USE THIS MANUAL WITH: AN650 SERVICE MANUAL (99500
Contents
1. COIL 1 2 BRKABSEM HAZARD IMOBILIZER SCREEN OOO SWITCH SCREEN FUSE MOTOR A T SENSOR E ABSCONT Is S RELAY Fl Oi Hi IMO DONT CVT n URP SIDE CENTER STAND STAND i SWITCH SWITCH go z azo gt gt EET ag IGNITION SWITCH 55 8585 Sosy abe oS Ses 88 55 8956 4006 52456622 35 8228 ELATLI ETT BRAKELOCK Boos B 1 THT TT SWITCH 550259 8 nzmor 3 852255 5 55 8 550033 5 H TT LH NNI LLLI LLLA FH MIRROR MOTOR R i B N POSITION LIGHT R D A H LICENSE PLATE LIGHT B W FRONT TURN SIGNAL HoH Bw LIGHT R HIM H Bw SIGNAL PN Li L T Lg L 61 5 sw LIGHT B W B W HEADLIGHT R LU L WB we2. HANDLEBAR SWITCH R SIDE STAND Ec SRK SWITCH IGNITION IGNITION IAC O O ENGINE FRONT COIL COIL 2 VALVE HAZARD STOP STARTER BRAKE meg SWITCH SWITCH BUTTON SWITCH ss 19 9 STAND MOTOR Oi SWITCH SOLENOID m zOr 5 OT 58 5 5 8558 854 5505 Sse SPEED SWITCH 5 SENSOR 5 SOO nooo oF oF Lock 220 9 m gt m m 5320488 i i8 8 vs 73S pay LICENSE PLATE LIGHT BW Gr FRONT TURN BW REAR TURN SIGNAL SIGNAL LIGHT L L L Lg D PER Br R BW W B Gr A d HEAD a gt _w LIGHT R t BRAKE LIGHT TAILLIGHT R HEAD 1 LIGHT L w D 2 7 BRAKE LIGHT TAILLIGHT L Gr Hew B W W B W B Gr B B B B BW B W FRONT TURN REAR TURN SIGNAL LIGHT L SIGNAL LIGHT L 2 m 22 55 m amp m m olo
3. 40A 10A POWER SOURCE FUSE FUSE AP SENSOR zm fo gt ma pe L 1 S505 X SENSOR SENSOR SEN SEn SENSOR SENSOR SENSOR REGULATOR START RECTIFIER GENERATOR STARTER MOTOR STARTER 40 A R BI Y G BATTERY TRUNK LIGHT LIGHT SWITCH TRUNK LIGHT SEAT SWITCH 650 5 E 03 24 28 33 HI HIGH BEAM INDICATOR LIGHT OI OIL PRESSURE INDICATOR LIGHT Fl FI PILOT BRK BRAKE LOCK INDICATOR LIGHT TR TURN SIGNAL INDICATOR LIGHT R TL TURN SIGNAL INDICATOR LIGHT L WT ENGINE COOLANT TEMP INDICATOR LIGHT D DRIVE MODE INDICATOR PM POWER MODE INDICATOR OD OVER DRIVE INDICATOR LIGHT TR
4. INTERVAL AEBES D12345 B D AN650A only 2 E 02 19 000 only TERMINAL ALIGNMENT Oil pressure switch G Y Turn signal L B Turn signal R Lg Illumination 2 O G ABS Br AN650A Brake lock switch V High beam Y Immobilizer E 02 19 000 Ambient air temperature sensor Fuel pump R B Power ground B W Speed sensor O R Ignition O G Battery R BI Speed sensor signal W Tachometer signal Br W Oil level switch FI P W Signal ground B W eee c ee 8 emo 8 6 8 S S 8 go 26 650 5 05 MODEL POWER WIND SCREEN 650 5 02 19 000 INSPECTION Remove the lower leg shield 650 9 10 Disconnect the wind screen regulator coupler Apply 12 V voltage to the terminals of the regulator coupler and check that the wind screen moves in the correct direction E 8 Terminal Terminal Window screen 3X R OG UP Repeat above inspection several times and replace the EWS window screen regulator assembly if necessary REMOVAL Remove the wind screen 4 e Remove the leg shield gt 650 Remove the meter front lowe 5 NOTE regulato
5. oc d gt 55 o 8 26594 58585 m 5 0555 2555 25655 53 s 88 Br 85 8 leg m zl og HORN IT ETTE EL 7i RELAY POWER coo M 15 217 5 SIDE SENSOR 7 00A MAIN DIODE STAND py RUEL SOURCE SENSORL3 SENSOR RELAY NWECTOR PULLEY PUMP FUSE IAT STARTER 40 POSITION SENSOR SENSOR REGULATOR GENERATOR RELAY 655 REVOLUTION RECTIFIER BATTERY eer TRUNK LIGHT PASSING SWITCH BUTTON SWITCH UP DOWN 1 AG LIGHT LIGHT r SWITCH SWITCH 2 HEADLO 10A STARTER SWITCH SWITCH TURNSIGNAL SWITCH pom 3 FUEL 10 MOTOR TRUNK LIGHT SWITCH SWITCH 4 IGNITION 15A LIGHT SEAT OIL 5 SIGNAL 15A SWITCH HANDLEBAR SWITCH L PRESSURE OIL LEVEL 6 FAN 15 SWITCH SWITCH 650 5 02 19 000 HIGH BEAM INDICATOR LIGHT OI OIL PRESSURE INDICATOR LIGHT FI FI PILOT BRK BRAKE LOCK INDICATOR LIGHT TR TURN SIGNAL INDICATOR LIGHT R TL TURN SIGNAL INDICATOR LIGHT L WT ENGINE COOLANT TEMP INDICATOR LIGHT D DRIVE MODE INDICATOR PM POWER MODE INDICATOR IMO IMMOBILIZER HANDLEBAR SWITCH R OD OVER DRIVE INDICATOR LIGHT ABS ABS INDICATOR LIGHT bl rhea ENGINESTOP STARTER SWITCH BUTTON TR IGNITION IGNITION
6. Oil pressure warning light Brake lock warning light eese High beam indicator 2 44422222 Turn signal indicator light Power mode indicator light Drive indicator light Gear position indicator light ABS warning light Immobilizer indicator light Over drive indicator light essent CAPACITIES Fuel tank including reserve Engine oil oil change with filter change overhaul Transmission oil oil change overhaul Final gear oil oil change overhaul s ER 2 260 mm 89 0 in 810 mm 31 9 in 1 435 mm 56 5 in 1 595 mm 62 8 in 130 mm 5 1 in 750 mm 29 5 in 243 kg 535 Ibs 4 stroke liquid cooled DOHC 2 75 5 mm 2 972 in 71 3 mm 2 807 in 638 38 9 in 11 2 1 Fuel injection Non woven fabric element Electric Wet sump 1 200 100 r min Wet multi plate automatic centrifugal type 1 333 88 66 Automatic amp Manual shift Variable change 1 800 0 465 1 580 32 31 x 31 32 x 34 31 x 49 34 Gear drive Electronic ignition Transistorized 10 B T D C at 1 200 r min NGK CR8E or DENSO U24ESR N 12 V 43 2 12 Ah 10 HR Three phase A C generator 40A 40A 15 15 15 15 15 10 10 15 15 A 12 V 60 55 55 55 H4
7. 22 650 5 05 MODEL FUEL OIL SPECIFICATION Fuel type Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Fuel tank capacity Including Fuel meter mark Approx 3 0 L 0 79 0 66 US Imp gal flickering Fuel meter are Approx 1 5 L 0 40 0 33 US Imp gal flickering Engine oil and transmission oil type SAE 10W 40 API SF SG or SJ SH with JASO MA Engine oil capacity 2 6L 2 7 2 3 US Imp qt Oil change Filter change 29L 3 1 2 6 US Imp qt 3 4 L Overhaul 3 6 3 0 Transmission oil capacity Oil change 360 m 12 2 12 7 05 lt 02 77 Overhaul 62 Final gear oil type Hypoid g ar oil SAE 90 ARI grade GL 5 Final gear oil capacity 300 ml 1071 10 6 US Imp oz 430 ml 14 5 15 1 US Imp oz 650 5 05 MODEL 23 IMMOBILIZER E 02 19 000 The immobilizer an anti theft system is installed as a Immobi antenna standard equipment The immobilizer verifies that the key ID agrees with ECM ID by means of radio communication through the immobilizer antenna When the ID agreement is verified the system makes the engine ready to start This system is same as the AN250 400K5 Immobilizer Indicator light Transponder antenna PF switch in ON and the side stand up position d r through the immobi antenna in
