between the tire bead and wheel rim Special tire irons and rim protectors or a special ized tire mounting machine must be used for removing and installing tires to prevent tire or rim dama...

Page 100: ...r lock system is working properly If the engine continues to run with the side stand down then the side stand igni tion interlock system is not working properly Have your motorcycle inspected by an authorized Suzuki dealer or a qualified service mechanic WARNING If the side stand ignition interlock system is not working properly it is possible to ride the motorcycle with the side stand in the down...

Page 101: ...lb follow the procedure below 1 Remove the right and left fasten ers 2 Unhook the hooks and remove the rear handle cover 1 3 Remove the front handle cover 2 NOTICE Failure to use a light bulb with the correct wattage rating can over load the electrical system of your motorcycle or cause the bulb to burn out sooner Use only the light bulbs shown in the chart as replacement bulbs Headlight 12V 60 55...

Page 102: ...0Z 5 Disconnect the socket 4 from the headlight 6 Remove the rubber cap 5 7 Unhook the bulb holder spring 6 and pull out the bulb socket 7 8 Fit the new bulb 9 To reinstall the headlight reverse the sequence described above NOTICE The headlight bulb s life may be shortened by oil from your fingers if you touch it When replacing the headlight bulb be careful not to touch the glass Grasp the new bul...

Page 103: ...wise To adjust the beam right and left Turn the adjuster 2 clockwise or counterclockwise FRONT TURN SIGNAL LIGHT BULB REPLACEMENT To replace the front turn signal light bulb follow the procedure below 1 Remove the cap 2 Remove the screw and take off the front turn signal assembly 3 Turn the socket counterclockwise and remove it 4 Push in on the bulb twisting it to the left and pull it out ...

Page 104: ...ers 1 Unhook the hooks 2 Pull the under frame cover 3 backward and remove it Brake Light Taillight Rear Turn Signal Light 2 Turn the socket counterclockwise and remove the socket Brake light Taillight bulb Rear turn signal light bulb 3 Turn the socket counterclockwise and remove the socket 4 Push in on the burned out bulb turn it to the left and pull it out 5 To fit the replacement bulb push it in...

Page 105: ...he elec trical problem must be inspected and repaired before replacing the blown fuse with a new fuse Consult your Suzuki dealer for the electrical system check and repair WARNING Replacing a fuse with a fuse that has an incorrect amperage rating or substitute e g aluminum foil or wire may cause serious damage to the electrical system and possi bly fire Always replace a blown fuse with a fuse of t...

Page 106: ...T cir cuits Fuse box 3 is located under the air cleaner maintenance lid To access the fuse box remove the lid by refer ring to the AIR CLEANER section Fuse box 3 has HEAD HI HEAD LO FUEL ABS V ABS M and FAN fuses Fuse box 4 is located under the seat Fuse box 4 has MIRROR OUTLET SCREEN S HEATER AN650Z IGNITION and SIGNAL fuses ...

Page 107: ...oller 3A MIRROR fuse protects the mir ror motor 20A SCREEN fuse protects the screen relay and screen 5A SEAT HEATER fuse protects the seat heater AN650Z CATALYTIC CONVERTER The purpose of the catalytic converter is to minimize the amount of harmful pollutants in your motorcycle s exhaust Use of leaded fuel in motor cycles equipped with catalytic con verters is prohibited because lead deactivates t...

Page 108: ...smission is in gear and the motorcycle is in motion Do not try to start the engine by pushing the motorcycle or by coasting down a hill Do not idle the engine with any spark plug wires disconnected or removed such as during diagnostic testing Do not idle the vehicle for pro longed periods if idling seems rough or there are other mal functions Do not allow the fuel tank to get near the empty level ...

Page 109: ...6 44 DIAGNOSTIC CONNECTOR Diagnostic connector 1 is located under the air cleaner maintenance lid NOTE Diagnostic connector is used by Suzuki dealer or a qualified service mechanic ...

Page 110: ...7 1 7 TROUBLESHOOTING IGNITION SYSTEM CHECK 7 2 ENGINE STALLING 7 2 ...

Page 111: ...k the fuel supply in the fuel tank 2 Check the ignition system for intermittent spark 3 Check the idle speed NOTICE Improper repairs or adjustments may damage the motorcycle instead of fixing it Such damage may not be covered under war ranty If you are not sure about the proper action consult your Suzuki dealer about the problem WARNING Performing the spark test improp erly can be hazardous You co...

