Download USE THIS MANUAL WITH: AN650 SERVICE MANUAL (99500

AN650/A
USE THIS MANUAL WITH:
AN650 SERVICE MANUAL (99500-36111-01E)
AN650/AK5 (’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-model) and 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 (*).
• Please refer to the AN650K3 (’03-model) service manual and AN650AK4 (’04-model)
service information for details which are not given in this manual.
CONTENTS
SPECIFICATION (AN650K5) .............................................................................. 3
SPECIFICATION (AN650AK5)............................................................................ 4
SERVICE DATA (AN650K5) ............................................................................... 5
SERVICE DATA (AN650AK5).............................................................................14
IMMOBILIZER (E-02, 19, 000) ............................................................................23
OPERATION...............................................................................................23
COMBINATION METER ......................................................................................25
TERMINAL ALIGNMENT ...........................................................................25
POWER WIND SCREEN (AN650AK5 E-02, 19, 000).........................................26
INSPECTION ..............................................................................................26
REMOVAL ..................................................................................................26
INSTALLATION..........................................................................................27
AMBIENT AIR TEMPERATURE SENSOR .........................................................28
INSPECTION ..............................................................................................28
FI SYSTEM WIRING DIAGRAM..........................................................................29
ECM COUPLERS ................................................................................................31
K4 MODEL ECM AND CVT CONTROL UNIT COUPLERS ......................31
K5 MODEL ECM COUPLERS ...................................................................31
MALFUNCTION CODE ..............................................................................33
ABS TROUBLESHOOTING (AN650AK5) ..........................................................34
MALFUNCTION CODE TROUBLESHOOTING.........................................34
WIND SCREEN CABLE ROUTING.....................................................................40
RADIATOR HOSE ROUTING .............................................................................41
EXTERIOR PARTS CONSTRUCTION................................................................42
CVT CONSTRUCTION ........................................................................................45
AMBIENT AIR TEMPERATURE SENSOR BRACKET INSTALLATION ...........46
SPECIAL TOOLS ................................................................................................47
TIGHTENING TORQUE CHART .........................................................................47
WIRING DIAGRAM..............................................................................................49
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2
AN650/AK5 (’05-MODEL)
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
CODE
AN650K5
AN650AK5
E-03
E-28
E-33
E-02
E-19
E-24
000
E-02
E-19
000
COUNTRY or AREA
U.S.A.
Canada
California (U.S.A.)
U.K.
E.U.
Australia
JAPAN
U.K.
E.U.
JAPAN
EFFECTIVE FRAME NO.
JS1CP51A52 100001 –
JS1BU111200100468 –
JS1BU111100113619 –
JS1BU121300100200 –
!""!""!""!""!
JS1BU132200100080 –
JS1BU132100105119 –
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!""!""!""!""!
AN650/AK5 (’05-MODEL)
SPECIFICATION (AN650K5)
DIMENSIONS AND DRY MASS
Overall length ..................................................................................... 2 260 mm (89.0 in)
Overall width.......................................................................................
810 mm (31.9 in)
Overall height ..................................................................................... 1 435 mm (56.5 in)
Wheelbase ......................................................................................... 1 595 mm (62.8 in)
Ground clearance ...............................................................................
130 mm (5.1 in)
Seat height .........................................................................................
750 mm (29.5 in)
Dry mass ............................................................................................ * 235 kg (518 lbs)
ENGINE
Type ....................................................................................................
Number of cylinders ...........................................................................
Bore....................................................................................................
Stroke .................................................................................................
Displacement......................................................................................
Compression ratio ..............................................................................
Carburetion.........................................................................................
Air cleaner ..........................................................................................
Starter system ....................................................................................
Lubrication system .............................................................................
Idle speed ...........................................................................................
4-stroke, liquid-cooled, DOHC
2
75.5 mm (2.972 in)
71.3 mm (2.807 in)
638 cm3 (38.9 cu. in)
11.2 : 1
Fuel injection
Non-woven fabric element
Electric
Wet sump
1 200 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................
Primary reduction ratio .......................................................................
Gearshift pattern.................................................................................
Automatic transmission ratio ..............................................................
Final reduction ratio ............................................................................
Drive system.......................................................................................
Wet multi-plate, automatic, centrifugal type
1.333 (88/66)
Automatic & Manual shift
Variable change (1.800 – 0.465)
1.580 (32/31 × 31/32 × 34/31 × 49/34)
Gear drive
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CHASSIS
Front suspension ................................................................................
Rear suspension ................................................................................
Front fork stroke..................................................................................
Rear wheel travel................................................................................
Caster.................................................................................................
Trail .....................................................................................................
Steering angle ....................................................................................
Turning radius .....................................................................................
Front brake .........................................................................................
Rear brake..........................................................................................
Front tire size ......................................................................................
Rear tire size ......................................................................................
A
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Telescopic, coil spring, oil damped
Swingarm type, coil spring, oil damped
110 mm (4.3 in)
100 mm (3.9 in)
26° 10’
106 mm (4.17 in)
41° (right and left)
2.7 m (8.9 ft)
Disc brake, twin
Disc brake
120/70R15M/C 56H, tubeless
160/60R14M/C 65H, tubeless
ELECTRICAL
Ignition type ........................................................................................
Ignition timing .....................................................................................
Spark plug ..........................................................................................
Battery ................................................................................................
Generator ...........................................................................................
Main fuse ............................................................................................
CVT fuse ............................................................................................
Fuse ...................................................................................................
Electronic ignition (Transistorized)
10° B.T.D.C. at 1 200 r/min
NGK CR8E or DENSO U24ESR-N
12 V 43.2 kC (12 Ah)/10 HR
Three-phase A.C. generator
40 A
40 A
15/15/15/15/10/10/10 A ................................. E-02, 19
15/15/15/15/15/10/10 A ................................. E-03, 24, 28, 33
Headlight ............................................................................................ 12 V 60 + 55/55 + 55 (H4 + H7)..................... E-02, 19
12 V 60/55 W × 2 (H4 × 2) ............................. E-03, 24, 28, 33
Position/parking light .......................................................................... 12 V 5 W ........................................................ E-02, 19
Brake light/Taillight.............................................................................. 12 V 21/5 W × 2
License plate light............................................................................... 12 V 5 W
Trunk light ........................................................................................... 12 V 5 W
Turn signal light .................................................................................. 12 V 21 W
Instrument panel light ......................................................................... 12 V 1.4 W × 2
Coolant temperature warning light ..................................................... 12 V 1.4 W
Fuel injection warning light ................................................................. 12 V 1.4 W
Oil pressure warning light ................................................................... 12 V 1.4 W
Brake-lock warning light ..................................................................... 12 V 1.4 W
High beam indicator light .................................................................... 12 V 1.4 W
Turn signal indicator light.................................................................... 12 V 1.4 W × 2
Power mode indicator light ................................................................. 12 V 1.4 W
Drive indicator light ............................................................................. 12 V 1.4 W
Gear position indicator light ................................................................ 12 V 1.4 W × 5
Immobilizer indicator light ................................................................... * LED ................................................................ E-02, 19
Over drive indicator light..................................................................... * 12 V 1.4 W ..................................................... E-02, 19
CAPACITIES
Fuel tank, including reserve ..............................................................
Engine oil, oil change ........................................................................
with filter change .............................................................
overhaul...........................................................................
Transmission oil, oil change ..............................................................
overhaul .................................................................
Final gear oil, oil change ....................................................................
overhaul.......................................................................
Coolant ...............................................................................................
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 qt)
3
4 AN650/AK5 (’05-MODEL)
SPECIFICATION (AN650AK5)
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 260 mm (89.0 in)
Overall width .......................................................................................
810 mm (31.9 in)
Overall height ...................................................................................... 1 435 mm (56.5 in)
Wheelbase .......................................................................................... 1 595 mm (62.8 in)
Ground clearance................................................................................
130 mm (5.1 in)
Seat height ..........................................................................................
750 mm (29.5 in)
Dry mass.............................................................................................* 243 kg (535 lbs)
ENGINE
Type.....................................................................................................
Number of cylinders ............................................................................
Bore ....................................................................................................
Stroke..................................................................................................
Displacement ......................................................................................
Compression ratio ...............................................................................
Carburetion .........................................................................................
Air cleaner ...........................................................................................
Starter system.....................................................................................
Lubrication system ..............................................................................
Idle speed ...........................................................................................
4-stroke, liquid-cooled, DOHC
2
75.5 mm (2.972 in)
71.3 mm (2.807 in)
638 cm3 (38.9 cu. in)
11.2 : 1
Fuel injection
Non-woven fabric element
Electric
Wet sump
1 200 ± 100 r/min
DRIVE TRAIN
Clutch ..................................................................................................
Primary reduction ratio........................................................................
Gearshift pattern .................................................................................
Automatic transmission ratio ...............................................................
Final reduction ratio.............................................................................
Drive system .......................................................................................
Wet multi-plate, automatic, centrifugal type
1.333 (88/66)
Automatic & Manual shift
Variable change (1.800 – 0.465)
1.580 (32/31 × 31/32 × 34/31 × 49/34)
Gear drive
CHASSIS
Front suspension.................................................................................
Rear suspension .................................................................................
Front fork stroke ..................................................................................
Rear wheel travel ................................................................................
Caster .................................................................................................
Trail......................................................................................................
Steering angle .....................................................................................
Turning radius .....................................................................................
Front brake ..........................................................................................
Rear brake ..........................................................................................
Front tire size ......................................................................................
Rear tire size .......................................................................................
Telescopic, coil spring, oil damped
Swingarm type, coil spring, oil damped
110 mm (4.3 in)
100 mm (3.9 in)
26° 10’
106 mm (4.17 in)
41° (right and left)
2.7 m (8.9 ft)
Disc brake, twin
Disc brake
120/70R15M/C 56H, tubeless
160/60R14M/C 65H, tubeless
ELECTRICAL
Ignition type.........................................................................................
Ignition timing ......................................................................................
Spark plug ...........................................................................................
Battery.................................................................................................
Generator ............................................................................................
Main fuse ............................................................................................
CVT fuse .............................................................................................
Fuse ....................................................................................................
Headlight .............................................................................................
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 ................................................................
ABS warning light................................................................................
