Мануалы на suzuki an 650

Brand: Suzuki
|
Category: Motorcycle
|
Size: 29.91 MB

• Foreword

  2

• Group Index

  2

• How to Use this Manual

  3

• Component Parts and Work to be Done

  3

• Symbol

  4

• Abbreviations Used in this Manual

  5

• Wire Color

  7

• General Information

  8

• Contents

  8

• Warning/Caution/Note

  9

• Suzuki AN650K3 (’03-Model) View

  11

• Serial Number Location

  11

• Fuel, Oil and Engine Coolant Recommendation Fuel

  11

• Engine Oil and Transmission Oil

  12

• Final Gear Oil

  12

• Brake Fluid

  12

• Anti-Freeze/Engine Coolant

  12

• Liquid Amount of Water/Engine Coolant

  13

• Break-In Procedures

  14

• Cylinder Identification

  14

• Information Labels

  15

• Specifications

  16

• Dimensions and Dry Mass

  16

• Engine/Drive Train

  16

• Electrical

  17

• Capacities

  17

• Country and Area Codes

  18

• Periodic Maintenance

  19

• Periodic Maintenance Schedule

  20

• Periodic Maintenance Chart

  20

• Lubrication Points

  21

• Maintenance and Tune-Up Procedures

  22

• Air Cleaner

  22

• Spark Plug Removal

  24

• Heat Range

  24

• Carbon Deposits

  25

• Spark Plug Gap/Installation

  25

• Electrodes Condition

  25

• Tappet Clearance

  25

• Tappet Clearance Adjustment

  27

• Intake Side

  29

• Tappet Shim Selection Table

  29

• Exhaust Side

  30

• Fuel Hose

  31

• Engine Oil and Oil Filter

  31

• Engine Oil Replacement

  31

• Oil Filter Replacement

  32

• Transmission Oil Replacement

  33

• Final Gear Oil Replacement

  33

• CVF Filter

  34

• Engine Idle Speed

  36

• Throttle Cable Play

  36

• Minor Adjustment

  36

• Major Adjustment

  37

• Cooling System

  38

• Engine Coolant Level Check

  38

• Engine Coolant Change

  38

• Air Bleeding the Cooling Circuit

  39

• Radiator Hoses

  40

• Brake Fluid Level Check

  40

• Brake Pads

  41

• Air Bleeding the Brake Fluid Circuit

  42

• Tire Tread Condition

  43

• Tire Pressure

  44

• Steering

  44

• Front Fork

  44

• Rear Suspension

  45

• Exhaust Pipe Bolt and Muffler Mounting Bolt

  45

• Chassis Bolts and Nuts

  46

• Compression Pressure Check

  48

• Compression Pressure Specification

  48

• Compression Test Procedure

  48

• Oil Pressure Check

  49

• Oil Pressure Specification

  49

• Oil Pressure Test Procedure

  49

• Automatic Clutch Inspection

  50

• Initial Engagement Inspection

  50

• Clutch «Lock-Up» Inspection

  50

• Brake-Lock Inspection

  51

• Engine

  52

• Engine Components Removable with Engine in Place

  53

• Center of Engine

  53

• Right Side of Engine

  53

• Left Side of Engine

  53

• Engine Removal and Remounting

  54

• External Parts

  54

• Engine Remounting

  61

• Muffler

  62

• Engine Disassembly

  63

• Starter Motor

  63

• Oil Pressure/Level Switch

  63

• Cylinder Head Cover

  63

• Cylinder Head, and Cylinder

  64

• Piston

  65

• Oil Hose

  65

• Generator Cover

  65

• Generator

  66

• Starter Clutch

  67

• Cam Chain

  68

• Water Pump

  68

• Oil Filter

  68

• Separation of Crankcase

  69

• Drive Shaft

  70

• Balancer Shaft

  70

• Oil Pump

  71

• Oil Pressure Regulator

  71

• Piston Cooling Nozzle

  71

• Crankshaft

  72

• Primary Driven Gear

  72

• Return Oil Pump

  72

• Engine Component Inspection and Service

  73

• Cam Position Sensor

  74

• Cam Face

  74

• Camshaft Runout

  74

• Camshaft Journal Wear

  75

• Cam Chain Tension Adjuster

  76

• Cam Chain Guide

  76

• Valve and Valve Spring Diassembly

  77

• Cylinder Head Distortion

  77

• Valve Stem Deflection

  78