8. 33 98 34 03 1 338 1 340 Camshaft journal oil clearance IN amp EX 0 032 0 066 0 0013 0 0026 0 0059 Camshaft journal holder I D IN amp EX 0 9454 25025 __ 0 9454 0 9459 Camshaft journal O D IN amp EX 0 8433 Camshaft runout IN amp EX __ 0 004 Cam chain pin at arrow 3 15th pin Cylinder head distortion __ 0 10 0 004 CYLINDER PISTON PISTON RING ITEM STANDARD Unit mm in LIMIT Compression pressure 1 200 kPa 12 kgf cm 171 psi Compression pressure difference 200 kPa 2 0 kgf cm 28 psi Piston to cylinder clearance 15 0 EC 5 000 0 0022 0 120 0 0047 Cylinder bore Piston diam 75 500 75 515 9724 2 9730 75 470 75 485 2 9705 2 9711 easure at 15 mm 0 6 in from the skirt end Nicks or scratches Cylinder distortion Piston ring free end gap Approx 11 6 0 46 Approx 8 6 0 34 Piston ring end gap 0 06 0 18 0 002 0 005 0 06 0 18 0 002 0 005 Piston ring to groove clearance Piston ring groove width 1 01 1 03 0 040 0 041 1 01 1 03 0 040 0 041 2 01 2 03 0 079 0 080 Piston ring thickness STANDARD 0 97 0 99 0 038 0 039 650 5 05 MODEL 7 LIMIT 0 97 0 99 0 038 0 039
9. H7 12V5W 12V 21 5W x2 12V5W 12V5W 12V21W 12V 1 4W 12V 1 4W 12V 1 4W 12V 1 4W 12V1 4W 12V 1 4 12 1 4W 12 1 4 12 1 4 12 1 4 12 1 4 LED 12V1 4W 15 0 L 4 0 3 3 US Imp gal 2 600 ml 2 7 2 3 US Imp qt 2 900 3 1 2 6 US Imp qt 3 400 ml 3 6 3 0 US Imp qt 360 ml 12 2 12 7 US Imp oz 400 ml 13 5 14 1 US Imp oz 300 ml 10 1 10 6 US Imp oz 430 ml 14 5 15 1 US Imp oz 1 6 L 1 7 1 4 US Imp qt SERVICE DATA 650 5 VALVE GUIDE 650 5 05 MODEL 5 STANDARD Unit mm in Valve diam 29 5 1 16 25 0 0 98 Tappet clearance when cold 0 10 0 20 0 0039 0 0079 0 20 0 30 0 0079 0 0118 Valve guide to valve stem clearance 0 010 0 040 0 0004 0 0016 0 030 0 060 0 0012 0 0024 Valve guide 1 0 4 500 4 515 0 1772 0 1778 Valve stem O D 4 475 44 P 0 1762 E EDS Valve stem deflection Valve stem runout Valve head thickness Valve seat width 0 9 1 1 0 035 0 043 Valve head radial He Valve spring free length IN amp X Valve spring tension IN amp EX 136 156 13 6 15 6 kgf 30 0 34 4 Ibs at length 33 4 mm 1 31 in 6 650 5 05 MODEL CAMSHAFT CYLINDER HEAD STANDARD Unit mm in Cam height 35 38 35 43 1 393 1 395
10. Including Fuel meter mark flickering Fuel meter Approx 3 0 L 0 79 0 66 US Imp gal mark and LCD Approx 1 5 L 0 40 0 33 US Imp gal flickering Engine oil and transmission oil type SAE 10W 40 API SF SG SJ SE with JASO MA Engine oil capacity 2 donde p qt Oil change Filter Ges GUN qt 3 4L 3 6 3 0 US Imp qt Transmission oil capacity dita M ZN 360 ml 12 2 12 7 US Imp oz 400 ml Overhaul 13 5 14 1 US Imp oz Final gear oil type Hypoid gear oil SAE 90 API grade GL 5 Final gear oil capacity 300 ml Oil change 10 1 10 6 US Imp oz 430 ml 14 5 15 1 US Imp oz Overhaul 14 650 5 05 MODEL SERVICE DATA AN650AK5 VALVE GUIDE STANDARD Unit mm in Valve diam 29 5 1 16 25 0 0 98 Tappet clearance when cold 0 10 0 20 0 0039 0 0079 0 20 0 30 0 0079 0 0118 Valve guide to valve stem clearance 0 010 0 040 0 0004 0 0016 0 030 0 060 0 0012 0 0024 Valve guide 1 0 4 500 4 515 0 1772 0 1778 Valve stem O D 4 475 4 490 0 1762 0 1768 gt Valve stem deflection 078 S 2 Valve stem runout Valve head thickness Valve seat width 0 0 035 0 043 Valve head radial runout Valve spring free length IN amp EX 4 Valve spring tens
11. Piston pin bore 16 002 16 008 0 6300 0 6302 Piston pin O D CONROD CRANKSHAFT ITEM 15 995 16 000 0 6297 0 6299 STANDARD Unit mm in Conrod small end 1 0 16 010 16 018 0 6303 0 6306 Conrod big end side clearance 0 10 0 20 0 004 0 008 Conrod big end width 19 950 20 000 0 7854 0 7874 Crank pin width Conrod big end oil clearance Crank pin O D Crankshaft journal oil clearance 018 0 045 0007 0 0018 Crankshaft journal O D 47 985 48 000 1 8892 1 8898 Crankshaft thrust 2 025 2 175 0 0797 0 0856 Crankshaft thrust clearance lt 0 10 0 15 0 0039 0 0059 Crankshaft runout OIL PUMP ITEM STANDARD Oil pressure at 60 C 140 F Above 350 kPa 3 5 kgf cm 49 8 psi Below 550 kPa 5 5 kgf cm 78 2 psi at 3 000 r min 8 650 5 05 MODEL CLUTCH ITEM STANDARD Unit mm in Drive plate thickness 2 92 3 08 0 115 0 121 Drive plate claw width Driven plate No 2 thickness 13 85 13 96 0 545 0 550 2 42 2 58 0 095 0 102 Driven plate distortion Clutch spring free length 18 9 0 547 d plate concaved washer height 3 2 0 126 Clutch engagement 1 500 2 100 r min Clutch lock up INJECTOR FUEL PUMP FUEL PRESSURE REGU
12. SUZUKI AN650 A SUPPLEMENTARY SERVICE MANUAL USE THIS MANUAL WITH AN650 SERVICE MANUAL 99500 36111 01 99501 36110 01 650 5 05 MODEL 1 AN650 AK5 05 MODEL This manual describes service data service specifications ABS and servicing procedures which differ from those of the AN650K3 03 AN650AK4 04 model NOTE Any differences between the AN650K3 03 model and AN650K5 05 model AN650AK4 04 model and AN650AK5 05 model in specifications and service data are indicated with an asterisk mark 5 e Please refer to the AN650K3 03 model service manual AN650AK4 O4 model service information for details which are not given in this manual CONTENTS SPECIFICATION 650 5 SPECIFICATION AN650AK5 SERVICE DATA 5 SERVICE DATA AN650AKo5 IMMOBILIZER E 02 19 000 OPERATION COMBINATION METER INSTALLATION FER BRI ERR ERR AMBIENT AIR TEMPERATURE INSPECTION DIES FI SYSTEM WIRING DIAGRAM eereee tenen nennen natn nna n nhan anna nana anna ECM COUPLERS MM K4 MODEL AND CVT CONTROL UNIT COUPLERS 31 K5 MODEL ECM COUPLERS iis cicsss