Immobilizer indicator light....................................................................*
Over drive indicator light .....................................................................*
Electronic ignition (Transistorized)
10° B.T.D.C. at 1 200 r/min
NGK CR8E or DENSO U24ESR-N
12 V 43.2 kC (12 Ah)/10 HR
Three-phase A.C. generator
40 A
40 A
15/15/15/15/15/10/10/15/15 A
12 V 60 + 55/55 + 55 (H4 + H7)
12 V 5 W
12 V 21/5 W × 2
12 V 5 W
12 V 5 W
12 V 21 W
12 V 1.4 W
12 V 1.4 W
12 V 1.4 W
12 V 1.4 W
12 V 1.4 W
12 V 1.4 W
12 V 1.4 W
12 V 1.4 W
12 V 1.4 W
12 V 1.4 W
12 V 1.4 W
LED
12 V 1.4 W
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CAPACITIES
Fuel tank, including reserve ................................................................ 15.0 L (4.0/3.3 US/Imp gal)
Engine oil, oil change......................................................................... 2 600 ml (2.7/2.3 US/Imp qt)
with filter change .............................................................. 2 900 ml (3.1/2.6 US/Imp qt)
overhaul ........................................................................... 3 400 ml (3.6/3.0 US/Imp qt)
Transmission oil, oil change ...............................................................
360 ml (12.2/12.7 US/Imp oz)
overhaul ..................................................................
400 ml (13.5/14.1 US/Imp oz)
Final gear oil, oil change.....................................................................
300 ml (10.1/10.6 US/Imp oz)
overhaul .......................................................................
430 ml (14.5/15.1 US/Imp oz)
Coolant................................................................................................
1.6 L (1.7/1.4 US/Imp qt)
AN650/AK5 (’05-MODEL)
5
SERVICE DATA (AN650K5)
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
STANDARD
29.5
(1.16)
25.0
(0.98)
0.10 – 0.20
(0.0039 – 0.0079)
0.20 – 0.30
(0.0079 – 0.0118)
0.010 – 0.040
(0.0004 – 0.0016)
0.030 – 0.060
(0.0012 – 0.0024)
4.500 – 4.515
(0.1772 – 0.1778)
4.475 – 4.490
(0.1762 – 0.1768)
4.455 – 4.470
(0.1754 – 0.1760)
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EX.
LIMIT
—
—
—
—
—
—
—
—
—
Valve stem deflection
IN. & EX.
—
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
IN. & EX.
—
0.03
(0.001)
40.6
(1.60)
IN. & EX.
136 – 156 N
(13.6 – 15.6 kgf, 30.0 – 34.4 lbs)
at length 33.4 mm (1.31 in)
Valve seat width
Valve head radial runout
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Valve spring free length (IN. & EX.)
Valve spring tension (IN. & EX.)
—
6 AN650/AK5 (’05-MODEL)
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
ITEM
Cam height
STANDARD
35.38 – 35.43
(1.393 – 1.395)
33.98 – 34.03
(1.338 – 1.340)
0.032– 0.066
(0.0013 – 0.0026)
24.012 – 24.025
(0.9454 – 0.9459)
23.959 – 23.980
(0.9433 – 0.9441)
IN.
EX.
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
Camshaft journal O.D.
IN. & EX.
Camshaft runout
IN. & EX.
15th pin
—
CYLINDER + PISTON + PISTON RING
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ITEM
Compression pressure
STANDARD
1 500 – 1 900 kPa
(15.0 – 19.0 kgf/cm2, 213 – 270 psi)
Compression pressure difference
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
—
0.045 – 0.055
(0.0018 – 0.0022)
75.500 – 75.515
(2.9724 – 2.9730)
* 75.470 – 75.485
(2.9705 – 2.9711)
Measure at 15 mm (0.6 in) from the skirt end.
A
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R
Approx. 11.6 (0.46)
2nd
RN
Approx. 8.6 (0.34)
2nd
Piston ring to groove clearance
Piston ring groove width
—
1st
1st
* 0.06 – 0.18
(0.002 – 0.005)
* 0.06 – 0.18
(0.002 – 0.005)
1st
—
2nd
—
1st
1.01 –
(0.040 –
1.01 –
(0.040 –
2.01 –
(0.079 –
2nd
Oil
—
—
0.10
(0.004)
—
0.10
(0.004)
—
Cam chain pin (at arrow “3”)
Cylinder head distortion
LIMIT
35.10
(1.382)
33.70
(1.327)
0.150
(0.0059)
1.03
0.041)
1.03
0.041)
2.03
0.080)
Unit: mm (in)
LIMIT
1 200 kPa
(12 kgf/cm2, 171 psi)
200 kPa
(2.0 kgf/cm2, 28 psi)
0.120
(0.0047)
Nicks or
scratches
75.380
(2.9677)
0.10
(0.004)
9.3
(0.37)
6.9
(0.27)
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
—
—
—
AN650/AK5 (’05-MODEL)
ITEM
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
STANDARD
0.97 – 0.99
(0.038 – 0.039)
0.97 – 0.99
(0.038 – 0.039)
16.002 – 16.008
(0.6300 – 0.6302)
15.995 – 16.000
(0.6297 – 0.6299)
CONROD + CRANKSHAFT
16.030
(0.6311)
15.980
(0.6291)
—
0.05
(0.002)
STANDARD
Above 350 kPa (3.5 kgf/cm2 , 49.8 psi)
Below 550 kPa (5.5 kgf/cm2, 78.2 psi)
at 3 000 r/min
LIMIT
Crank pin width
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Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft runout
—
0.080
(0.0031)
Conrod big end width
A
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Crankshaft thrust clearance
—
STANDARD
16.010 – 16.018
(0.6303 – 0.6306)
0.10 – 0.20
(0.004 – 0.008)
19.950 – 20.000
(0.7854 – 0.7874)
20.100 – 20.150
(0.7913 – 0.7933)
0.032 – 0.056
(0.0013 – 0.0022)
44.976 – 45.000
(1.7707 – 1.7717)
0.018 – 0.045
(0.0007 – 0.0018)
47.985 – 48.000
(1.8892 – 1.8898)
2.025 – 2.175
(0.0797 – 0.0856)
0.10 – 0.15
(0.0039 – 0.0059)
Conrod big end side clearance
Crankshaft thrust bearing thickness
LIMIT
Unit: mm (in)
ITEM
Conrod small end I.D.
Crankshaft journal O.D.
LIMIT
16.040
(0.6315)
0.30
(0.012)
—
—
—
0.080
(0.0031)
—
—
—
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
7
—
8 AN650/AK5 (’05-MODEL)
CLUTCH
Unit: mm (in)
ITEM
Drive plate thickness
STANDARD
2.92 – 3.08
(0.115 – 0.121)
13.85 – 13.96
(0.545 – 0.550)
2.42 – 2.58
(0.095 – 0.102)
Drive plate claw width
Driven plate No. 2 thickness
Driven plate distortion
—
Clutch spring free length
13.9
(0.547)
3.2
(0.126)
1 500 – 2 100 r/min
3 200 – 3 800 r/min
Clutch plate concaved washer
height
Clutch engagement
Clutch lock-up
LIMIT
2.62
(0.103)
13.05
(0.514)
2.27
(0.089)
0.10
(0.004)
13.2
(0.520)
3.1
(0.12)
—
—
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
FI/CVT-SENSORS
ITEM
CMP sensor resistance
CMP sensor peak voltage
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor output voltage
Injector voltage
SPECIFICATION
11 – 13 Ω at 20 °C (68 °F)
More than 0.9 L (0.95/0.79 US/Imp qt)
For 30 sec. at 300 kPa (3.0 kgf/cm2, 43 psi)
NOTE
—
Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
—
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SPECIFICATION
0.9 – 1.7 kΩ
More than 0.5 V (When cranking)
150 – 300 Ω
More than 2.0 V (When cranking)
4.5 – 5.5 V
Approx. 2.6 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.1 kΩ
Opened
Approx. 4.2 kΩ
Closed
Approx. 1.1 V
Opened
Approx. 4.3 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 3.6 V at 100 kPa (760 mmHg)
19.1 – 19.7 kΩ
Normal
0.4 – 1.4 V
Leaning
3.7 – 4.4 V
Battery voltage
—
NOTE
+: B/Y, -: Br
+: Bl, -: G
+: B, -: B/Br
+: B, -: B/Br
AN650/AK5 (’05-MODEL)
ITEM
Ignition coil primary peak voltage
SPECIFICATION
More than 80 V (When cranking)
NOTE
#1 +: W/Bl,
-: Ground
#2 +: B/Y,
-: Ground
4 – 5 Ω at 23 °C (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 Ω at 20 °C (68 °F)
CVT primary pulley position sensor Compressed
1.9 – 2.3 kΩ
Extended
0.2 – 1.0 kΩ
Approx. 3.3 V
CVT primary pulley position sensor 1st: Idle speed
output voltage
Approx. 1.3 V
3rd : 3 000 r/min
th
5 : 3 000 r/min
Approx. 0.5 V
CVT secondary pulley revolution
400 – 600 Ω
sensor resistance
CVT secondary pulley revolution
More than 5 V at idle speed
sensor peak voltage
HO2 sensor resistance
HO2 sensor output voltage
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THROTTLE BODY
ITEM
I.D. No.
Bore size
Fast idle r/min
Idle r/min
Synchronizing screw opening
IAC valve resistance
Throttle cable play
+: Y, -: W
A
S
SPECIFICATION
10GO
32 mm (1.26 in)
1 300 – 1 600 r/min
1 200 ± 100 r/min
1 and 1/2 turns out
Approx. 4 Ω at 20 – 24 °C (68 – 75 °F)
2.0 – 4.0 mm
(0.08 – 0.16 in)
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Engine coolant temperature sensor
resistance
Radiator cap valve opening pressure
Eclectic fan thermo-switch operating temperature
Engine coolant type
STANDARD/SPECIFICATION
LIMIT
Approx. 88 °C (190 °F)
—
Over 8.0 mm (0.3
20 °C (68 °F)
50 °C (122 °F)
80 °C (176 °F)
110 °C (230 °F)
in) at 100 °C (212 °F)
Approx. 2.45 kΩ
Approx. 0.811 kΩ
Approx. 0.318 kΩ
Approx. 0.142 kΩ
—
—
—
—
—
110 kPa (1.1 kgf/cm²)
—
ON
93 – 103 °C (199 – 217 °F)
OFF
87 – 97 °C (188 – 206 °F)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
—
—
—
9
10 AN650/AK5 (’05-MODEL)
ITEM
Engine coolant including reserve
STANDARD/SPECIFICATION
Reverse
Approx. 250 ml
tank side
(0.264/0.220 US/Imp qt)
Approx. 1 350 ml
Engine side
(1.427/1.188 US/Imp qt)
ELECTRICAL
Firing order
Spark plug
Type
STD/SPEC.
1·2
NGK: CR8E
DENSO: U24ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8.0 (0.3) at 1 atm.