• Valve Stem Wear

  78

• Valve Stem Runout

  78

• Valve Head Radial Runout

  78

• Valve Face Wear

  79

• Valve Sprign

  79

• Valve Guide Servicing

  80

• Valve Seat Width Inspection

  81

• Valve Seat Servicing

  81

• Initial Seat Cut

  82

• Top Narrowing Cut

  82

• Bottom Narrowing Cut

  83

• Final Seat Cut

  83

• Valve and Valve Spring Reassembly

  84

• Intake Pipe

  85

• Cylinder Distortion

  85

• Cylinder Bore

  86

• Piston and Piston Ring

  87

• Piston Diameter

  87

• Piston to Cylinder Clearance

  87

• Piston Pins and Pin Bore

  87

• Piston Ring to Groove Clearance

  88

• Piston Ring Free End Gap and Piston Ring End Gap

  88

• Clutch

  89

• Clutch Drive Plates/Clutch Driven Plates No.2 Inspection

  90

• Clutch Driven Plate No.2 Inspection

  91

• Clutch Spring Free Height

  91

• Clutch Plate Concaved Washer Inspection

  91

• Starter Clutch View

  94

• Starter Torque Limiter

  95

• Oil Pump Inspection

  95

• Oil Pressure Regulator/Oil Sump Filter

  95

• Crank Balancer

  96

• Drive Shaft Disassembly

  96

• Conrod/Crankshaft

  98

• Conrod Small End I.D.

  98

• Conrod Big End Side Clearance

  98

• Conrod-Crank Pin Bearing Inspection

  98

• Conrod-Crank Pin Bearing Selection

  99

• Conrod I.D.

  100

• Crank Pin O.D.

  100

• Bearing Thickness

  100

• Bearing Assembly

  100

• Crankcase-Crankshaft Bearing Inspection

  101

• Crankcase-Crankshaft Bearing Selection

  101

• Crankshaft Journal Bearing Replacement

  102

• Crankshaft Thrust Clearance

  105

• Oil Jet

  106

• Crankcase

  107

• Oil Pressure Switch

  107

• Bearing Disassembly

  107

• Bearing Inspection

  108

• Bearing Reassembly

  108

• Oil Seal Disassembly

  108

• Oil Seal Reassembly

  109

• Engine Reassembly

  110

• Primary Driven Gear/Crankshaft

  110

• Oil Sump Filter

  111

• Oil Pump/Oil Pressure Regulator

  111

• Crank Balancer Shaft

  112

• Piston Ring

  120

• Cam Shaft

  123

• Position of Camshafts and Sprockets

  124

• Oil Level Switch

  126

• Drive Train

  127

• Drive Train Construction

  128

• Removal and Disassembly

  129

• Inspection and Replacement

  130

• Gears

  130

• Oil Seals

  130

• Bearings

  131

• Final Driven Gear Hub

  132

• Reassembly and Remounting

  133

• Cvt

  135

• CVT Assembly Removal and Installation

  136

• CVT Assembly Installation

  138

• CVT Disassembly and Reassembly

  139

• CVT Disassembly

  140

• CVT Casing/Cover

  140

• Secondary Pulley Assembly

  143

• CVT Belt

  144

• Primary Pulley

  144

• CVT Inspection

  145

• Primary Pulley Inspection

  145

• Secondary Pulley Inspection

  145

• Secondary Pulley Disassembly

  146

• CVT Motor

  146

• Secondary Pulley Reassembly

  147

• CVT Bely Inspection

  147

• CVT Casing/Cover Inspection

  148

• CVT Casing/Cover Disassembly

  148

• CVT Casing/Cover Reassembly

  149

• Primary Slide Pulley Idle Gear Inspection

  150

• CVT Primary Pulley Shims Adjustment

  150

• CVT Cover Depth Measurement

  150

• Primary Pulley Height Measurement

  150

• Shim Selection Table

  152

• CVT Reassembly

  153

• Primary Pulley Assembly

  153

• CVT Belt Installation

  154

• CVT Belt Brake-In Procedures

  161

• Clamp Location

  161

• FI System/ CVT System

  162

• Precautions in Servicing

  163

• Electrical Parts

  163

• Connector/Coupler

  163

• Fude

  164

• ECM/CVT Control Unit/Various Sensors

  164

• Electrical Circuit Inspection Procedure

  166

• Open Circuit Check

  166

• Continuity Check

  167

• Voltage Check

  167

• Short Circuit Check (Wire Harness to Ground)