13. 24 68 75 F 2 0 4 0 mm 0 08 0 16 in L THERMOSTAT RADIATOR FAN COOLANT ITEM STANDARD SPECIFICATION Thermostat valve opening temper ature Approx 88 C 190 F Thermostat valve lift Over 8 0 mm 0 3 in at 100 C 212 F Engine coolant temperature sensor resistance 20 C 68 F Approx 2 45 kQ 50 C 122 F Approx 0 811 kQ 80 C 176 F Approx 0 318 kQ 110 C 230 F Approx 0 142 kQ Radiator cap valve opening pres sure 110 kPa 1 1 kgf cm Eclectic fan thermo switch operat ing temperature ON 93 103 C 199 217 F OFF 87 97 C 188 206 F Engine coolant type Use an anti freeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50 ITEM STANDARD SPECIFICATION 650 5 05 MODEL 19 Engine coolant including reserve ELECTRICAL Reverse tank side Engine side Approx 250 ml 0 264 0 220 US Imp qt Approx 1 350 ml 1 427 1 188 US Imp qt STD SPEC Unit mm in Firing order 1 2 Spark plug NGK CR8E DENSO U24ESR N 0 7 0 8 0 028 0 031 Spark performance Over 8 0 0 3 at 1 atm CKP sensor peak voltage More than 2 0 V Ignition coil resistance Primary 0 8 2 5 Q Secondary 8 18 Ignition coil primary peak vo
14. Normal value Continuity Tester knob indication Continuity test Is the continuity OK YES Go to step 6 NO Inspect the wire harness Faulty B Y wire Normal value Continuity Tester knob indication Continuity te Is the continuity OK Bw YES gt _____ No inspect th re aradsg WY wire vc Connect the rear wheel speed sensor coupler 7 Connect three 1 5 V dry cells in series as shown and make sure that their total voltage is more than 4 5 V Measure the current between 9 dry cell terminal and 2 B Y on the ABS control unit coupler Normal value 3 14 mA 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Current 20 mA Is the current OK YES Replace the ABS control unit HU NO Replace the rear wheel speed sensor 650 5 05 MODEL 39 40 650 5 05 MODEL WIND SCREEN CABLE ROUTING Do net drop the cushion N Dx x Air pressure 17 1 sensor Fun motor gm relay Side stand relay Fuel pump relay n y ET Am E Screen relay d Clamp p N ti f p 7 p V x Co m
15. 3 08 0 115 0 121 Drive plate claw width Driven plate No 2 thickness 13 85 13 96 0 545 0 550 2 42 2 58 0 095 0 102 Driven plate distortion Clutch spring free length 13 9 0 547 plate concaved washer height 3 2 0 126 Clutch engagement 1 500 2 100 r min Clutch lock up 3 200 3 800 r min INJECTOR FUEL PUMP FUEL PRESSURE REGULATOR ITEM SPECIFICA Injector resistance SES 11 13 0 at 20 Fuel pump discharge amount More than 0 For 30 seo at 300 m 7 US imp qt 2 9 m Fuel pressure regulator operating set pressure FI CVT SENSORS f cm 43 psi Cx JS 3 SPECIFICATION NOTE CMP sensor resistanc CMP sensor peak voltage CKP sensor resistance More than 0 5 V When cranking 150 300 Q Br sensor peak voltage More than 2 0 V When cranking BI IAP sensor input voltage 45 55V IAP sensor output voltage Approx 2 6 V at idle speed TP sensor input voltage 4 5 5 5 TP sensor resistance Closed Approx 1 1 kQ Opened Approx 4 2 kQ TP sensor output voltage Closed Approx 1 1 V Opened Approx 4 3 V ECT sensor input voltage 45 55V ECT sensor resistance Approx 2 45 kQ at 20 C 68 F IAT sensor input voltage 45 55V IAT sensor resistance Appro
16. 8 pum BRAKE LIGHT TAILLIGHT R W s B W 5 Y BRAKE LIGHT TAILLIGHT L a B W Br Gr POSITION LIGHT L H 1 1 A BW B B T B B hH FRONT TURN SIGNAL H T REAR TURN SIGNAL LIGHT L LIGHT L 1 i H MIRROR MOTOR L Coy E im im M 1 FA m m mc oco 2 m m m of m m m mam m mg gt go 5 a 28 9555 2555 225845 552 83 8 RB 45 85 fg 5858 28 esa z ee Pc 85 om 520 32255500 3505 SELECT 95 gt gt COUPLER MIRROR 3 7 E MP AP 40A 10A F CUT MAIN ABS ABS e FUSE M RELAY SIDAID N FUEL SENSOR SENSOR cry SENSOR FUSE FUSE MOT 99 RELAY 2 pump FUSE SOURCE W T 05 STARTER 40 15
17. Ignition 15A Turn signal 15A Fan motor 15A Main 40A CVT 40A Power source 10A 650 5 05 MODEL 11 WATTAGE Unit W STD SPEC E 02 19 E 03 24 28 33 Headlight 60 55 60 x 2 55 55x2 Parking or position light 5x2 Brake light Taillight 21 5 x 2 Turn signal light 21x4 License light 5 Instrument panel light 1 4x2 Engine coolant temp indicator light 1 4 Fl indicator light 1 4 Engine oil pressure indicator light 1 4 Brake lock indicator light 1 4 High beam indicator light 1 4 Turn signal indicator light Power mode indicator light Drive indicator light Gear position indicator light Trunk light Immobilizer indicator light Over drive indicator light TITITITITITITITITITITITITIT BRAKE WHEEL Unit mm in gt Brake disc thickness pr Brake disc runout Master cylinder bore 12 700 12 743 0 5000 0 5017 12 700 12 743 0 5000 0 5017 Master cylinder piston diameter 12 657 12 684 0 4983 0 4994 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore 25 400 25 450 1 0000 1 0020 27 000 27 050 1 0630 1 0650 Brake caliper piston diameter 25 318 25 368 0 9968 0 9987 26 918 26 968 1 0598 1 0617 Brake fluid type DOT 4 12 650
18. TURN SIGNAL LIGHT SIGNAL Lg Lg Lg Lg Br R BW WIB lt HEAD gp LIGHT R Gr B w WB BRAKE LIGHT TAILLIGHT R HEAD Cl B W LIGHT L Br BRAKE LIGHT TAILLIGHT L POSITION LIGHT L FRONT TURN SIGNAL LIGHT L Br Gr B W B W E B B B W 19 REAR TURN SIGNAL LIGHT L 0 BI 34 B W B BI FAN MOTOR RELAY EE PASSING DIMMER HORN LIGHT SWITCH BUTTON SWITCH TURN SIGNAL LIGHT SWITCH REAR BRAKE SWITCH SWITCH HANDLEBAR SWITCH L SWITCH UP DOWN SWITCH SWITCH OIL PRESSURE OIL LEVEL SWITCH SWITCH SIDE STAND RELAY FP RELAY gt 1 2 INJECTOR REVOLUTION FUSE BOX SENSOR 1 HEADHI 15A 2 HEADLO 10A 3 FUEL 10A 4 IGNITION 15A 5 SIGNAL 15A 6 FAN 15A CVT PULLEY PUMP POSITION SENSOR TP SENSOR