More than 2.0 V
0.8 – 2.5 Ω
8 – 18 kΩ
Gap
Spark performance
CKP sensor peak voltage
Ignition coil resistance
Primary
Secondary
Ignition coil primary peak voltage
E
L
P
M
More than 80 V
Generator no-load voltage
(When cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Fuse size
—
—
Unit: mm (in)
ITEM
Generator coil resistance
LIMIT
CKP sensor
Charging
150 – 300 Ω
0.1 – 1.0 Ω
More than 50 V at 5 000 r/min
Approx. 500 W at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
A
S
Type
designation
Capacity
Head- LO
light
HI
Fuel pump
Ignition
Turn signal
Fan motor
Main
CVT
Power
source
FTX14-BS
12 V 43.2 kC (12 Ah)/10 HR
15 A .......... E-03, 24, 28, 33
10 A .......... E-02, 19
15 A
10 A
15 A
15 A
15 A
40 A
40 A
10 A
NOTE
+: Bl, -:G
#1 +: W/Bl,
-: Ground
#2 +: B/Y,
-: Ground
G – BI
Y–Y
AN650/AK5 (’05-MODEL)
WATTAGE
11
Unit: W
STD/SPEC.
ITEM
Headlight
E-02, 19
60 + 55
55
5×2
21/5 × 2
21 × 4
5
1.4 × 2
1.4
1.4
1.4
1.4
1.4
1.4 × 2
1.4
1.4
1.4 × 5
5
LED
1.4
HI
LO
Parking or position light
Brake light/Taillight
Turn signal light
License light
Instrument panel light
Engine coolant temp. indicator light
FI indicator light
Engine oil pressure indicator light
Brake-lock indicator light
High beam indicator light
Turn signal indicator light
Power mode indicator light
Drive indicator light
Gear position indicator light
Trunk light
* Immobilizer indicator light
* Over drive indicator light
BRAKE + WHEEL
ITEM
Brake disc thickness
E
L
P
M
A
S
Front
Rear
Brake disc runout
Master cylinder bore
Front
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diameter
Front
Rear
Brake fluid type
STANDARD
4.5 ± 0.2
(0.177 ± 0.008)
5.5 ± 0.2
(0.217 ± 0.008)
—
Rear
Master cylinder piston diameter
E-03, 24, 28, 33
60 × 2
55 × 2
12.700 – 12.743
(0.5000 – 0.5017)
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
12.657 – 12.684
(0.4983 – 0.4994)
25.400 – 25.450
(1.0000 – 1.0020)
27.000 – 27.050
(1.0630 – 1.0650)
25.318 – 25.368
(0.9968 – 0.9987)
26.918 – 26.968
(1.0598 – 1.0617)
DOT 4
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
Unit: mm (in)
LIMIT
4.0
(0.16)
5.0
(0.20)
0.30
(0.012)
—
—
—
—
—
—
—
—
—
12 AN650/AK5 (’05-MODEL)
ITEM
Wheel rim runout
STANDARD
Wheel axle runout
Wheel rim size
Axial
—
Radial
—
Front
—
Rear
—
Front
Rear
15 M/C × MT3.50
14 M/C × MT4.50
SUSPENSION
Unit: mm (in)
ITEM
Front fork stroke
Front fork spring free length
Front fork inner tube diam.
TIRE
ITEM
A
S
Cold inflation tire pressure
Solo
riding
Dual
riding
Tire size
Tire type
Tire tread depth
(Recommended depth)
LIMIT
—
341
(13.4)
SUZUKI FORK OIL G-10 (#10) or
an equivalent fork oil
458 ml
151
(5.9)
41
(1.61)
100
(3.9)
Front fork oil capacity (each leg)
Front fork oil level
Rear shock absorber spring
adjuster
STANDARD
110
(4.3)
E
L
P
M
Front fork oil type
Rear wheel travel
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
LIMIT
—
Rear
—
Rear
—
STANDARD
Front
Front
—
—
Front
Rear
Front
Rear
Rear
—
2nd
225 kPa
(2.25 kgf/cm2, 33 psi)
250 kPa
(2.50 kgf/cm2, 36 psi)
225 kPa
(2.25 kgf/cm2, 33 psi)
280 kPa
(2.80 kgf/cm2, 41 psi)
120/70R15M/C 56H
160/60R14M/C 65H
BRIDGESTONE TH01F
BRIDGESTONE TH01R
Front
—
—
—
—
—
—
—
—
—
1.6 mm
(0.06 in)
2.0 mm
(0.08 in)
AN650/AK5 (’05-MODEL)
FUEL + OIL
ITEM
SPECIFICATION
Fuel type
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 corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Fuel tank capacity
Including
15.0 L (4.0/3.3 US/lmp gal)
reserve
Fuel meter
mark
Approx. 3.0 L (0.79/0.66 US/lmp gal)
flickering
Fuel meter
mark and
Approx. 1.5 L (0.40/0.33 US/lmp gal)
LCD
flickering
Engine oil and transmission oil type * SAE 10W-40, API, SF/SG or SJ/SH with JASO MA
Engine oil capacity
2.6 L
Oil change
(2.7/2.3 US/lmp qt)
2.9 L
Filter change
(3.1/2.6 US/lmp qt)
3.4 L
Overhaul
(3.6/3.0 US/lmp qt)
Transmission oil capacity
360 ml
Oil change
(12.2/12.7 US/lmp oz)
400 ml
Overhaul
(13.5/14.1 US/lmp 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/lmp oz)
430 ml
Overhaul
(14.5/15.1 US/lmp oz)
A
S
E
L
P
M
NOTE
E-03, 28, 33
The others
13
14 AN650/AK5 (’05-MODEL)
SERVICE DATA (AN650AK5)
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
E
L
P
M
EX.
Valve stem deflection
IN. & EX.
Valve stem runout
IN. & EX.
Valve head thickness
IN. & EX.
Valve seat width
Valve head radial runout
A
S
Valve spring free length (IN. & EX.)
Valve spring tension (IN. & EX.)
IN. & EX.
IN. & EX.
STANDARD
29.5
(1.16)
25.0
(0.98)
0.10 – 0.20
(0.0039 – 0.0079)
0.20 – 0.30
(0.0079 – 0.0118)
0.010 – 0.040
(0.0004 – 0.0016)
0.030 – 0.060
(0.0012 – 0.0024)
4.500 – 4.515
(0.1772 – 0.1778)
4.475 – 4.490
(0.1762 – 0.1768)
4.455 – 4.470
(0.1754 – 0.1760)
LIMIT
—
—
—
—
—
—
—
—
—
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
0.9 – 1.1
(0.035 – 0.043)
—
—
0.03
(0.001)
40.6
(1.60)
—
—
IN. & EX.
—
IN. & EX.
136 – 156 N
(13.6 – 15.6 kgf, 30.0 – 34.4 lbs)
at length 33.4 mm (1.31 in)
—
AN650/AK5 (’05-MODEL)
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
Camshaft journal O.D.
IN. & EX.
Camshaft runout
IN. & EX.
Cam chain pin (at arrow “3”)
Cylinder head distortion
STANDARD
35.38 – 35.43
(1.393 – 1.395)
33.98 – 34.03
(1.338 – 1.340)
0.032– 0.066
(0.0013 – 0.0026)
24.012 – 24.025
(0.9454 – 0.9459)
23.959 – 23.980
(0.9433 – 0.9441)
—
15th pin
—
CYLINDER + PISTON + PISTON RING
E
L
P
M
ITEM
Compression pressure
STANDARD
1 500 – 1 900 kPa
(15.0 – 19.0 kgf/cm2, 213 – 270 psi)
Compression pressure difference
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring to groove clearance
Piston ring groove width
—
0.045 – 0.055
(0.0018 – 0.0022)
75.500 – 75.515
(2.9724 – 2.9730)
* 75.470 – 75.485
(2.9705 – 2.9711)
Measure at 15 mm (0.6 in) from the skirt end.
A
S
Piston ring end gap
—
1st
R
Approx. 11.6 (0.46)
2nd
RN
Approx. 8.6 (0.34)
2nd
* 0.06 – 0.18
(0.002 – 0.005)
* 0.06 – 0.18
(0.002 – 0.005)
1st
—
2nd
—
1st
1.01 – 1.03
(0.040 – 0.041)
1.01 – 1.03
(0.040 – 0.041)
2.01 – 2.03
(0.079 – 0.080)
1st
2nd
Oil
15
LIMIT
35.10
(1.382)
33.70
(1.327)
0.150
(0.0059)
—
—
0.10
(0.004)
—
0.10
(0.004)
Unit: mm (in)
LIMIT
1 200 kPa
(12 kgf/cm2, 171 psi)
200 kPa
(2.0 kgf/cm2, 28 psi)
0.120
(0.0047)
Nicks or
scratches
75.380
(2.9677)
0.10
(0.004)
9.3
(0.37)
6.9
(0.27)
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
—
—
—
16 AN650/AK5 (’05-MODEL)
ITEM
Piston ring thickness
1st
STANDARD
0.97 – 0.99
(0.038 – 0.039)
0.97 – 0.99
(0.038 – 0.039)
16.002 – 16.008
(0.6300 – 0.6302)
15.995 – 16.000
(0.6297 – 0.6299)
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
—
0.05
(0.002)
STANDARD
Above 350 kPa (3.5 kgf/cm2, 49.8 psi)
Below 550 kPa (5.5 kgf/cm2, 78.2 psi)
at 3 000 r/min
LIMIT
Crank pin width
E
L
P
M
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft runout
16.030
(0.6311)
15.980
(0.6291)
0.080
(0.0031)
Conrod big end width
Crankshaft thrust clearance
—
STANDARD
16.010 – 16.018
(0.6303 – 0.6306)
0.10 – 0.20
(0.004 – 0.008)
19.950 – 20.000
(0.7854 – 0.7874)
20.100 – 20.150
(0.7913 – 0.7933)
0.032 – 0.056
(0.0013 – 0.0022)
44.976 – 45.000
(1.7707 – 1.7717)
0.018 – 0.045
(0.0007 – 0.0018)
47.985 – 48.000
(1.8892 – 1.8898)
2.025 – 2.175
(0.0797 – 0.0856)
0.10 – 0.15
(0.0039 – 0.0059)
Conrod big end side clearance
A
S
Crankshaft thrust bearing thickness
—
Unit: mm (in)
ITEM
Conrod small end I.D.
Crankshaft journal O.D.