  168

• Using the Tester

  169

• FI System Technical Features Injection Time (Injection Volume)

  170

• Compensation of Injection Time (Volume)

  171

• Injection Stop Control

  171

• FI System Parts Location

  172

• FI System Wiring Diagram

  174

• CVT System Technical Features

  175

• CVT System Parts Location

  176

• Self-Diagnosis Function

  179

• User Mode

  179

• Dealer Mode

  180

• TPS Adjustment

  181

• Fail-Safe Function

  182

• FI System/Cvt System Troubleshooting Customer Complaint Analysis

  183

• Self-Diagnostic Procedures

  185

• Self-Diagnosis Reset Procedure

  185

• Malfunction Code and Defective Condition

  186

• «C11» CMP Sensor Circuit Malfunction

  188

• «C12» CKP Sensor Circuit Malfunction

  189

• «C13» IAP Sensor Circuit Malfunction

  190

• «C14» TP Sensor Circuit Malfunction

  192

• «C15» ECT Sensor Circuit Malfunction

  194

• «C16» Speed Sensor Circuit Malfunction

  195

• «C21» IAT Sensor Circuit Malfunction

  197

• «C22» AP Sensor Circuit Malfunction

  198

• «C23» to Sensor Circuit Malfunction

  200

• «C24» or «C25» Ignition System Malfunction

  201

• «C32» or «C33» Fuel Injector Circuit Malfunction

  201

• «C40» IAC Valve Circuit Malfunction

  202

• «C41» FP Relay Circuit Malfunction

  202

• «C42» IG Switch Circuit Malfunction

  202

• «C44» HO2 Sensor (HO2S) Circuit Malfunction (E-02,19)

  203

• «C50» CVT Serial Communication Circuit Malfunction

  205

• «C51» CVT Motor Circuit Malfunction

  206

• «C52» CVT Pulley Position Sensor (PPS) Circuit Malfunction

  208

• «C53» CVT Speed Sensor Circuit Malfunction

  210

• «C54» CVT Secondary Pulley Revolution Sensor Circuit Mal­function

  212

• «C55» CVT Engine Revolution Signal Circuit Malfunction

  214

• «C56» CVT Throttle Position Signal Circuit Malfunction

  215

• «C58» CVT Reduction Ratio Disagreement

  216

• Throttle Position Sensor (TPS) Setting

  217

• CMP/CKP Sensor

  217

• IAP Sensor

  217

• TP Sensor

  218

• ECT Sensor

  218

• Speed Sensor

  218

• IAT/AP Sensor

  218

• To Sensor

  219

• H02 Sensor (E-02,19)