19. order to make comparison Ignition switch 1019 24 650 5 05 MODEL Also when the ignition switch is turned ON the indicator light flashes as many as the number of IDs registered in ECM Thereafter if the IDs are in agreement the indicator light turns on for two seconds to notify of completion in successful communication If the indicator light flashes fast it notifies of communication error or disagreement of ID NOTE If the indicator light flashes fast turn the ignition switch OFF then ON to make judgment again as there is possible misjudg ment due to environmental radio interference CAUTION 2 registered 3 registered 4 registered Flashing Lighting Fast flashing Approx 1 6 Approx 2 0 sec 3 Normal Normal Normal Abnormal 1000r min 34 When the battery performance is lowered in winter low temperature the system may make a re judgment at the time of beginning of the starter motor operation In this case the indicator light operation starts immediately after the starter motor operation MODE SELECT RESET 650 5 05 MODEL 25 5 E
20. r lay 9 42 AN650K3 6 41 C42 Ignition switch C44 Heated oxygen sensor HO2S E 02 19 p 9 C51 CVT motor AN650K3 6 43 C52 CVT pulley position sensor 8 4 control unit coupler C53 CVT speed sensor 650 6 48 54 CVT secondary pulley revolution sensor C55 CVT engine revolution signal CVT control unit coupler 65 ECM coupler CP AN650K3 6 53 CVT reduction ratio disagreement 34 650 5 05 MODEL ABS TROUBLESHOOTING AN650AK5 MALFUNCTION CODE TROUBLESHOOTING 41 Wheel speed sensor signal malfunction F POSSIBLE CAUSE Poor contact on the front wheel speed sensor coupler Faulty front wheel speed sensor etc 1 Inspect the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge PV Wheel speed sensor sensor rotor clearance 0 3 1 5 mm 09900 20803 Thickness gauge 09900 20806 Thickness gauge Is the clearance OK YES Go to step 2 NO Adjust the clearance 2 Inspect the front wheel speed sensor rotor for damage and check that no foreign objects are caught in the openings Is the sensor rotor OK YES Go to step 3 Clean or replace the senso rotor 3 Check that the front wheel speed sensor is mounted steadily Is the sensor mounted steadily Go to malfuncti
21. 0 F Approx 0 142 kQ Radiator cap valve opening pres sure 110 kPa 1 1 kgf cm Eclectic fan thermo switch operat ing temperature ON 93 103 C 199 217 F OFF 87 97 C 188 206 F Engine coolant type ratio of 50 50 Use an anti freeze coolant compatible with alumi num radiator mixed with distilled water only at the 10 650 5 05 MODEL ITEM STANDARD SPECIFICATION Engine coolant including reserve Reverse tank side Approx 250 ml 0 264 0 220 US Imp qt rox 1 350 ml ELECTRICAL T Approx 1 427 1 188 US Imp qt STD SPEC Unit mm in Firing order 1 2 Spark plug NGK CR8E DENSO U24ESR N 0 7 0 8 0 028 0 031 Spark performance Over 8 0 0 3 at 1 atm CKP sensor peak voltage More than 2 0 V BI O G Ignition coil resistance Primary 0 8 2 5 Q Secondary 8 18 Ignition coil primary peak voltage More than 80 V 1 W BI Generator coil resistance CKP sensor 150 3000 Charging 011 00 Generator no load voltage When cold Generator Max output Regulated voltage DY 5 000 r min Starter relay resistance Battery designation FTX14 BS Capacity 12 V 43 2 kC 12 Ah 10 HR Fuse size Head LO light E 03 24 28 33 E 02 19 HI 15A Fuel pump 10A
22. 5 05 MODEL STANDARD LIMIT Wheel rim runout Axial Radial Wheel axle runout Front Rear Wheel rim size Front 15 M C x MT3 50 Rear 14 M C x MT4 50 SUSPENSION Unit mm in ITEM STANDARD LIMIT Front fork stroke 110 4 3 Front fork spring free length 341 13 4 Front fork oil type SUZUKI FORK OIL G 10 an equivalent fork di Front fork oil capacity each leg 45841 Front fork oil level Front fork inner tube diam Rear wheel travel eS Rear shock absorber spring mmr emma Cono TIRE ITEM STANDARD Cold inflation tire pressure 225 kPa 2 25 kgf cm 33 psi 250 kPa 2 50 kgf cm 36 psi 225 kPa 2 25 kgf cm 33 psi 280 kPa 2 80 kgf cm 41 psi Tire size 120 70R15M C 56H 160 60R14M C 65H Tire type BRIDGESTONE THO1F BRIDGESTONE THO1R Tire tread depth Recommended depth FUEL OIL 650 5 05 MODEL SPECIFICATION 13 Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or 91 octane or higher rated by the research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corro sion inhibitor is permissible E 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended The others Fuel tank capacity
23. FUSE FVW RVW L SOURCE INJECTOR PULLEY SENSOR FUSE SENSORSENSOR seNsoR REGULATOR RELAY 15 zrEG5onat 55920590 REVOLUTION POSITION RECTIFIER FAN MOTOR SENSOR SENSOR GENERATOR LH SWITCH FUSE BOX 1 HEADHI 15A STARTER TRUNK BOX 5 2 HEADLO 10A MOTOR BOX LIGHT 3 FUEL 10A LIGHT OIL 4 ee 15 SWITCH 5 15 PRESSURE SPAN POWER switch MIRROR DIMMER OIL LEVEL SWITCH TURN SIGNAL UP DOWN SWITCH WIRE COLORS LIGHT SWITCH SWITCH Black Red O G Orange with Green tracer HANDLEBAR SWITCH L BI Blue W White O R Orange with Red tracer Br Brown Yellow O W Orange with White tracer Dg Dark green B BI Black with Blue tracer O Y Orange with Yellow tracer Dgr Dark gray B R Black with Red tracer White with Black tracer Green B W Black with White tracer Y B Yellow with Black tracer Gr Gray B Y Black with Yellow tracer Y G Yellow with Green tracer Lbl Light blue BI B Blue with Black tracer Y W Yellow with White tracer Lg Light green O B Orange with Black tracer O Orange O BI Orange with Blue tracer Prepared by SUZUKI MOTOR CORPORATION Printed in Japan 5