LIMIT
LIMIT
16.040
(0.6315)
0.30
(0.012)
—
—
—
0.080
(0.0031)
—
—
—
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
—
AN650/AK5 (’05-MODEL)
CLUTCH
Unit: mm (in)
ITEM
Drive plate thickness
STANDARD
2.92 – 3.08
(0.115 – 0.121)
13.85 – 13.96
(0.545 – 0.550)
2.42 – 2.58
(0.095 – 0.102)
Drive plate claw width
Driven plate No. 2 thickness
Driven plate distortion
—
Clutch spring free length
13.9
(0.547)
3.2
(0.126)
1 500 – 2 100 r/min
3 200 – 3 800 r/min
Clutch plate concaved washer
height
Clutch engagement
Clutch lock-up
LIMIT
2.62
(0.103)
13.05
(0.514)
2.27
(0.089)
0.10
(0.004)
13.2
(0.520)
3.1
(0.12)
—
—
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
FI/CVT-SENSORS
ITEM
CMP sensor resistance
CMP sensor peak voltage
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor output voltage
Injector voltage
17
SPECIFICATION
11 – 13 Ω at 20 °C (68 °F)
More than 0.9 L (0.95/0.79 US/Imp qt)
For 30 sec. at 300 kPa (3.0 kgf/cm2 , 43 psi)
NOTE
—
Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
—
A
S
E
L
P
M
SPECIFICATION
0.9 – 1.7 kΩ
More than 0.5 V (When cranking)
150 – 300 Ω
More than 2.0 V (When cranking)
4.5 – 5.5 V
Approx. 2.6 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.1 kΩ
Opened
Approx. 4.2 kΩ
Closed
Approx. 1.1 V
Opened
Approx. 4.3 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 3.6 V at 100 kPa (760 mmHg)
19.1 – 19.7 kΩ
Normal
0.4 – 1.4 V
Leaning
3.7 – 4.4 V
Battery voltage
—
NOTE
+: B/Y, -: Br
+: Bl, -: G
+: B, -: B/Br
+: B, -: B/Br
18 AN650/AK5 (’05-MODEL)
ITEM
Ignition coil primary peak voltage
SPECIFICATION
More than 80 V (When cranking)
4 – 5 Ω at 23 °C (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 Ω at 20 °C (68 °F)
CVT primary pulley position sensor Compressed
1.9 – 2.3 kΩ
Extended
0.2 – 1.0 kΩ
st
Approx. 3.3 V
CVT primary pulley position sensor 1 : Idle speed
output voltage
rd
3 : 3 000 r/min
Approx. 1.3 V
th
:
3
000
r/min
Approx. 0.5 V
5
CVT secondary pulley revolution
400 – 600 Ω
sensor resistance
CVT secondary pulley revolution
More than 5 V at idle speed
sensor peak voltage
NOTE
#1 +: W/Bl,
-: Ground
#2 +: B/Y,
-: Ground
HO2 sensor resistance
HO2 sensor output voltage
E
L
P
M
THROTTLE BODY
ITEM
I.D. No.
Bore size
Fast idle r/min
Idle r/min
Synchronizing screw opening
IAC valve resistance
Throttle cable play
+: Y, -: W
A
S
SPECIFICATION
10GO
32 mm (1.26 in)
1 300 – 1 600 r/min
1 200 ± 100 r/min
1 and 1/2 turns out
Approx. 4 Ω at 20 – 24 °C (68 – 75 °F)
2.0 – 4.0 mm
(0.08 – 0.16 in)
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Engine coolant temperature sensor
resistance
Radiator cap valve opening pressure
Eclectic fan thermo-switch operating temperature
Engine coolant type
STANDARD/SPECIFICATION
LIMIT
Approx. 88 °C (190 °F)
—
Over 8.0 mm (0.3 in) at 100 °C (212 °F)
20 °C
Approx. 2.45 kΩ
(68 °F)
50 °C
Approx. 0.811 kΩ
(122 °F)
80 °C
Approx. 0.318 kΩ
(176 °F)
110 °C
Approx. 0.142 kΩ
(230 °F)
—
—
—
—
—
110 kPa (1.1 kgf/cm²)
—
ON
93 – 103 °C (199 – 217 °F)
OFF
87 – 97 °C (188 – 206 °F)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
—
—
—
AN650/AK5 (’05-MODEL)
ITEM
Engine coolant including reserve
STANDARD/SPECIFICATION
Reverse
Approx. 250 ml
tank side
(0.264/0.220 US/Imp qt)
Engine
Approx. 1 350 ml
side
(1.427/1.188 US/Imp qt)
ELECTRICAL
LIMIT
—
—
Unit: mm (in)
ITEM
Firing order
Spark plug
Type
Gap
Spark performance
CKP sensor peak voltage
Ignition coil resistance
Primary
Secondary
Ignition coil primary peak voltage
STD/SPEC.
1·2
NGK: CR8E
DENSO: U24ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8.0 (0.3) at 1 atm.
More than 2.0 V
0.8 – 2.5 Ω
8 – 18 kΩ
E
L
P
M
More than 80 V
Generator coil resistance
CKP sensor
Charging
Generator no-load voltage
(When cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Fuse size
19
150 – 300 Ω
0.1 – 1.0 Ω
More than 50 V at 5 000 r/min
A
S
Approx. 500 W at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
Type
designation
Capacity
Head- LO
light
HI
Fuel pump
Ignition
Turn signal
Fan motor
Main
CVT
Power
source
ABS
FTX14-BS
12 V 43.2 kC (12 Ah)/10 HR
15 A
15 A
10 A
15 A
15 A
15 A
40 A
40 A
10 A
15 A × 2
NOTE
+: Bl, -:G
#1 +: W/Bl,
-: Ground
#2 +: B/Y,
-: Ground
G – BI
Y–Y
20 AN650/AK5 (’05-MODEL)
WATTAGE
Unit: W
STD/SPEC.
ITEM
Headlight
E-02, 19
60 + 55
55
5×2
21/5 × 2
21 × 4
5
1.4 × 2
1.4
1.4
1.4
1.4
1.4
1.4 × 2
1.4
1.4
1.4 × 5
1.4
5
LED
1.4
HI
LO
Parking or position light
Brake light/Taillight
Turn signal light
License light
Instrument panel light
Engine coolant temp. indicator light
FI indicator light
Engine oil pressure indicator light
Brake-lock indicator light
High beam indicator light
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
BRAKE + WHEEL
ITEM
Brake disc thickness
E
L
P
M
A
S
Front
Rear
Brake disc runout
Master cylinder bore
Front
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diameter
Front
Rear
Brake fluid type
STANDARD
4.5 ± 0.2
(0.177 ± 0.008)
5.5 ± 0.2
(0.217 ± 0.008)
—
Rear
Master cylinder piston diameter
E-03, 24, 28, 33
60 × 2
55 × 2
12.700 – 12.743
(0.5000 – 0.5017)
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
12.657 – 12.684
(0.4983 – 0.4994)
25.400 – 25.450
(1.0000 – 1.0020)
27.000 – 27.050
(1.0630 – 1.0650)
25.318 – 25.368
(0.9968 – 0.9987)
26.918 – 26.968
(1.0598 – 1.0617)
DOT 4
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
Unit: mm (in)
LIMIT
4.0
(0.16)
5.0
(0.20)
0.30
(0.012)
—
—
—
—
—
—
—
—
—
AN650/AK5 (’05-MODEL)
ITEM
Wheel rim runout
STANDARD
Wheel axle runout
Wheel rim size
Axial
—
Radial
—
Front
—
Rear
—
Front
Rear
15 M/C × MT3.50
14 M/C × MT4.50
SUSPENSION
Front fork spring free length
Front fork oil capacity (each leg)
Front fork oil level
Front fork inner tube diam.
A
S
Rear shock absorber spring
adjuster
ITEM
Cold inflation tire pressure
Solo
riding
Dual
riding
Tire size
Tire type
Tire tread depth
(Recommended depth)
STANDARD
110
(4.3)
LIMIT
—
341
(13.4)
E
L
P
M
Front fork oil type
TIRE
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
Unit: mm (in)
ITEM
Front fork stroke
Rear wheel travel
21
SUZUKI FORK OIL G-10 (#10) or
an equivalent fork oil
458 ml
151
(5.9)
41
(1.61)
100
(3.9)
2nd
Front
Rear
Front
Rear
STANDARD
225 kPa
(2.25 kgf/cm2, 33 psi)
250 kPa
(2.50 kgf/cm2, 36 psi)
225 kPa
(2.25 kgf/cm2, 33 psi)
280 kPa
(2.80 kgf/cm2, 41 psi)
120/70R15M/C 56H
160/60R14M/C 65H
BRIDGESTONE TH01F
BRIDGESTONE TH01R
Front
—
Rear
—
Front
Rear
Front
Rear
—
—
—
—
—
—
LIMIT
—
—
—
—
—
—
—
—
1.6 mm
(0.06 in)
2.0 mm
(0.08 in)
22 AN650/AK5 (’05-MODEL)
FUEL + OIL
ITEM
SPECIFICATION
Fuel type
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Fuel tank capacity
Including
15.0 L (4.0/3.3 US/lmp gal)
reserve
Fuel meter
mark
Approx. 3.0 L (0.79/0.66 US/lmp gal)
flickering
Fuel meter
mark and
Approx. 1.5 L (0.40/0.33 US/lmp gal)
LCD
flickering
Engine oil and transmission oil type * SAE 10W-40, API, SF/SG or SJ/SH with JASO MA
Engine oil capacity
2.6 L
Oil change
(2.7/2.3 US/lmp qt)
2.9 L
Filter change
(3.1/2.6 US/lmp qt)
3.4 L
Overhaul
(3.6/3.0 US/lmp qt)
Transmission oil capacity
360 ml
Oil change
(12.2/12.7 US/lmp oz)
400 ml
Overhaul
(13.5/14.1 US/lmp 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/lmp oz)
430 ml
Overhaul
(14.5/15.1 US/lmp oz)
A
S
E
L
P
M
NOTE
AN650/AK5 (’05-MODEL)
23
IMMOBILIZER (E-02, 19, 000)
• The immobilizer, an anti-theft system, is installed as a
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
antenna
Transponder
Immobi-antenna
Indicator light
ECM
E
L
P
M
ID
OPERATION
When the ignition switch is turned ON with the engine stop switch in ON and the side stand in up position,
the immobi-antenna and ECM are powered ON.
The ECM transmits a signal to the transponder through the immobi-antenna in order to make comparison
between the key ID and ECM ID.
With the signal received, the transponder transmits the key ID signal to ECM so that ECM can make comparison with its own ID, and if it matches, the engine is made ready to start.
A
S
Transponder
Immobi-antenna
Ignition switch
ECM
24 AN650/AK5 (’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.
Flashing
2 registered
Normal
3 registered
Normal
Normal
4 registered
Abnormal
Fast flashing
Approx. 1.6 sec.
NOTE:
If the indicator light flashes fast, turn the ignition switch OFF
then ON to make judgment again as there is possible misjudgment due to environmental radio interference.
#
When the battery performance is lowered in winter
(low temperature), the system may make a rejudgment at the time of beginning of the starter motor
operation. In this case, the indicator light operation
starts immediately after the starter motor operation.
E
L
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M
A
S
Lighting
Approx. 2.0 sec.