Page 112: ...8 1 8 STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE 8 2 PROCEDURE FOR RETURNING TO SERVICE 8 3 CORROSION PREVENTION 8 3 MOTORCYCLE CLEANING 8 4 INSPECTION AFTER CLEANING 8 6 ...

Page 113: ...ignition key FUEL 1 Fill the fuel tank to the top with fuel mixed with the amount of gas oline stabilizer recommended by the stabilizer manufacturer 2 Run the engine for a few minutes until the stabilized gasoline fills the fuel injection system BATTERY 1 Remove the battery from the motorcycle by referring to the BATTERY section 2 Clean the outside of the battery with a mild detergent and remove a...

Page 114: ...ard to reach areas Chipping scratches and any damage to treated or painted metal surfaces resulting from minor accidents or impacts from stones and gravel Road salt sea air industrial pollution and high humidity will all contribute to corrosion How to Help Prevent Corrosion Wash your motorcycle frequently at least once a month Keep your motorcycle as clean and dry as possible Remove foreign materi...

Page 115: ...e cover can help protect the finish from the harmful UV rays in sunlight and can reduce the amount of dust and air pollution reaching the surface Your Suzuki dealer can help you select the right cover for your motorcycle MOTORCYCLE CLEANING WASHING THE MOTORCYCLE When washing the motorcycle follow the instructions below 1 Remove dirt and mud from the motorcycle with cool running water You may use ...

Page 116: ...motorcycle or riding in the rain Headlight fogging will be cleared gradually when the headlight is turned on When clearing the headlight lens fogging run the engine to avoid battery discharge NOTICE High pressure washers such as those found at coin operated car washes have enough pressure to damage the parts of your motorcy cle It may cause rust corrosion and increase wear Parts cleaner can also d...

Page 117: ... surfaces which have a matte finish The use of polishing compounds will change the appear ance of the matte finish Solid type waxes may be difficult to remove from surfaces with a matte finish Friction while riding excessive rub bing or polishing of a surface with a matte finish will change its appear ance INSPECTION AFTER CLEANING For extended life of your motorcycle lubricate it according to the...

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Page 119: ...rter Lubrication system Wet sump DRIVE TRAIN Clutch Wet multi plate automatic centrifugal type Primary reduction ratio 1 333 88 66 Gearshift pattern Automatic and Manual shift Automatic transmission ratio Variable 1 800 0 465 Secondary reduction ratio 3 934 39 31 43 25 40 22 Final reduction ratio 1 580 32 31 31 32 34 31 49 34 Drive system Gear drive CHASSIS Front suspension Telescopic coil spring ...

Page 120: ...ED Coolant temperature indicator light LED Fuel injection indicator light LED Oil pressure indicator light LED Brake lock indicator light LED High beam indicator light LED Turn signal indicator light LED Freeze indicator light LED ABS indicator light LED Immobilizer indicator light if equipped LED CAPACITIES Fuel tank 15 0 L 4 0 3 3 US Imp gal Engine oil oil change 2600 ml 2 7 2 3 US Imp qt With f...

Page 121: ...GINE OIL 3 4 6 21 ENGINE STALLING 7 2 F FINAL GEAR OIL 3 5 FRONT SMALL BOX 2 30 FRONT TRUNK 2 29 FUEL OCTANE RATING 3 2 FUEL TANK CAP 2 27 FUSES 6 40 H HELMET HOLDER 2 31 I IGNITION SWITCH 2 6 IGNITION SYSTEM CHECK 7 2 INSPECTION AFTER CLEANING 8 6 INSPECTION BEFORE RIDING 4 3 INSTRUMENT PANEL 2 8 K KEY 2 5 L LABELS 1 6 LEFT HANDLEBAR 2 20 LIGHT BULB REPLACEMENT 6 36 LOCATION OF PARTS 2 2 LUBRICAT...

Page 122: ...LE RIDERS 1 4 SERIAL NUMBER LOCATION 1 6 SIDE STAND IGNITION INTERLOCK SYSTEM 6 35 SPARK PLUG 6 8 STAND 2 32 STARTING OFF 5 3 STARTING THE ENGINE 5 2 STOPPING AND PARKING 5 5 STORAGE PROCEDURE 8 2 T THROTTLE CABLE PLAY 6 16 TIRES 6 32 TOOLS 6 5 TRANSMISSION OIL 3 5 TRANSMISSION OIL AND FINAL GEAR OIL 6 26 TRUNK 2 30 TRUNK BOX LIGHT SWITCH 2 32 Total page 124 ...

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