24. ICATION AN650K5 DIMENSIONS AND DRY MASS Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry mass ENGINE Displacement Compression ratio Carburetion Air cleaner Starter system Lubrication system Idle speed DRIVE TRAIN Clutch Primary reduction ratio Gearshift pattern Automatic transmission ratio Final reduction ratio Drive system CHASSIS Front suspension Rear suspension Front fork stroke Rear wheel travel Trail Steering angle Turning radius Front brake Rear brake Front tire size Rear tire size ELECTRICAL Ignition type Ignition timing Spark plug Battery Generator Main fuse CVT fuse Headlight e nee Position parking light Brake light Taillight License plate light Trunk light Turn signal light Instrument panel light Coolant temperature warning light Fuel injection warning light Oil pressure warning light Brake lock warning light High beam indicator light Turn signal indicator light Power mode indicator light Drive indicator light Gear position indicator light Immobilizer indicator light Over drive indicator 22222 2002 CAPACITIES Fuel tank including reserve Engine oil oil change with filter chang overhaul Transmission oil oil change overhaul Final gear oil oil ch
25. LATOR ITEM 3 200 3 800 r min SPECIFICATION Injector resistance 11 13 Q at 20 C 68 a Fuel pump discharge amount More than 0 9 L 0 95 0 79 US I For 30 sec at 30 va 30 E Fuel pressure regulator operating set pressure FI CVT SENSORS CMP sensor resistance 243 psi CMP sensor peak voltage CKP sensor resistance L2 More than 0 5 V When cranking 150 3000 Br CKP sensor peak voltage More than 2 0 V When cranking Q BI G IAP sensor input voltage 4 5 5 5 IAP sensor output voltage Approx 2 6 V at idle speed TP sensor input voltage 45 55V TP sensor resistance Closed Approx 1 1 kQ Opened Approx 4 2 kQ TP sensor output voltage Closed Approx 1 1 V Opened Approx 4 3 V ECT sensor input voltage 45 55V ECT sensor resistance Approx 2 45 kQ at 20 C 68 F IAT sensor input voltage 45 55V IAT sensor resistance Approx 2 45 kQ at 20 C 68 F AP sensor input voltage 4 5 5 5 V AP sensor output voltage Approx 3 6 V at 100 kPa 760 mmHg TO sensor resistance 19 1 19 7 TO sensor output voltage Normal 0 4 1 4V B Br Leaning 3 7 4 4V B B Br Injector voltage Battery voltage Ignition coil primary peak voltage SPECIFICATION More than 80 V When cranking 650 5 05 M
26. ODEL 9 HO2 sensor resistance HO2 sensor output voltage 4 5 Q at 23 73 4 F Idle speed Less than 0 4 V 3 000 r min More than 0 6 V PAIR solenoid valve resistance 20 24 Q at 20 C 68 F CVT primary pulley position sensor Compressed 1 9 2 3 Extended 0 2 1 0 CVT primary pulley position sensor 1 Idle speed Approx 3 3 V output voltage 3 000 r min Approx 1 3 V 000 r min Approx 0 5 V CVT secondary pulley revolution sensor resistance 400 600 Q CVT secondary pulley revolution sensor peak voltage THROTTLE BODY More than 5 V at idle sx Po ITEM NN SPECIFICATION 1 0 No 0GO Bore size Fast idle r min 82 mm 1 26 in 1 300 1 600 r min Idle r min Synchronizing screw opening N S 1 200 100 r min 1 and 1 2 turns out IAC valve resistance Throttle cable play pe Approx 4 Q at 20 24 C 68 75 F 2 0 4 0 mm 0 08 0 16 in THERMOSTAT RADIATOR FAN COOLANT ITEM STANDARD SPECIFICATION Thermostat valve opening temper ature Approx 88 C 190 F Thermostat valve lift Over 8 0 mm 0 3 in at 100 C 212 F Engine coolant temperature senso resistance 20 C 68 F Approx 2 45 kQ 50 C 122 F Approx 0 811 kQ 80 C 176 F Approx 0 318 kQ 110 C 23
27. OOOO 10000900001 0009090000 CVT control unit couplers K5 MODEL ECM COUPLERS ECM couplers LI 000000000 006006000 15509 6963 6006 90009090606 ECM TERMINAL NO Ignition coi TERMINAL NO CIRCUIT Battery B IS Fuel Fuel injector 2 Center stand switch CSTD Side stand switch SS Shift up switch UP Brake switch Pulley position sensor PPS Mode select switch MS PTC heater PTC Test switch TS Speedometer SPD CO and injection pulse width adjust box COV1 amp Solenoid valve SOL 8 Gees CO and injection pulse width adjust box COV2 Fuel pump relay FP CO and injection pulse width adjust box Ignition coil 122 Ground E03 Fan motor relay FRL Ground E01 Power switch POWER Starter relay STA Mode switch MODE Writing tool RXD1 6 Shift down switch DOWN 8 8 S 8 8 Writing tool TXD1 CO and injection pulse width adjust box COS1 SDL KWP SDL CO and injection pulse width adjust box COS2 9 Writing tool FWE 32 650 5 05 MODEL ECM TERMINAL CIRCUIT NO Battery BATT ECM TERMINAL NO CIRCUIT TP sensor VTA Writing tool RST Ground E1 eie IAT
28. RESSURE INDICATOR LIGHT FI FI PILOT BRAKE LOCK INDICATOR LIGHT TURN SIGNAL INDICATOR LIGHT R TURN SIGNAL INDICATOR LIGHT L D DRIVE MODE INDICATOR POWER MODE INDICATOR IMMOBILIZER OVER DRIVE INDICATOR LIGHT ENGINE COOLANT TEMP INDICATOR LIGHT TR BRK PM FI OI HI IMO O R POSITION LIGHT R LOCK HANDLEBAR SWITCH R HAZARD SWITCH ENGINE FRONT STOP STARTER BRAKE SWITCH BUTTON SWITCH BRAKE SWITCH IGNITION IGNITION COIL 1 COIL 2 SIDE STAND SWITCH Iac VALVE CENTER CVT STAND SWITCH MOTOR SOLENOID al oo IMOBILIZER A T SENSOR gt BW B O ON BI BW ECM Gr w sla letstsorz og HETIELEEFERREFEDEEEHE BIG BNW BW Gr R R BI B W WIG B Y B O O B Y R W Br B G G B R 09 B BI GIy B Br B Br Briw P B BIW BIB BUR BIN R Gr R B W B Br Oo _ LICENSE PLATE LIGHT GL 4A j 1 BM B W Gr FRONT
29. ange overhaul Coolant 2 260 mm 89 0 in 810 mm 31 9 in 1 435 mm 56 5 in 1 595 mm 62 8 in 130 mm 5 1 in 750 mm 29 5 in 235 kg 518 165 Rae ee 4 stroke liquid cooled DOHC 2 75 5 mm 2 972 in 71 3 mm 2 807 in 638 cm 38 9 cu in 11 2 1 Fuel injection Non woven fabric element Electric Wet sump 1 200 100 r min Wet multi plate automatic centrifugal type 1 333 88 66 Automatic amp Manual shift Variable change 1 800 0 465 1 580 32 31 x 31 32 x 34 31 x 49 34 Gear drive Telescopic coi spring oil d Swingarm type soil spring 11 Bi 120 70R15M C 56H tubeless 160 60R14M C 65H tubeless Electronic ignition Transistorized 10 B T D C at 1 200 r min NGK CR8E or DENSO U24ESR N 12 V 43 2 12 Ah 10 HR Three phase A C generator 40A 40A 15 15 15 15 10 10 10 A 15 15 15 15 15 10 10 A 12 V 60 55 55 55 H4 H7 12 V 60 55 W x 2 H4 x 2 12V 21 5 x2 12V5W 12V5W 12V21W 12V 1 4W x2 12V 1 4W 12V 1 4W 12V 1 4W 12V 1 4W 12V 1 4W 12V 1 4W x2 12V 1 4W 12V 1 4W 12V 1 4Wx5 E 02 19 E 03 24 28 33 E 02 19 E 03 24 28 33 E 02 19 15 0 L 4 0 3 3 US Imp gal 2 600 ml 2 7 2 3 US Imp qt 2 900 ml 3 1 2 6 US Imp qt 3 400 ml 3 6 3 0 US Imp qt 360 ml 12 2 12 7 US Imp oz 400 ml 13 5 14 1 US Imp oz 300 ml 10 1 10 6 US Imp oz 430 ml 14 5 15 1 US Imp oz 1 6 L 1 7 1 4 US Imp