AN650/AK5 (’05-MODEL)
25
COMBINATION METER
E
L
P
M
1 AN650A only
2 E-02, 19, 000 only
A
S
TERMINAL ALIGNMENT
1
2
3
4
5
6
7
8
9
0
Oil pressure switch (G/Y)
—
Speed sensor (O/R)
Ignition (O/G)
Battery (R/Bl)
Speed sensor signal (W)
Tachometer signal (Br/W)
Oil level switch (Bl)
FI (P/W)
Signal ground (B/W)
A
B
C
D
E
F
G
H
I
J
Turn signal L (B)
Turn signal R (Lg)
Illumination + (O/G)
ABS (Br) [AN650A]
Brake lock switch (V)
High beam (Y)
Immobilizer (E-02, 19, 000)
Ambient air temperature sensor (Bl)
Fuel pump (R/B)
Power ground (B/W)
26 AN650/AK5 (’05-MODEL)
POWER WIND SCREEN (AN650AK5 E-02, 19, 000)
INSPECTION
• Remove the lower leg shield. ($AN650K3 9-10)
• Disconnect the wind screen regulator coupler 1.
• Apply 12 V voltage to the terminals of the regulator coupler
and check that the wind screen moves in the correct direction.
Terminal – Terminal
R+–-G
G+–-R
G
Window screen
UP
DOWN
• Repeat above inspection several times and replace the
window screen regulator assembly if necessary.
REMOVAL
E
L
P
M
• Remove the wind screen. ($Page 42)
• Remove the leg shield. ($AN650K3 9-10)
• Remove the meter front lower panel 1.
A
S
NOTE:
Remove the bolts/screws behind the regulator by moving the
regulator up or down.
• Remove the meter front upper panel 2.
R
AN650/AK5 (’05-MODEL)
• Remove the regulator mounting bolts.
E
L
P
M
• Disconnect the couplers.
A
S
• Disconnect the regulator coupler 4.
• Remove the regulator motor mounting bolt and nuts.
• Remove the wind screen regulator assembly.
INSTALLATION
Installation is in the reverse order of removal. Pay attention to
the following point:
• Rout the cables properly. ($Page 40)
• Apply grease to the wires, pulleys and guide rails.
27
28 AN650/AK5 (’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 kΩ at 20 °C (68 °F)
(Terminal – Terminal)
& 09900-25008: Multi-circuit tester set
E
L
P
M
' Tester knob indication: Resistance (Ω)
Intake Air Temp
20 °C (68 °F)
25 °C (77 °F)
30 °C (86 °F)
40 °C (104 °F)
Resistance
Approx. 2.1 kΩ
Approx. 1.7 kΩ
Approx. 1.4 kΩ
Approx. 0.9 kΩ
A
S
NOTE:
AAT sensor resistance measurement method is the same way
as that of the ECT sensor. Refer to AN650K3 8-13 for details.
• If neccesary, replace the AAT sensor with a new one.
AAT sensor
R/W
Lg/Y
Lg
W/B
Power sw.
Center stand sw.
s
Mode sw.
Brake sw.
R
G/W
Shift down
down sw.
s
Y
Br/R
Dg
B/Bl
BRK
CSTD
MODE
POWER
DOWN
UP
DON
THA
THW
PA
VCC
PM
E2
VTA
+G
-G
+N
-N
Y/Bl
Gr/W
SDL
SPR-
SPR+
PPS
MO-
MO+
TXCK
RXCK
OX
EXS
E1
TS
MS
STA
SS
SPD
IG1
IG2
VM
GND
PTC
OXH
SOL
Gr/B
#1
Ignition coil
(IG coil)
PTC heater
O2 heater
Solenoid valve
Fan motor relay
Fuel injector (FI)
CVT motor
Gr/R
G/B
G/R
Bl
B/R
R/W
Y/Bl
B/O
B/G
B/W
CVT unit
Immobilizer
Test select
EXS sw.
W/R
B/Br
B/Br
Secondary
pulley
sensor
Pulley
position
sensor
Speed sensor
Mode select
W/Bl
B/Y
#2
B/Br
Y/G
G
P
Y/R
B
Br/B
Y/W
Y/W
G/Bl
O/W
R/B
VB
+B
Gr/Y
FRL
FP
#2
#1
BATT
(+B1)
E
L
P
M
Shift up sw.
Tip over sensor (TOS)
Intake air temp. sensor (IATS)
Engine coolant temp. sensor (ECTS)
G/Y
Lg/B
R
B
P/B
Br
B/Y
W/G
W
R/B
A
S
Atomospheric pressure sensor (APS)
Intake air pressure sensor (IAPS)
Throttle position sensor (TPS)
Crankshaft position sensor
(CKPS)
Camshaft position sensor (CMPS)
Combination meter
Brake sw.
Heated oxygen sensor
(HO2S)
Side
stand
sw.
Side
stand
relay
15 A
Engine stop sw. 10 A
40 A
Starter sw.
30 A
Main sw.
(Ignition coil)
Starter motor
Starter relay
Brake lamp
10 A
Battery
Fuel pump (PU)
AN650/AK5 (’05-MODEL)
FI SYSTEM WIRING DIAGRAM
E-02, 19, 000
29
R/W
Lg/Y
Lg
W/B
Power sw.
Center stand sw.
s
Mode sw.
Brake sw.
R
G/W
Shift down
down sw.
s
Y
Br/R
Dg
B/Bl
BRK
CSTD
MODE
POWER
DOWN
UP
DON
THA
THW
PA
VCC
PM
E2
VTA
+G
-G
+N
-N
VB
FRL
FP
#2
#1
BATT
(+B1)
R/B
B/Lg
Gr/Y
Y/Bl
Gr/W
Gr/B
R/B
SDL
SPR-
SPR+
PPS
MO-
MO+
E1
TS
MS
STA
SS
SPD
IG1
IG2
VM
GND
PTC
SOL
AT
+B
Br/B
G/Bl
O/W
#2
#1
Speed sensor
Ignition coil
(IG coil)
PTC heater
Solenoid valve
Fan motor relay
Fuel injector (FI)
Gr/R
G/B
G/R
CVT motor
B/R
R/W
CVT unit
Test select
B/W
Mode select
W/R
W/Bl
B/Y
B/Br
Y/G
G
Y/R
Side
stand
relay
Secondary pulley sensor
15 A
Brake sw.
40 A
Fuel pump (PU)
Starter sw.
30 A
Main sw.
(Ignition coil)
Starter motor
Starter relay
Brake lamp
100 Ω
10 A
Engine stop sw. 10 A
Side-stand sw.
Pulley position sensor
E
L
P
M
Shift up sw.
Tip over sensor (TOS)
Intake air temp. sensor (IATS)
Engine coolant temp. sensor (ECTS)
G/Y
Lg/B
R
B
P/B
Br
B/Y
W/G
W
A
S
Atomospheric pressure sensor (APS)
Intake air pressure sensor (IAPS)
Throttle position sensor (TPS)
Crankshaft position sensor
(CKPS)
Camshaft position sensor (CMPS)
Combination meter
Battery
30 AN650/AK5 (’05-MODEL)
E-03, 28, 33
AN650/AK5 (’05-MODEL)
31
ECM COUPLERS
K4 MODEL ECM AND CVT CONTROL UNIT COUPLERS
ECM couplers
CVT control unit couplers
K5 MODEL ECM COUPLERS
ECM couplers
9
8
7
6
5
4
3
2
E
L
P
M
1
17 16 15 14 13 12 11 10
25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 27 26
ECM
TERMINAL
NO.
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
35 36 37 38 39 40 41
Ignition coil (IG1)
Fuel injector (#1)
Fuel injector (#2)
Shift up switch (UP)
Pulley position sensor (PPS)
PTC heater (PTC)
Speedometer (SPD)
61
64
63
53 52 51 50 49 48
60 59 58 57 56 55 54
A
S
CIRCUIT
62
47 46 45 44 43 42
Solenoid valve (SOL)
Fuel pump relay (FP)
Ignition coil (IG2)
Fan motor relay (FRL)
Power switch (POWER)
Mode switch (MODE)
Shift down switch (DOWN)
CO and injection pulse width adjust box
(COS1)
CO and injection pulse width adjust box
(COS2)
ECM
TERMINAL
NO.
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
CIRCUIT
Battery (+B)
Center stand switch (CSTD)
Side stand switch (SS)
Brake switch (BRK)
Mode select switch (MS)
Test switch (TS)
CO and injection pulse width adjust box
(COV1)
CO and injection pulse width adjust box
(COV2)
CO and injection pulse width adjust box
(COV3)
Ground (E03)
Ground (E01)
Starter relay (STA)
Writing tool (RXD1)
Writing tool (TXD1)
SDL-KWP (SDL)
Writing tool (FWE)
32 AN650/AK5 (’05-MODEL)
ECM
TERMINAL
NO.
W
X
Y
Z
[
\
]
^
a
b
c
d
e
f
g
h
CIRCUIT
Battery (BATT)
Writing tool (RST)
Ground (E1)
CKP sensor (N-)
CMP sensor (G+)
OX heater (OXH)
Immobilizer (TXCK)
Immobilizer (RXCK)
Immobilizer LED (LED)
Injector power voltage (VM)
CKP sensor (N+)
CMP sensor (G-)
O2 sensor (OX)
Secondary pulley sensor (SPR-)
Secondary pulley sensor (SPR+)
Sensor power (VCC)
ECM
TERMINAL
NO.
i
j
k
l
m
n
o
p
q
r
s
t
u
v
w
x
CIRCUIT
TP sensor (VTA)
IAT sensor (THA)
ECT sensor (THW)
AP sensor (PA)
O2 sensor control selector (EXS)
Ground (E2)
Tachometer (TACO)
Meter (TECH)
Writing tool (SCK)
IAP sensor (PM)
TO sensor (DON)
Blank
Battery (VB)
Motor (MO+)
Ground
Motor (MO-)
A
S
E
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M
AN650/AK5 (’05-MODEL)
MALFUNCTION CODE
MALFUNCTION
CODE
C00
C11
C12
C13
C14
C15
C16
C21
C22
C23
C24 or C25
C32 or C33
C40
C41
C42
C44
C51
C52
C53
C54
C55
C58
DETECTED ITEM
NO FAULT
Camshaft position
sensor
Crankshaft position
sensor
Intake air pressure
sensor
Throttle position
sensor
Engine coolant
temperature sensor
Speed sensor
Intake air temperature
sensor
Atmospheric pressure
sensor
Tip over sensor
E
L
P
M
Ignition signal
A
S
Fuel injector
Intake air control (IAC)
valve
Fuel pump relay
Ignition switch
Heated oxygen sensor
(HO2S) [E-02, 19]
CVT motor
CVT pulley position
sensor
CVT speed sensor
CVT secondary pulley
revolution sensor
CVT engine revolution
signal
CVT reduction ratio
disagreement
ECM COUPLER TERMINALS TO CHECK
K4
K5
–––––––––––
–––––––––––
[, d
←
($AN650K3 6-27)
Z, c
←
($AN650K3 6-28)
h, n, r
←
($AN650K3 6-30)
h, i, n
←
($AN650K3 6-32)
k, n
←
($AN650K3 6-33)
–––––––––––
–––––––––––
j, n
←
($AN650K3 6-36)
h, l, n
←
($AN650K3 6-38)
h, n, s
←
($AN650K3 6-39)
4, 5, b
←
($AN650K3 6-40)
4, 5, b
2, 3, b
($AN650K3 6-40)
–––––––––––
9, b
($AN650K3 6-41)
–––––––––––
G, \, e, n
($AN650K3 6-43)
–––––––––––
8, D, J
(CVT control unit coupler)
($AN650K3 6-48)
–––––––––––
–––––––––––
←
–––––––––––
←
–––––––––––
5, Q, h
–––––––––––
–––––––––––
–––––––––––
3 (CVT control unit coupler)
o (ECM coupler)
($AN650K3 6-53)
o
–––––––––––
–––––––––––
33
34 AN650/AK5 (’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.
% Wheel speed sensor – sensor rotor clearance:
0.3 – 1.5 mm
& 09900-20803: Thickness gauge
09900-20806: Thickness gauge
Is the clearance OK?