  219

• CVT Pulley Position Sensor

  219

• CVT Secondary Pulley Revolution Sensor

  219

• Fuel System and Throttle Body

  220

• Fuel System

  221

• Fuel Tank Components

  221

• Fuel Tank Removal

  222

• Fuel Tank Installation

  223

• Fuel Tank Pressure Control (FTPC) Valve Inspection

  223

• Fuel Pressure Inspection

  224

• Fuel Pump Inspection

  225

• Fuel Discharge Amount Inspection

  225

• Fuel Pump Relay Inspection

  225

• Fuel Pump Components

  226

• Fuel Pump/Fuel Level Gauge Removal and Disassembly

  226

• Fuel Mesh Filter Inspection and Cleaning

  229

• Fuel Level Gauge Inspection

  229

• Fuel Meter Inspection

  229

• Fuel Pump/Fuel Level Gauge Reassembly and Installation

  230

• Throttle Body Components

  233

• Throttle Body Removal

  234

• Throttle Body Disassembly

  236

• Throttle Body Cleaning and Inspection

  238

• IAC Valve Inspection

  239

• Throttle Body Reassembly

  239

• Throttle Body Installation

  241

• Throttle Body Clamp Position

  241

• Throttle Cable Adjustment

  242

• Fuel Injector Removal

  242

• Fuel Injector Inspection

  242

• Fuel Injector Installation

  242

• Throttle Valve Synchronization

  243

• Cooling and Lubrication System

  244

• Cooling System Description

  245

• Cooling Circuit

  245

• Oil Cooler

  245

• Engine Coolant

  246

• Radiator and Hoses

  247

• Cooling Circuit Inspection

  247

• Radiator Cap Inspection

  247

• Radiator Hose Inspection

  248

• Radiator Removal

  249

• Radiator Reservoir Tank Removal/Remounting

  250

• Cooling Fan

  251

• Inspection

  251

• Removal

  251

• Remounting

  252

• Cooling Fan Thermo-Switch

  253

• Engine Coolant Temperature Sensor

  255

• Thermostat

  257

• Water Pump Construction

  259

• Mechanical Seal

  262

• Oil Seal

  263

• Bearing Case/Mechanical Case

  263

• Impeller

  263

• Reassembly and Installation

  264

• Engine Lubrication System Chart

  269

• Engine Lubrication System

  270

• Chassis

  272

• Exterior Parts Construction

  274

• Front Box

  277

• Foot Board Assembly

  277

• Location of Exterior Components

  278

• Removal Procedure Flow Chart

  278

• Wind Screen

  279

• Handlebar Cover

  280

• Front Panel

  280

• Rear View Mirror

  281

• Lower Leg Shield

  282

• Right Leg Side Cover

  284

• Left Leg Side Cover

  284

• Maintenance Lid

  285

• Seat

  285

• Seat Damper

  286

• Pillon Rider Handle

  287

• Trunk Box Cover

  288

• Frame Cover

  288

• Foot Board

  290

• Rear Fender

  292

• Trunk Box

  292

• Leg Shield Brace

  294

• Seat Rail

  295

• Front Wheel Construction

  297

• Dust Seal

  299

• Front Axle

  299

• Wheel

  299

• Wheel Bearing

  300

• Brake Disc

  302

• Brake Caliper

  303

• Front Fork Construction

  304

• Inner and Outer Tubes

  307

• Fork Spring

  307

• Cylinder

  308

• Metals and Seals

  308

• Cylinder Bolt

  309

• Fork Oil

  310

• Front Fork Cap Bolt

  311

• Steering and Handlebars Construction

  312

• Handlebars

  313

• Steering Stem

  313

• Bearing Races

  315

• Steering Tension Adjustment

  318

• Rear Wheel Construction

  319

• Rear Axle

  322

• Rear Hub Damper

  322

• Rear Hub Driven Joint

  322

• Rear Shock Absorber Construction

  329

• Suspension Setting

  330

• Spring Rpe-Load Adjustment

  330

• Rear Swingarm Construction

  331

• Swingarm Bearing

  332

• Bushing

  333

• Front Brake Construction

  335

• Brake Pad Replacement

  336

• Brake Fluid Replacement

  337

• Caliper Removal and Disassembly

  338

• Caliper Inspection

  339

• Brake Caliper Piston

  339

• Caliper Holder

  339

• Rubber Parts

  340

• Caliper Reassembly and Remounting

  340

• Piston Seal

  340

• Master Cylinder Removal and Disassembly

  342

• Master Cylinder Inspection

  343

• Master Cylinder Reassembly and Remounting

  343

• Rear Brake Construction

  345

• Boot

  351