30. eel speed sensor 650 5 05 MODEL 37 44 Wheel speed sensor signal malfunction R POSSIBLE CAUSE Poor contact on the rear wheel speed sensor coupler Faulty rear wheel speed sensor etc 1 Inspect the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge Wheel speed sensor sensor rotor clearance 0 3 1 5 mm 09900 20803 Thickness gauge 09900 20806 Thickness gauge Is the clearance OK YES Go to step 2 NO Adjust the clearance 2 Inspect the rear wheel speed sensor rotor for damage and check that no foreign objects are caught in the rotor openings canon DOE E 5 9995 Pos 0 gt S M o gt p NBN Is the sensor rotor OK YES Go to step 3 NO Clean or replace the sensok rotor 3 Check that the rear v Is the sensor mounted Go to malfunction code 45 38 Tighten the mounting bolts or replace the bracket if necessary 38 650 5 05 MODEL 45 Wheel speed sensor circuit open R POSSIBLE CAUSE Poor contact on the rear wheel speed sensor coupler Faulty rear wheel speed sensor etc Turn the ignition switch to OFF Remove t
31. ess Brake disc runout Master cylinder bore 12 700 12 743 0 5000 0 5017 12 700 12 743 0 5000 0 5017 Master cylinder piston diameter 12 657 12 684 0 4983 0 4994 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore 25 400 25 450 1 0000 1 0020 27 000 27 050 1 0630 1 0650 Brake caliper piston diameter 25 318 25 368 0 9968 0 9987 26 918 26 968 1 0598 1 0617 Brake fluid type DOT 4 650 5 05 MODEL 21 STANDARD LIMIT Wheel rim runout Axial Radial Wheel axle runout Front Rear Wheel rim size Front 15 M C x MT3 50 Rear 14 M C x MT4 50 SUSPENSION Unit mm in ITEM STANDARD LIMIT Front fork stroke 110 4 3 Front fork spring free length 341 13 4 Front fork oil type SUZUKI FORK OIL Front fork oil capacity each leg Front fork oil level an gue gt Front fork inner tube diam Rear wheel travel TIRE ITEM YN Rear shock absorber sp adjuster STANDARD Cold inflation tire pressure 225 kPa 2 25 kgf cm 33 psi 250 kPa 2 50 kgf cm 36 psi 225 kPa 2 25 kgf cm 33 psi 280 kPa 2 80 kgf cm 41 psi Tire size 120 70R15M C 56H 160 60R14M C 65H Tire type BRIDGESTONE THO1F BRIDGESTONE THO1R Tire tread depth Recommended depth
32. groove width 1 01 1 03 0 040 0 041 1 01 1 03 0 040 0 041 2 01 2 03 0 079 0 080 16 650 5 05 MODEL STANDARD Piston ring thickness 0 97 0 99 0 038 0 039 0 97 0 99 0 038 0 039 Piston bore 16 002 16 008 0 6300 0 6302 Piston pin O D CONROD CRANKSHAFT ITEM 15 995 16 000 0 6297 0 6299 STANDARD Unit mm in Conrod small end 1 0 16 010 16 018 0 6303 0 6306 Conrod big end side clearance 0 10 0 20 0 004 0 008 Conrod big end width 19 950 20 000 0 7854 0 7874 Crank pin width Conrod big end oil clearance 20 100 20 150 0 7913 0 7933 0 032 0 056 0 0013 0 0022 Crank pin O D 6708215 m Crankshaft journal oil clearance 0 018 lt 0 045 0 0007 50 0018 Crankshaft journal O D 47 985 48 000 8892 1 8898 Crankshaft thrust bearing thickness 2 025 2 175 0 0797 0 0856 Crankshaft thrust clearance 555 0 10 0 15 0 0039 0 0059 Crankshaft runout OIL PUMP ITEM STANDARD Oil pressure at 60 C 140 F Above 350 kPa 3 5 kgf cm 49 8 psi Below 550 kPa 5 5 kgf cm 78 2 psi at 3 000 r min CLUTCH ITEM STANDARD 650 5 05 MODEL 17 Unit mm in Drive plate thickness 2 92
33. he front box AN650K3 9 18 Remove the trunk box cover AN650K3 9 16 Check the ABS control unit HU coupler and rear wheel speed sensor coupler for loose or poor contacts If OK then disconnect the ABS control unit HU coupler 1 Check the resistance between terminal B Y on the ABS control unit coupler and ground Normal value Q Infinity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Resistance Q Is the resistance OK YES Go to step 3 NO Go to step 2 2 Check the resistance between 4B and ground Normal value Q Infin Tester knob indication Resistance Q Is the resistance OK YES Inspect the wire harness Faulty B Y wire NO Replace the rear wheel speed sensor 3 Check the resistance between terminal 09 W Y and ground Normal value Q Infinity Tester knob indication Resistance Is the resistance OK YES Go to step 5 NO Go to step 4 Disconnect the rear wheel speed sensor coupler 4 Check the resistance between W and ground Normal value ce Infinity Is the resistance OK YES Inspect the wire harness Faulty W Y wire NO Replace the rear wheel speed sensor 5 Check the continuity between B Y and terminal
34. ion IN amp EX 136 156 13 6 15 6 kgf 30 0 34 4 Ibs at length 33 4 mm 1 31 in CAMSHAFT CYLINDER HEAD 650 5 05 MODEL 15 STANDARD Unit mm in 35 38 35 43 1 393 1 395 33 98 34 03 1 338 1 340 Camshaft journal oil clearance IN amp EX 0 032 0 066 i 5 0 0013 0 0026 0 0059 Camshaft journal holder I D IN amp EX 0 9454 6 6468 n 0 9454 0 9459 Camshaft journal O D IN amp EX 55459 25200 s Camshaft runout 0 10 IN amp EX 0 004 Cam chain pin at arrow 3 15th pin Cylinder head distortion 0 10 0 004 CYLINDER PISTON PISTON RING ITEM Unit mm in LIMIT Compression pressure 1 500 411 900 213 1 200 12 kgf cm 171 psi Compression pressure difference 200 2 0 kgf cm 28 psi Piston to cylinder clearance 045 0 055 8 0018 0 0022 0 120 0 0047 Cylinder bore Piston diam Measure at 15 mm 0 6 in from the skirt end 75 500 75 515 2 9724 2 9730 75 470 75 485 2 9705 2 9711 Nicks or scratches Cylinder distortion Piston ring free end gap Approx 11 6 0 46 Approx 8 6 0 34 Piston ring end gap 0 06 0 18 0 002 0 005 0 06 0 18 0 002 0 005 Piston ring to groove clearance Piston ring