YES
NO
Go to step 2.
Adjust the clearance.
E
L
P
M
2) Inspect the front wheel speed sensor rotor for damage and
check that no foreign objects are caught in the rotor
openings.
Is the sensor rotor OK?
YES
NO
Go to step 3.
Clean or replace the sensor rotor.
A
S
3) Check that the front wheel speed sensor is mounted steadily.
Is the sensor mounted steadily?
YES
NO
Go to malfunction code “42”. ($Page 16).
Tighten the mounting bolts or replace the bracket
if necessary.
AN650/AK5 (’05-MODEL)
“42” Wheel speed sensor circuit open (F)
POSSIBLE CAUSE
• Poor contact on the front wheel speed sensor coupler
• Faulty front wheel speed sensor, etc.
•
•
•
•
Turn the ignition switch to OFF.
Remove the leg shield. ($AN650K3 9-10)
Remove the meter front lower panel. ($Page 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 B (B/R) and ground at the
ABS control unit coupler.
% Normal value: ∞
E
L
P
M
& 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Resistance (Ω)
Is the resistance between B and ground OK?
YES
NO
Go to step 3.
Go to step 2.
A
S
• Disconnect the front wheel speed sensor coupler.
2) Measure the resistance between A (B) and ground at the
front wheel speed sensor coupler.
% Normal value: ∞
' Tester knob indication: Resistance (Ω)
Is the resistance between A and ground OK?
YES
NO
Inspect the wire harness. (Faulty B/R wire)
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 indication: Resistance (Ω)
Is the resistance between 3 and ground OK?
YES
NO
Go to step 5.
Go to step 4.
35
36 AN650/AK5 (’05-MODEL)
4) Measure the resistance between B (W) and ground at the
front wheel speed sensor coupler.
% Normal value: ∞
' Tester knob indication: Resistance (Ω)
Is the resistance between B and ground OK?
YES
NO
Inspect the wire harness. (Faulty W/R wire)
Faulty front wheel speed sensor
5) Check for continuity between B (B/R) on the ABS control unit
coupler and C (B/R) on the front wheel speed sensor
coupler.
( Tester knob indication: Continuity ())
Is there continuity between B and C?
YES
NO
Go to step 6.
Inspect the wire harness. (Faulty B/R wire)
E
L
P
M
6) Check for continuity between 3 (W/R) on the ABS control
unit coupler and D (W/R) on the front wheel speed sensor
coupler.
( Tester knob indication: Continuity ())
Is there continuity between 3 and D?
YES
NO
A
S
Go to step 7.
Inspect the wire harness. (Faulty W/R wire)
• Connect the front wheel speed sensor coupler.
7) Connect three 1.5 V dry cells A in series as shown and make
sure that their total voltage is more than 4.5 V.
Measure the current between + dry cell terminal and B (B/
R) on the ABS control unit coupler.
% Normal value: 3 – 14 mA
* Tester knob indication: Current (+, 20 mA)
Is the current OK?
YES
NO
Replace the ABS control unit/HU.
Faulty front wheel speed sensor.
DCmA
AN650/AK5 (’05-MODEL)
“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
NO
Go to step 2.
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.
E
L
P
M
Is the sensor rotor OK?
YES
NO
Go to step 3.
Clean or replace the sensor rotor.
A
S
3) Check that the rear wheel speed sensor is mounted steadily.
Is the sensor mounted steadily?
YES
NO
Go to malfunction code “45”. ($Page 38)
Tighten the mounting bolts or replace the bracket
if necessary.
37
38 AN650/AK5 (’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 the 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 2 (B/Y) on the ABS
control unit coupler and ground.
% Normal value: ∞ Ω (Infinity)
E
L
P
M
& 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Resistance (Ω)
Is the resistance OK?
YES
NO
Go to step 3.
Go to step 2.
A
S
2) Check the resistance between A (B) and ground.
% Normal value: ∞ Ω (Infinity)
' Tester knob indication: Resistance (Ω)
Is the resistance OK?
YES
NO
Inspect the wire harness. (Faulty B/Y wire)
Replace the rear wheel speed sensor.
3) Check the resistance between terminal H (W/Y) and ground.
% Normal value: ∞ Ω (Infinity)
' Tester knob indication: Resistance (Ω)
Is the resistance OK?
YES
NO
Go to step 5.
Go to step 4.
AN650/AK5 (’05-MODEL)
• Disconnect the rear wheel speed sensor coupler.
4) Check the resistance between B (W) and ground.
% Normal value: ∞ Ω (Infinity)
Is the resistance OK?
YES
NO
Inspect the wire harness. (Faulty W/Y wire)
Replace the rear wheel speed sensor.
5) Check the continuity between C (B/Y) and terminal 2.
!
% Normal value: Continuity ())
( Tester knob indication: Continuity test ())
Is the continuity OK?
YES
NO
Go to step 6.
Inspect the wire harness. (Faulty B/Y wire)
E
L
P
M
6) Check the continuity between D (W/Y) and terminal H.
% Normal value: Continuity ())
( Tester knob indication: Continuity test ())
Is the continuity OK?
YES
NO
A
S
Go to step 7.
Inspect the wire harness. (Faulty W/Y wire)
• Connect the rear wheel speed sensor coupler.
7) Connect three 1.5 V dry cells A in series as shown and make
sure that their total voltage is more than 4.5 V.
Measure the current between + 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
NO
Replace the ABS control unit/HU.
Replace the rear wheel speed sensor.
DCmA
!
39
40 AN650/AK5 (’05-MODEL)
WIND SCREEN CABLE ROUTING
Cushion
Speedometer
Do not drop the
cushion.
E
L
P
M
Wind screen
regulator
Clamp
Screen
relay
Tip over
sensor
A
S
ECM
Pass through
the cable
back side
of relay.
ECM
Clamp
Air pressure
sensor
Fun motor
relay
Side stand relay
Fuel pump relay
Cushion
Attach
Screen relay
Cushion
AN650/AK5 (’05-MODEL)
RADIATOR HOSE ROUTING
Face the tip of clamp to the bottom.
Reservoir
inlet hose
White mark
Oil cooler
inlet hose
14˚
E
L
P
M
Oil cooler
outlet hose
10˚
White mark
A
S
Radiator outlet
hose
Yellow mark
Face the tip of clamp to the forward.
Face the tip of clamps to the bottom.
41
42 AN650/AK5 (’05-MODEL)
EXTERIOR PARTS CONSTRUCTION
E
L
P
M
A
S
1
2
3
4
5
Meter front upper panel
Leg shield brace
Meter cover
Front panel
Leg shield
6
7
8
9
0
Lower leg shield
Floor mat
Front box
Wind screen
Wind screen cover
A
B
C
D
Wind screen regulator
Meter front lower panel
Front leg shield cover
Lower bracket cover
AN650/AK5 (’05-MODEL)
E
L
P
M
A
S
1
2
3
4
Maintenance lid
Foot board
Frame cover
Leg side cover
5
6
7
8
Center frame cover
Lower frame cover
Rear fender
Floor mat
9 Fuel tank inlet tray
0 Fuel tank inlet packing
43
44 AN650/AK5 (’05-MODEL)
A
S
E
L
P
M
AN650/AK5 (’05-MODEL)
CVT CONSTRUCTION
K4
93 N·m
(9.3 kgf-m, 67.5 lb-ft)
K5
D
FW
E
L
P
M
A
S
1 Secondary pulley shaft nut
2 Secondary pulley shaft adapter
3 O-ring
9 CVT belt
0 Primary pulley assembly
A Shim
G Secondary pulley fan
H Bearing
I Snap ring
4 Primary pulley shaft bolt
5 Primary pulley shaft adapter
6 CVT casing
B O-ring
C Bearing
D Oil seal
J Primary slide pulley idle gear
K Secondary pulley revolution sensor
L CVT motor
7 Bearing
8 O-ring
E Washer
F Secondary pulley assembly
M CVT cover
N CVT filter
• Use new special tool for 4.
! 09924-51010: Primary pulley shaft bolt holder
" Primary pulley shaft bolt: 93 N·m (9.3 kgf-m, 67.5 lb-ft)
NOTE:
Do not reuse the removed primary pulley shaft bolt.