• Caliper Reassembly Ans Remounting

  351

• Caliper

  353

• Brake Lock

  353

• Brake Disc Inspection

  355

• Brake Lock Adjustment

  356

• Brake Lock Cable Replacement

  357

• Brake-Lock System

  359

• Brake-Lock Operation

  359

• Automatic Brake-Lock Adjuster System

  360

• Over-Adjust Prevention Mechanism

  362

• Tire and Wheel

  363

• Tire Removal

  363

• Valve Installation

  364

• Tire Installation

  364

• Balancer Weight Installation

  365

• Electrical System

  366

• Cautions in Servicing

  367

• Location of Electrical Components

  369

• Charging System

  371

• Battery Current Leakage

  373

• Regulated Voltage

  374

• Generator Coil Resistance

  374

• Generator No-Load Performance

  375

• Regulator/Rectifier

  375

• Starter System

  376

• Starter Motor Removal and Disassembly

  377

• Starter Motor Inspection

  378

• Carbon Brushes

  378

• Commutator

  378

• Armature Coil Inspection

  378

• Oil Seal Inspection

  379

• Starter Motor Reassembly

  379

• Starter Relay Inspection

  380

• Side Stand/Ignition Interlock System Parts Inspection

  381

• Side-Stand Switch

  381

• Side-Stand Relay

  381

• Starter Relay Diode Inspection

  382

• Ignition System

  383

• Ignition Coil Primary Peak Voltage

  385

• Ignition Coil/Plug Cap Resistance

  386

• CKP Sensor Peak Voltage

  386

• CKP Sensor Resistance

  387

• Combination Meter Parts Names

  388

• Operating Procedure

  389

• Initial Display

  389

• Change the Display Mode

  389

• Tripmeter

  389

• To Reset the Oil Change Indicator

  390

• To Vary the Preset Interval of Oil Change Indicator

  390

• Example of Oil Change Indicator Setting

  390

• Engine Coolant Temperature Meter and Indicator Light

  391

• Fuel Meter

  392

• Fuel Gauge

  392

• Fuel Pump Relay

  393

• Oil Pressure Indicator

  393

• Engine Oil Level Indicator

  394

• Engine Oil Level Switch

  394

• Speedometer

  394

• Speedometer Sensor

  395

• Lamp

  396

• Headlight Bulb Replacement

  396

• Headlight Beam Adjustment

  396

• Brake Light/Taillight, Turn Signal Light and License Light

  397

• Bulb Replacement

  397

• Front Turn Signal Light

  397

• Rear Turn Signal Light

  398

• Brake Light/Taillight

  398

• License Light

  398

• Turn Signal Relays

  399

• Cooling Fan Motor Relay

  399

• Battery Specifications

  402

• Initial Charging

  402

• Filling Electrolyte

  402

• Servicing

  404

• Recharging Operation

  404

• Servicing Information

  405

• Troubleshooting

  406

• FI System/Cvt System Malfunction Code and Defective Condition

  406

• Engine Servicing Information

  408

• CVT Servicing Information

  413

• Radiator (Cooling System) Servicing Information

  413

• Chassis Servicing Information

  414

• Brakes Servicing Information

  415

• Electrical Servicing Information

  416

• Battery Servicing Information

  417

• Wiring Harness, Cable and Hose Routing

  418

• Cable Routing

  422

• Throttle Body Installation/Hose Routing

  424

• Fuel Tank Mounting

  425

• Fuel Tank Hose Routing

  426

• Radiator Hose Routing

  427

• Front Brake Hose Routing

  428

• Rear Brake Hose Routing

  429

• Side-Stand Set-Up

  430

• Center Stand Set-Up

  430

• Special Tools

  431

• Tightening Torque Engine

  435

• Tightening Torque Chart

  437

• Service Data

  438

• Valve + Guide

  438

• Camshaft + Cylinder Head

  439

• Cylinder + Piston + Piston Ring

  439

• Conrod + Crankshaft

  440

• Injector + Fuel Pump + Fuel Pressure Regulator

  441

• FI/CVT-Sensors

  441

• Throttle Body

  442

• Thermostat + Radiator + Fan + Coolant

  442

• Wattage

  443

• Brake + Wheel

  444

• Suspension

  444

• Tire

  445

• Fuel + Oil

  445

• Emission Control Information

  446

• Emission Control Systems

  447

• Fuel Injection System

  447

• Crankcase Emission Control System

  448

• Exhaust Emission Control System (Pair System)