35. istsvessdsenscassstenectsussscosyastvaterncssduaacsaedes 31 MALFUNCTION CODE 33 ABS TROUBLESHOOTING AN650AK5 34 MALFUNCTION CODE 34 WIND SCREEN CABLE 40 RADIATOR HOSE ROUTING 550 ava 41 EXTERIOR PARTS 42 CVT CONSTRUCTION Bette 45 AMBIENT AIR TEMPERATURE SENSOR BRACKET INSTALLATION 46 SPECIAL TOOLS coins si ox EROR FAI ERES 47 TIGHTENING TORQUE CHART iras rta tu tob ra ak diari ru nay a RA vado 47 WIRING DIAGRAM suco Exe paa 49 2 650 5 05 MODEL COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s COUNTRY or AREA EFFECTIVE FRAME NO U S A Canada JS1CP51A52 100001 California U S A AN650K5 U K JS1BU111200100468 E U JS1BU111100113619 Australia JS1BU121300100200 JAPAN CK JS1BU132200100080 AN650AK5 U _45180132100105119 650 5 05 MODEL 3 SPECIF
36. l I q I Screen relay over sensor ECM Pass through the cable lt back side of relay 650 5 05 MODEL 41 RADIATOR HOSE ROUTING Face the tip of clamp to the bottom Reservoir inlet hose MA White mark Oil cooler Ld inlet hose v 14 m A Oil cooler ait Al outlet hose 2 A Yellow mark White mark Face the tip of clamp to the forward Face the tip of clamps to the bottom 42 650 5 05 MODEL EXTERIOR PARTS CONSTRUCTION D Meter front upper panel Lower leg shield 17 Wind screen regulator 2 Leg shield brace Floor mat Meter front lower panel 3 Meter cover Front box 43 Front leg shield cover 4 Front panel Wind screen Lower bracket cover 5 Leg shield Wind screen cover 650 5 05 MODEL 43 Center frame cover Lower frame cover Rear fender Floor mat Maintenance lid Foot board Frame cover Leg side cover Fuel tank inlet tray Fuel tank inlet packing amp eqmo 9 69 9 6 44 650 5 05 MODEL CVT CONSTRUCTION 93 N m 9 3 kgf m 67 5 Ib ft 650 5 05 MODEL 45 Secondary pulley shaft nut 9 CVT belt Secondary pulley fan Secondary pulley shaft adapte
37. ltage More than 8 Generator coil resistance CKP sensor 150 9000 Charging 04 1 00 Generator no load voltage When cold than 50 V at 5 000 r min Generator Max output Approx 500 W at 5 000 r min Regulated voltage 14 0 15 5 V at 5 000 r min Starter relay resistance 3 60 Battery Type designation FTX14 BS Capacity 12 V 43 2 12 Ah 10 HR Fuse size Head LO 15A light HI 15A Fuel pump 10A Ignition 15A Turn signal 15A Fan motor 15A Main 40A CVT 40A Power source 10A ABS 15Ax2 20 650 5 05 MODEL WATTAGE Unit W STD SPEC E 02 19 E 03 24 28 33 Headlight 60 55 60 2 55 55 2 Parking or position light 5x2 Brake light Taillight 21 5 2 Turn signal light 21x4 License light 5 Instrument panel light 1 4x2 Engine coolant temp indicator light 1 4 FI indicator light 1 4 Engine oil pressure indicator light 1 4 Brake lock indicator light 1 4 High beam indicator light 1 4 Turn signal indicator light Power mode indicator light Drive indicator light Gear position indicator light ABS warning indicator light Trunk light Immobilizer indicator light Over drive indicator light TITITITITITIT TIT T T 11 Unit mm in Brake disc thickn
38. on Resistance Q HT Is the resistance between 3 and ground OK YES Go to step 5 NO Go to step 4 7777 36 650 5 05 MODEL 4 Measure the resistance between W and ground at the front wheel speed sensor coupler Normal value Tester knob indication Resistance Q Is the resistance between and ground OK YES Inspect the wire harness Faulty W R wire NO Faulty front wheel speed sensor 5 Check for continuity between 42 B R on the ABS control unit coupler and B R on the front wheel speed sensor coupler Tester knob indication Continuity Is there continuity between and YES Go to step 6 NO Inspect the wire harness Faulty B R wire 6 Check for continuity between 3 W R on the ABS control unit coupler and W R on the front wheel speed coupler Tester knob indication Continuity 41 Is there continuity between 3 and Go to step 7 Inspect the wire S Faulty W R wire Connect the front wheel speed sensor coupler 7 Connect three 1 5 V dry cells in series as shown and make sure that their total voltage is more than 4 5 V Measure the current between 9 dry cell terminal and 42 B R on the ABS control unit coupler Normal value 3 14 mA Tester knob indication Current 20 mA Is the current OK YES Replace the ABS control unit HU NO Faulty front wh
39. on code 42 16 Tighten the mounting bolts or replace the bracket if necessary 650 5 05 MODEL 35 42 Wheel speed sensor circuit open F POSSIBLE CAUSE Poor contact on the front wheel speed sensor coupler Faulty front wheel speed sensor etc Turn the ignition switch to OFF Remove the leg shield C 5 AN650K3 9 10 Remove the meter front lower panel 8 Check the ABS control unit coupler and front wheel speed sensor coupler for looseness If OK disconnect the ABS control unit coupler 1 Measure the resistance between 2 B R and ground at the ABS control unit coupler Normal value 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Resistance Q Is the resistance between 2 and grour d O YES Go to step 3 NO Go to step e Disconnect the front wheelspeed sensor coupler 2 Measure the resistanc between B and ground at the front wheel speed sensor coupler 9 Normal value eOe Tester knob indication Resistance 0 Is the resistance between and ground OK Inspect the wire harness Faulty B R wire 7777 Faulty front wheel speed sensor 3 Measure the resistance between 3 W R and ground at the ABS control unit coupler Normal value Tester knob indicati
40. ous MS V OL ms dois Josuas Asepuosas T MS ine MS 1H Josues MS JOMOq gat Josues n uonisod p 5 0 0 p YUS dn yius ae a uia 5 Mem epo S1VI 40sues 1979 5123 Josuas amp juejooo al XS Josuas ainssaid A ER 5 EXE 30 650 5 05 MODEL E 03 28 33 06 MS JOURS uous 105 5 4osues uonisod 5 Erud a 51 PON Qe _ MS TOMOd ms 71 N67 MS 5 12199 WSnils 9 ____ SOL 10sues d 19 9 NO exeig ms VOL ms dois 91 108095 ainssaid 10sues eunsseid Josues uonisod y ECM COUPLERS K4 MODEL ECM AND CVT CONTROL UNIT COUPLERS 650 5 05 MODEL 31 ECM couplers 0 LJ OOOO