45
46 AN650/AK5 (’05-MODEL)
AMBIENT AIR TEMPERATURE SENSOR BRACKET INSTALLATION
Wind screen
regulator motor
Leg shield brace
E
L
P
M
Ambient air
temperature
sensor
A
S
Mirror drive relay
(Electric mirror only)
FWD
AN650/AK5 (’05-MODEL)
SPECIAL TOOLS
09900-20803
09900-20806
Thickness gauge
09900-25008
Multi circuit tester
set
09900-25009
Needle pointed
probe set
09924-51010
Primary pulley shaft 09930-82710
bolt holder
Mode select switch
TIGHTENING TORQUE CHART
For other nuts and bolts not listed in the preceding page, refer to this chart:
Bolt Diameter A
(mm)
4
5
6
8
10
12
14
16
18
E
L
P
M
Conventional or “4” marked bolt
N·m
kgf-m
1.5
0.15
3
0.3
5.5
0.55
13
1.3
29
2.9
45
4.5
65
6.5
105
10.5
160
16.0
A
S
N·m
2.3
4.5
10
23
50
85
135
210
240
“7” marked bolt
kgf-m
0.23
0.45
1.0
2.3
5.0
8.5
13.5
21.0
24.0
A
Conventional bolt
“4” marked bolt
“7” marked bolt
47
WIRING DIAGRAM
AN650K5 (E-02, 19, 000)
HI : 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
OD : OVER DRIVE INDICATOR LIGHT
PM
BRK
BRK FI OI HI
ABS
PM
WT
HAZARD
SWITCH
SP/TA
D
1
2
3
4
5
OFF
ON
FI OI HI IMO
OD
ENGINE
STOP
SWITCH
OFF
RUN
SIDE-STAND
SWITCH
FRONT
BRAKE
SWITCH
STARTER
BUTTON
IGNITION IGNITION
COIL #1 COIL #2
PUSH
FREE
CENTER
STAND
SWITCH
OFF
ON
PUSH
ECM
IMOBILIZER A.T-SENSOR
IAC
VALVE
CVT
MOTOR
M
Y
B
G
R
HANDLEBAR SWITCH (R)
TR
TL
SOLENOID
Br
B/W
W/Y
B/W
Br
B/W
POSITION LIGHT (L)
W/R
Gr/R
B/W
O/W
Lg/B
Br/R
B/W
W/G
B/Y
Y/W
Y/Bl
B/O
O/Bl
Y/R
W
Br
B/G
G/B
G/R
R
P/B
Dg
B/Bl
G/Y
B/Br
B/Br
Br/W
P/B
R/Bl
Gr/R
R/B
R/W
B
B/R
Gr
B/W
W/B
BRAKE LIGHT/TAILLIGHT (R)
BRAKE LIGHT/TAILLIGHT (L)
Gr
B/W
W/B
B
B/W
Br
B/W
W/B
B
B
B/W
FRONT TURN
SIGNAL LIGHT (L)
HI
LO
PUSH
L
PUSH
R
PASSING DIMMER HORN
SWITCH BUTTON
LIGHT
SWITCH
TURN SIGNAL
LIGHT SWITCH
OFF
ON
FREE
PUSH
FREE
PUSH
UP
FREE
DOWN
POWER
REAR
SWITCH UP/DOWN
BRAKE
SWITCH
SWITCH D↔M
SWITCH
HANDLEBAR SWITCH (L)
G/Y
FAN
MOTOR
#1
#2
INJECTOR
CVT
REVOLUTION
SENSOR
ON
OFF
ON
OFF
OIL
PRESSURE OIL LEVEL
SWITCH
SWITCH
1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. FAN
15 A
10 A
10 A
15 A
15 A
15 A
CVT
FUEL
PULLEY PUMP
POSITION
SENSOR
TP
SENSOR
HO2
ECT
IAT
SENSOR SENSOR SENSOR REGULATOR/
RECTIFIER
CMP
SENSOR
TO
SENSOR
GENERATOR
MAIN
FUSE
STARTER (40 A)
RELAY
PUSH
BATTERY
STARTER
MOTOR
OFF
ON
TRUNK
LIGHT
SWITCH
TRUNK
LIGHT SEAT
SWITCH
Y/B
Y/G
B/W
R/Bl
G
R
R/W
R
B/W
B
B/W
B/W
B/W
B
B
B/W
R
R/W
Y/B
Y/G
R/W
R
Br/R
B/Br
W
W/G
B/Y
Br
R
B/W
O/W
B/Br
B/G
Y/W
Dg
B/Br
B/Bl
B/Br
O
O/Bl
R/B
R/W
B/Br
G/Y
R
IAP
AP
(40 A) (10 A)
SENSOR SENSOR
POWER
CTV SOURCE
FUSE FUSE
B
B
3
Bl
G
Y
Y
Y
2
W
Gr
B
W
1
B/Br
Lg/B
R
M
R
P/B
B/Br
Y/R
B/W
R/B
B/W
6
Y
W
5
FUSE BOX
ON
OFF
FAN
MOTOR
SWITCH
4
Bl
Y
B
R
/R
Bl
Bl
B/Br
BBr
R
Bl
B
Gr/B
Y/R
Gr/W
Y/R
G/R
G/B
Br
Lbl
O/G
R
B/O
Y
Y/W
W/Y
R/Bl
B/R
O/Y
B
Y/G
O/W
Y/R
R/Bl
FP
RELAY
R
G
O/W
B/W
Y/B
SIDESTAND
RELAY
POWER
SOURCE
B
PUSH
B/W
O/Bl
Bl
Bl/Y
R/W
Y/G
Br/W
G
G/Y
Lg/Y
R/W
Y
B/W
G/W
B/G
B/R
B/O
B
O/G
W/B
W
Y
Y/W
B/Bl
B/W
Lg
Lbl
B
O/R
FAN MOTOR
RELAY
Bl
B
W
Y
Y/W
B/Bl
B/W
Lg
Lbl
B
O
HORN
Gr/Y
O/G
B
B/W
O/G
B/Bl
O/Bl
B/W
REAR TURN SIGNAL LIGHT (L)
B
R/Bl
B
B/W
REAR TURN
SIGNAL LIGHT
(R)
B/W
Lg
Lg
Br
B/W
W/B
R
HEAD
LIGHT(L)
B/W
Gr
A
S
Lg
B/W
Y
B/W
W
HEAD
LIGHT(R)
LICENSE PLATE LIGHT
B/W
Lg
B/W
B/Y
Gr/W
Gr/B
Y
Bl
B/Br
P
G/Bl
B
W/Bl
Gr/Y
R/W
Lg/Y
G/W
L/G
Bl/Y
O/W
Lg
G
W/B
B/Br
W/R
Bl/W
Bl/B
Bl/G
B/W
B/W
Y/G
B/Br
Bl/W
Bl/B
Bl/G
Bl/R
Bl/Y
R
Br/B
O/W
R/W
B/R
O/W
G/Bl
Lg
B/W
E
L
P
M
POSITION LIGHT (R)
FRONT TURN
SIGNAL
LIGHT (R)
Bl
B/W
Y/Bl
B/W
B/O
O/Y
B/W
Y/W
R
B/W
B
B
G
B/W
G
B/W
G
B/W
B
B
B
O
B
O/W
B/Y
O/W
W/Bl
B/G
B/Br
O/Y
O/W
Y/G
O
Y
O/G
W/B
B
Lg
Lbl
O/G
V
O/Bl
Bl
B/W
B
O/G
R/Bl
O/G
B/W
O/R
W
R/B
P/W
Br/W
Bl
G/Y
Lg
Y
V
O/R
W
B/W
ON
OFF
IGNITION
SWITCH
ON
OFF
LOCK
P
B
B/R
O/G
P
B/W
BRAKELOCK
SWITCH
O/B
O/W
Y/G
O/R
Y/W
B/R
W/Bl
SPEED SENSOR
B
Lg
Lbl
Gr
P
PUSH
FREE
TRUNK
LIGHT
DIODE
AN650K5 (E-03, 24, 28, 33)
HI : 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
OD : OVER DRIVE INDICATOR LIGHT
TR
SIDE-STAND
SWITCH
CVT
MOTOR
SOLENOID
HI
LO
PUSH
L
PUSH
R
PASSING DIMMER HORN
SWITCH BUTTON
LIGHT
SWITCH
TURN SIGNAL
LIGHT SWITCH
OFF
ON
FREE
PUSH
FREE
PUSH
UP
FREE
DOWN
SWITCH
HANDLEBAR SWITCH (L)
G/Y
B/W
Y/W
R
B/W
B
B
Br/B
O/W
R/W
B/R
O/W
G/Bl
#1
#2
INJECTOR
CVT
REVOLUTION
SENSOR
ON
OFF
ON
OFF
OIL
PRESSURE OIL LEVEL
SWITCH
SWITCH
1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. FAN
15 A
10 A
10 A
15 A
15 A
15 A
CVT
FUEL
PULLEY PUMP
POSITION
SENSOR
TP
SENSOR
ECT
IAT
SENSOR SENSOR
CMP
SENSOR
REGULATOR/
RECTIFIER
TO
SENSOR
GENERATOR
Gr
B/W
W/B
B
B/W
B/W
B
MAIN
FUSE
STARTER (40 A)
RELAY
PUSH
BATTERY
STARTER
MOTOR
OFF
ON
TRUNK
LIGHT
SWITCH
TRUNK
LIGHT SEAT
SWITCH
B/W
R/Bl
R/W
R
B/W
B
B
B/W
R
R/W
Y/B
Y/G
R/W
R
Br/R
B/Br
W
W/G
B/Y
Br
R
B/W
Dg
B/Br
B/Bl
B/Br
O
O/Bl
R/B
R/W
B/Br
G/Y
R
IAP
AP
(40 A) (10 A)
SENSOR SENSOR
POWER
CTV SOURCE
FUSE FUSE
B/W
3
B/W
2
B
B
4
B/Br
Lg/B
R
M
Bl
G
Y
Y
Y
6
R
P/B
B/Br
Y/R
B/W
R/B
B/W
5
FUSE BOX
ON
OFF
FAN
MOTOR
SWITCH
4
BRAKE LIGHT/TAILLIGHT (R)
Bl
Y
B
R
/R
Bl
Bl
B/Br
BBr
FP
RELAY
Gr
B/W
W/B
REAR TURN SIGNAL LIGHT (L)
R
Bl
B
Y/G
O/W
Y/R
R/Bl
B/W
O/Bl
Bl
G/Y
B/O
B
FAN
MOTOR
POWER
REAR
SWITCH UP/DOWN
BRAKE
SWITCH
SWITCH D↔M
SIDESTAND
RELAY
POWER
SOURCE
B
PUSH
G
O/W
B/W
Y/B
FAN MOTOR
RELAY
REAR TURN
SIGNAL LIGHT
(R)
B/W
Lg
Lg
Br
B/W
W/B
BRAKE LIGHT/TAILLIGHT (L)
Bl
B
O/G
W/B
B/G
B/R
R
Bl/Y
R/W
Y/G
Br/W
G
Gr/Y
O/G
B
B/W
W
Y
Y/W
B/Bl
B/W
Lg
Lbl
B
O
W
Y