  449

• Noise Emission Control System

  450

• Pair (Air Supply) System Inspection Hose

  451

• Pair Reed Valve

  451

• Pair Control Solenoid Valve

  451

• Pair (Air Supply) System Hose Routing

  453

• Heated Oxgen Sensor (HO2S) Inspection

  454

• Wiring Diagram E-02, 19

  455

• Wiring Diagram AN650L

  458

Brand: Suzuki
|
Category: Motorcycle
|
Size: 2.01 MB

• Table of Contents

  4

• Consumer Information

  6

  • Accessory Use and Motorcycle Loading

    7

  • Safe Riding Recommendations for Motorcycle Riders

    9

  • Labels

    11

  • Serial Number Location

    11

• Controls

  12

  • Location of Parts

    13

  • Key

    16

  • Ignition Switch

    17

  • Instrument Panel

    19

  • Left Handlebar

    31

  • Right Handlebar

    35

  • Brake Lock Lever

    37

  • Fuel Tank Cap

    38

  • Front Trunk

    40

  • Front Small Box

    41

  • Trunk

    41

  • Helmet Holder

    42

  • Backrest Adjustment

    42

  • Trunk Box Light Switch

    43

  • Stand

    43

  • Rear Suspension

    44

  • Output Terminal

    45

• Fuel, Engine Oil and Coolant Recommendations

  46

  • Fuel Octane Rating

    47

  • Oxygenated Fuel Recommendation

    47

  • Engine Oil

    49

  • Transmission Oil

    50

  • Final Gear Oil

    50

  • Engine Coolant Solution

    51

• Break-In (Running-In) and Inspection before Riding

  54

• Riding Tips

  58

  • Starting the Engine

    59

  • Starting off

    60

  • RIDING on HILLS (MANUAL Mode)

    61

  • Stopping and Parking

    62

• Inspection and Maintenance

  66

  • Maintenance Schedule

    67

  • Tools

    70

  • Lubrication Points

    70

  • Battery

    71

  • Spark Plug

    73

  • Air Cleaner

    77

  • Engine Idle Speed Inspection

    80

  • Throttle Cable Play

    81

  • Cvt Filter

    82

  • Engine Coolant

    84

  • Engine Oil

    86

  • Transmission Oil and Final Gear Oil

    91

  • Brakes

    94

  • Tires

    97

  • Side Stand/Ignition Interlock System

    100

  • Light Bulb Replacement

    101

  • Fuses

    105

  • Catalytic Converter

    107

  • Diagnostic Connector

    109

• Troubleshooting

  110

• Storage Procedure and Motorcycle Cleaning

  112

  • Storage Procedure

    113

  • Procedure for Returning to Service

    114

  • Corrosion Prevention

    114

  • Motorcycle Cleaning

    115

  • Inspection after Cleaning

    117

• Specifications

  119

Brand: Suzuki
|
Category: Motorcycle
|
Size: 7.81 MB

Brand: SUZUKI
|
Category: Motorcycle
|
Size: 3.58 MB

• Battery

  3

• Air Cleaner

  4

• Alternator

  5

• Cam Chain

  6

• Cam Shaft + Valve

  7

• Carburetor Fittings

  8

• Carburetor

  9

• Clutch

  11

• Cooling Fan

  12

• Cosling Body Installation Parts

  13

• Cowling Body (Model W)

  14

• Crankcase Cover

  15

• Crankcase

  16

• Crankshaft

  17

• Electrical

  18

• Footrest

  19

• Frame Cover (Model W/X)

  20

• Frame

  21

• Front Brake Hose

  22

• Front Caliper

  23

• Front Damper

  24

• Front Fender

  25

• Front Wheel

  26

• Fuel Cock

  27

• Fuel Tank (Model W/X)

  28

• Gear Shifting

  29

• Handlebar

  30

• Handle Lever

  31

• Handle Switch

  32

• Cylinder Head Cover

  33

• Cylinder Head

  34

• Headlamp

  35

• Muffler

  36

• Oil Cooler

  37

• Oil Pan

  38

• Oil Pump

  39

• Rear Caliper

  40

• Rear Fender

  41

• Rear Master Cylinder

  42

• Rear Cushion Lever

  43

• Rear Wheel

  44

• Seat (Model W/X)

  45

• Signal Generator

  46

• Speedometer (Model W/X)

  47

• Stand

  48

• Starter Clutch

  49

• Starting Motor

  50

• Steering Stem

  51

• Rear Swinging Arm

  52

• Tail Lamp

  53

• Transmission

  54

• Turn Signal Lamp

  55

• Under Cowling

  56

• Wiring Harness

  57