41. qt 4 650 5 05 MODEL SPECIFICATION AN650AK5 DIMENSIONS AND DRY MASS Overallletgthi Rec Renten Overall width Overall height Wheelbase Ground clearance Seat height Dry mass Number of cylinders es Bore Compression ratio Carburetion Air cleaner Starter system Lubrication system 2 eu neces etc ace alco ren DRIVE TRAIN Primary reduction ratio Gearshift pattern Automatic transmission ratio Final reduction ratio Eger RN CHASSIS Front suspension Rear suspension 2 diede utto Rear wheel travel Caster Steering angle Turning radius Front brake Rear brake Front tire size Rear tire 5126 ELECTRICAL Ignition 2 4442242 5 Ignition timing Spark plug paper teens Generator Main fuse CVT fuse Headlight Position parking light Brake light Taillight License plate light Trunk light Turn signal light Instrument panel lig Coolant temperature warning light Fuel injection warning light
42. r 40 Primary pulley assembly Bearing O ring Shim Primary pulley shaft bolt 42 O ring Primary slide pulley idle gear Primary pulley shaft adapter 43 Bearing Secondary pulley revolution sensor casing Oil seal CVT motor D Bearing Washer Q3 CVT cover O ring 46 Secondary pulley assembly CVT filter Use new special tool for 09924 51010 Primary pulley shaft bolt holder V Primary pulley shaft bolt 93 N m 9 3 kgf m 67 5 Ib ft NOTE Do not reuse the removed primary pulley shaft bolt 46 650 5 05 MODEL AMBIENT AIR TEMPERATURE SENSOR BRACKET INSTALLATION Wind screen regulator motor temperature sensor Mirror drive relay Electric mirror only 650 5 05 MODEL 47 SPECIAL TOOLS 09900 20803 09900 25008 09900 25009 09924 51010 09900 20806 Multi circuit tester Needle pointed Primary pulley shaft 09930 82710 Thickness gauge set probe set bolt holder Mode select switch TIGHTENING TORQUE CHART Bolt Diameter A Conventional or 4 marked bolt mm N m kgf m kgf m 1 5 0 15 0 23 3 03 0 45 5 5 NOS 1 0 13 1 2 3 297 29 5 0 45 4 5 8 5 2265 6 5 13 5 N05 12 21 0 60 Conventional bolt 4 marked bolt 7 marked bolt WIRING DIAGRAM AN650K5 E 02 19 000 BEAM INDICATOR LIGHT OIL P
43. r up or down Remove the meter front upper panel 2 650 5 05 MODEL 27 Remove the regulator mounting bolts Disconnect the couplers Disconnect the regulator coupler e Remove the regulator motor mounting bolt and nuts Remove the wind screen regulator assembly INSTALLATION Installation is in the reverse order of removal Pay attention to the following point e Rout the cables properly 40 Apply grease to the wires pulleys and guide rails 28 650 5 05 MODEL AMBIENT AIR TEMPERATURE SENSOR INSPECTION Turn the ignition switch to OFF Remove the AAT Ambient Air Temperature sensor by pushing off the clamp Check the AAT sensor coupler for loose or poor contacts If OK measure the AAT sensor resistance AAT sensor resistance Approx 2 12 kO at 20 C 68 F Terminal Terminal 09900 25008 Multi circuit tester set Tester knob indication Resistance Q AAT sensor Intake Air Temp Resistance 20 C 68 F Approx 2 1 kQ 25 C 77 F Approx 1 7 30 C 86 F 40 C 104 F NOTE AAT sensor resistance measure m as that of the ECT sensor Re OA the same way 3 8 13 for details f neccesary replace the AA or with a new one 650 5 05 MODEL 29 FI SYSTEM WIRING DIAGRAM E 02 19 000 06 u
44. sensor THA ECT sensor THW CKP sensor N AP sensor PA CMP sensor G 2 sensor control selector EXS OX heater OXH Ground E2 Immobilizer TXCK Tachometer TACO Immobilizer Meter TECH Immobilizer LED LED Writing tool SCK Injector power voltage VM IAP sensor PM CKP sensor N TO sensor DON CMP sensor G Blank D D O2 sensor OX Secondary pulley sensor SPR Secondary pulley sensor SPR Sensor power VCC MALFUNCTION CODE MALFUNCTION CODE Coo DETECTED ITEM NO FAULT ECM COUPLER TERMINALS TO CHECK 650 5 05 MODEL 33 K4 K5 C11 Camshaft position sensor Gp W AN650K3 6 27 C12 Crankshaft position sensor AN650K3 6 28 C13 Intake air pressure sensor 09 Gb AN650K3 6 30 C14 Throttle position sensor 09 49 AN650K3 6 32 C15 Engine coolant temperature sensor C16 Speed sensor 65 6 33 C21 Intake air temperature sensor gt AN650K3 6 3 C22 Atmospheric pressure sensor 60 60 C23 Tip over sensor C AN650K3 6 38 C24 or C25 C32 or C33 Ignition signal AN650K3 6 40 C40 Fuel injector Ss Intake air contral valve C41 Fuel p mp
45. x 2 45 kQ at 20 C 68 F AP sensor input voltage 45 55V AP sensor output voltage Approx 3 6 V at 100 kPa 760 mmHg TO sensor resistance 19 1 19 7 kQ TO sensor output voltage Normal 0 4 1 4V B Br Leaning 3 7 4 4 V B B Br Injector voltage Battery voltage 18 650 5 05 MODEL ITEM SPECIFICATION NOTE Ignition coil primary peak voltage 1 W BI More than 80 V When cranking HO2 sensor resistance 4 50 at 23 73 4 F HO2 sensor output voltage Idle speed Less than 0 4 V 3 000 r min More than 0 6 V PAIR solenoid valve resistance 20 240 at 20 C 68 F CVT primary pulley position sensor Compressed 1 9 2 3 Extended 0 2 1 0 CVT primary pulley position sensor output voltage 1 Idle speed Approx 3 3 V 3 3 000 r min Approx 1 3 V 5 3 000 r min Approx 0 5 V CVT secondary pulley revolution sensor resistance 400 600 Q CVT secondary pulley revolution sensor peak voltage THROTTLE BODY More than 5 V at idle Space A zo ITEM SPECIFICATION 1 0 No 10GO Bore size Fast idle r min 32 mnt 1 26 in 300 1 600 r min SEM CU Idle r min Synchronizing screw opening d 2 1 200 100 r min gt gt 1 and 1 2 turns out IAC valve resistance Throttle cable play Approx 4 Q at 20
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