Y/W
B/Bl
B/W
Lg
Lbl
B
O/R
Lg/Y
R/W
Y
B/W
G/W
O/G
B/Bl
O/Bl
B/W
HORN
W/R
B/W
Gr
Br
B/W
W/B
B
Gr/B
Y/R
B
B/W
FRONT TURN
SIGNAL LIGHT (L)
Gr/R
B/W
G
B/W
Lg
B/W
Bl
B/W
G
B/W
G
B/W
O/W
B/Y
O/W
W/Bl
O/G
V
B/Br
Bl/W
Bl/B
Bl/G
Bl/R
Bl/Y
R
LICENSE PLATE LIGHT
A
S
Gr/W
Y/R
Y
B/W
W
G/R
G/B
HEAD
LIGHT(L)
Y
W
Y
B/W
W
Br
Lbl
HEAD
LIGHT(R)
B
B/W
O/Bl
Bl
Lg
B/W
O/G
R
B/O
Lg
B/W
E
L
P
M
R
W
Y
Y/W
W/Y
R/Bl
B/R
O/Y
FRONT TURN
SIGNAL
LIGHT (R)
B/W
B
O/G
R/Bl
O/G
B/W
O/R
W
R/B
P/W
Br/W
Bl
G/Y
Lg
Y
V
O/R
W
B/W
ON
OFF
IGNITION
SWITCH
ON
OFF
LOCK
P
B
B/R
B/Lg
B/W
B/G
B/Br
O/B
O/W
Y/G
O/R
Y/W
B/R
B/Bl
O/Y
O/W
Y/G
O
Y
O/G
W/B
O/G
P
B/W
BRAKELOCK
SWITCH
B
Lg
Lbl
Gr
P
SPEED
SENSOR
B
Lg
Lbl
PUSH
FREE
O/W
M
Y/B
Y/G
CENTER
STAND
SWITCH
OFF
ON
PUSH
G
R
OFF
RUN
R
OFF
ON
FI OI HI
OD
B
R/Bl
5
B/W
4
Lg/B
Br/R
B/Lg
R/B
R/W
B
B/R
3
B/Br
Br/W
P/W
2
G/B
G/R
R
P/B
Dg
B/Bl
G/Y
1
ECM
O/Bl
Y/R
W
Br
D
PUSH
FREE
R/Bl
SP/TA
STARTER
BUTTON
IAC
VALVE
IGNITION IGNITION
COIL #1 COIL #2
FRONT
BRAKE
SWITCH
B/W
W/G
B/Y
HAZARD
SWITCH
ENGINE
STOP
SWITCH
Gr/R
HANDLEBAR SWITCH (R)
PM
BRK
BRK FI OI HI
ABS
PM
WT
B/Y
Gr/W
Gr/B
Y
Bl
Br/B
P
G/Bl
Y/G
W/Bl
Gr/Y
R/W
Lg/Y
G/W
Bl/R
Bl/Y
O/W
Lg
G
W/B
B/Br
W/R
Bl/W
Bl/B
Bl/G
B/W
B/W
Y/G
TL
TRUNK
LIGHT
DIODE
AN650AK5 (E-02, 19, 000)
HI : 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
OD : OVER DRIVE INDICATOR LIGHT
ABS : ABS INDICATOR LIGHT
HANDLEBAR SWITCH (R)
WINDSCREEN
SWITCH
ENGINESTOP
SWITCH
Y
B
G
R
Br
B/W
FRONT TURN SIGNAL
LIGHT (R)
Lg
B/W
HEADLIGHT (R)
Y
B/W
W
PASSING
LIGHT
SWITCH HI
LO
DIMMER
SWITCH
FREE
PUSH
OFF
ON
HORN
BUTTON
REAR BRAKE
SWITCH
L
PUSH
R
•
OPEN
CLOSE
POWER
SWITCH
FREE
PUSH
TURN SIGNAL
LIGHT SWITCH
B/R
W/R
B/Y
W/Y
B
W
B
W
O
B/W
R/B
R
R/B
R
Y/B
Y/G
B/W
R/Bl
R
B
R/Bl
R/W
B/W
B/W
B
B
B/W
B/W
MAIN
FUSE
STARTER (40 A)
RELAY
R
R/W
F-CUT
SENSOR
Y/B
Y/G
W
W/G
B/Y
Br
R
B/W
O/W
B/Br
B/G
Y/W
Dg
B/Br
B/Bl
B/Br
O
O/Bl
R/B
R/W
R/W
D↔M
SWITCH
HANDLEBAR SWITCH (L)
UP
FREE
DOWN
UP/DOWN
SWITCH
MIRROR
1
2
G/Y
1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. FAN
15 A
10 A
10 A
15 A
15 A
15 A
FUEL
PUMP
CAM
SENSOR
REGULATOR/
RECTIFIER
PUSH
12 V
BATTERY
GENERATOR
STARTER
MOTOR
TRUNK
BOX
SWITCH
G
R
B/W
B
B
B
Y
Y
Y
Bl
G
W
Gr
B
W
BI
Y
B
M.P
A.P
(40 A) (10 A)
SENSOR SENSOR CTV POWER
FUSE SOURCE W.T
TP
M.T
O2
FUSE
SENSOR
SENSORSENSOR SENSOR
DIODE
R
#1
#2 CVT
INJECTOR PULLEY
CVT
POSITION
REVOLUTION
SENSOR
SENSOR
3
FUSE BOX
OIL
PRESSURE
SWITCH
M
Y
W
6
B/W
POWER
SOURCE
ON
OFF
ON
OFF
PUSH
W/R
Br
B/W
W/B
B
R
Br/B
B/Br
L/Y
R/W
Y/G
Br/W
G
G/R
B/O
G/B
B/G
B/R
W
Y
Y/W
B/Bl
B/W
Lg
Lbl
B
O/R
/R
FAN
MOTOR
5
R
Bl
B
Bl
B
4
B
FAN MOTOR
SWITCH
PUSH
Gr/R
B/W
O/W
B/Y
W/R
W/B
R
R
Gr/R
Br
B/R
O
O/Y
W/Y
B/W
B/W
R/B
R/W
B
B/R
Lg/B
Br/R
B/W
W/G
B/Y
Y/W
Y/Bl
B/O
O/Bl
Y/R
W
Br
B/G
G/B
O/R
R
P/B
Dg
B/Bl
G/Y
B/Br
B/Br
Br/W
P/W
R/Bl
Gr/R
BRAKE LIGHT/TAILLIGHT (L)
ABS ABS
FUSE MOT
(15 A) FUSE
(15 A)
MODE
SELECT
COUPLER
FVW RVW
OFF
ON
TRUNK
TRUNK BOX
LIGHT
BOX
LIGHT
SWITCH
ON
OFF
OIL LEVEL
SWITCH
Gr
B/W
W/B
B
B/W
REAR TURN SIGNAL LIGHT (L)
B/Br
G/Y
R
Br
Lbl
O/G
R
B/O
F-P
RELAY
Y
Y/W
W/Y
R/Bl
B/R
O/Y
B
O/W
Y/R
R/Bl
SIDESTAND
RELAY
R
G
O/W
B/W
Y/B
B/W
O/Bl
Bl
G/Y
B/O
B
Gr/Y
O/G
B
B/W
FAN MOTOR
RELAY
HORN
M-RELAY
REAR TURN
SIGNAL
LIGHT (R)
BRAKE LIGHT/TAILLIGHT (R)
OPTION
MIRROR
FUSE
(3 A)
B/W
Gr
B/W
Lg
Gr
B/W
W/B
Lg
Br
B/W
W/B
Lg/Y
R/W
Y
B/W
G/W
G/R
O
G/B
W
Y
Y/W
B/Bl
B/W
Lg
Lbl
B
O
B/G
W/B
O/G
B/Bl
O/BI
B/W
G/R
Bl
B/O
B/W
B
G/B
B/O
O
MIRROR-MOTOR (L)
Y/R
B/W
R/B
B/W
B
Bl
R
Bl
B/Bl
M
B
Bl
Gr/B
Y/R
FRONT TURN SIGNAL
LIGHT (L)
Gr/W
Y/R
B
B/W
G/R
O/R
G/B
O/B
Br
B/W
POSITION LIGHT (L)
B
B/W
LICENSE PLATE LIGHT
A
S
W/Y
B/W
HEADLIGHT (L)
B/Br
Lg/B
R
Lg
B/W
B/Y
Gr/W
Gr/B
Y
Bl
Br/B
P
G/Bl
B
W/Bl
Gr/Y
R/W
Lg/Y
G/W
Bl/R
Bl/Y
O/W
Lg
G
W/B
B/Br
W/R
Bl/W
Bl/B
Bl/G
B/W
B/W
Y/G
E
L
P
M
B
Bl
POSITION LIGHT (R)
R
P/B
B/Br
B
Bl
O
O
SOLENOID
MIRROR-MOTOR (R)
M
ABS-CONT
B/Br
Bl/W
Bl/B
Bl/G
Bl/R
Bl/Y
R
G
B/W
B
B
B
B
B
O/W
B/Y
O/W
W/Bl
B/G
B/Br
O/B
O/W
Y/G
O/R
Y/W
B/R
B/Bl
O/Y
O/W
Y/G
O
Y
O/G
W/B
ON
OFF
LOCK
P
B
B/R
Bl
B/W
G
B
Lbl
Lg
Bl
B/W
G/B
B
Lbl
Lg
B/W
B
O/G
R/Bl
O/G
B/W
O/R
W
R/B
P/W
Br/W
Bl
G/Y
Lg
Y
V
Br
O/Bl
Bl
O/G
P
B/W
O/R
W
B/W
O/G
V
ON
OFF
ECM
M
PUSH
FREE
PUSH
FREE
IGNITION SWITCH
CVT
MOTOR
YBl
B/W
B/O
O/Y
SPEED SENSOR
BRAKELOCK
SWITCH
CENTER
STAND
SWITCH
SIDESTAND
SWITCH
M
Bl
B/W
OFF
ON
S-RELAY
R
G
5
FI OI HI IMO
OD
IMOBILIZER SCREEN
SCREEN
FUSE
MOTOR A.T-SENSOR
PTC
B/W
Y/W
R
B/W
B
B
4
3
FRONT
BRAKE
LIGHT
SWITCH
G/B
G
B/W
O
R
Bl
OFF
ON
G
B/W
2
1
IGNITION IGNITION
COIL #1 COIL #2
HAZARD
SWITCH
SP/TA
D
PUSH
Lg
B/W
BRK ABS PM
BRK FI OI HI
ABS
PM
WT
STARTER
BUTTON
OFF
RUN
Br/B
O/W
R/W
B/R
O/W
G/Bl
TR
TL
O
G
B/W
UP
FREE
DOWN
WIRE COLORS
B : Black
Bl : Blue
Br : Brown
Dg : Dark green
Dgr : Dark gray
G : Green
Gr : Gray
Lbl : Light blue
Lg : Light green
O : Orange
R : Red
W : White
: Yellow
Y
B/Bl : Black with Blue tracer
B/R : Black with Red tracer
B/W : Black with White tracer
B/Y : Black with Yellow tracer
Bl/B : Blue with Black tracer
O/B : Orange with Black tracer
O/Bl : Orange with Blue tracer
O/G : Orange with Green tracer
O/R : Orange with Red tracer
O/W : Orange with White tracer
O/Y : Orange with Yellow tracer
W/B : White with Black tracer
Y/B : Yellow with Black tracer
Y/G : Yellow with Green tracer
Y/W : Yellow with White tracer
E
L
P
M
Prepared by
December, 2004
Part No. 99501-36110-01E
Printed in Japan
A
S
48
Printed in Japan
K5