MOTORCYCLE

DATE: Oct. 12, 2007

PAGE: 1 OF 19

SUBJECT: NOTICE OF SET-UP MANUALAPPLICABLE MODEL: AN650AK8EFFECTIVE ENGINE OR FRAME NO.: REFERENCE:

This bulletin is to inform you of set-up procedures of AN650AK8.Please inform your dealers of this notice.AN650AK8 Set-Up Manual will not be issued because the set-up procedures for this model remainunchanged from AN650K3 except the differences described below.To set-up AN650AK8, please use the AN650K3 Set-Up Manual and this Service Bulletin.

DIFFERENCE BETWEEN AN650K3 AND AN650AK8

AN650K3 Set-Up Manual: 99505-01063-011

1. LOCATION OF PARTS [Page: 2, 3, 4]

PP

Item Part Name Q’ty Remarks

A

Windscreen 1Screw 4 5 × 16 mmCollared spacer 4 OD:14.0 ID:5.5 T:5.0Rubber cushion (with nut) 4 5 mm L:15.0

BWindscreen cover 1Tapping screw 2 5 × 16 mm

CFront brake lever 1Stepped screw 1 6 × 35 mmFlange nut 1 6 mm

DRear brake lever 1Stepped screw 1 6 × 35 mmFlange nut 1 6 mm

ELower bracket cover 1Flange stepped bolt 2 6 × 12 mm

FFront fender 1Stepped Allen screw 2 6 × 16 mmFlange stepped bolt 2 6 × 16 mm

G Flange bolt 1 8 × 28 mmfor front brake caliper

H Front wheel assembly 1I Front wheel spacer 0 Spec is eliminated.J Washer 2 OD:13.0 ID:6.5K Warning label set 7 For E-19 CC selectionL Warning label set 4 For E-19 CD selection

Item Part Name Q’ty RemarksM Battery electrolyte container 1N Owner’s manual set 1

O Strap 1L:140 mmFor Front wheel ABS sensor lead wire

P

Back rest assembly 1Fastener 2Pillion rider handle cover front 1Rubber grommet 2Screw 4 6 × 12 mmBracket 1Cushion 1Allen bolt 3 8 × 45 mmFitting nut 4 6 mmPillion rider handle cover rear 1

QReflector bracket 2 Right and LeftReflex reflector 2Flange nut 2 5 mm

RBattery cover 1Fastener 1

SBattery 1Terminal bolt 2 6 × 12 mmTerminal nut (square) 2 6 mm

NOTE:The parts shown as Item C, D and G in the above table are in the trunk.The parts shown as Item J, K, L and Q in the above table are supplied for limited markets.Use washers of Item J for mounting the license plate.

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DATE: Oct. 12, 2007

PAGE: 2 OF 19

[Page: 2, 3, 4]The photograph shown indicates the parts dismountedfrom the motorcycle in addition to the items listedabove.

A: Brake caliperB: Front wheel ABS sensor assemblyC: Tool set

Helmet holder wireD: Screw, Crown nut (License plate) (For E-28 market)

2. ASSEMBLY

FRONT WHEEL[Page: 11, 12 Paragraph: 2]Mount the front wheel assembly properly.

A: Right fork legB: Left fork legC: Front wheel ABS sensor bracketD: Front axle

[Page: 13, 14 Paragraph: 1, 2]Attach the front wheel ABS sensor bracket to the frontwheel hub.

Carefully insert the front brake disc plate between thecaliper brake pads.

A: Front wheel ABS sensor bracketB: Oil seal (Lip)C: Disc plateD: Pads

When attach the front wheel ABS sensorbracket, be careful not to damage the oil seallip.

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DATE: Oct. 12, 2007

PAGE: 3 OF 19

Insert the front axle from the left side of fork leg and fixthe front wheel assembly to the front fork.

A: Front axleB: Oil seal (Lip)

A: Front wheel ABS sensor bracketB: Stopper (Front wheel ABS sensor bracket)C: Right fork legD: Stopper (Right fork leg)

REFLEX REFLECTOR (FOR E-28 MARKET)[Page: 13, 14 Paragraph: The next of 4]Align the boss of reflex reflector with the hole of reflec-tor bracket.Install the reflex reflector to the bracket.

A: Reflex reflectorB: BracketC: BossD: Hole E: 5 mm flange nutF: Mark (Right or Left)

FRONT BRAKE CALIPER (FOR E-28 MARKET)[Page: 15, 16 Paragraph: 1 through 3]Remove the supporter from the brake pad of the rightfront brake caliper.

A: SupporterB: Brake caliper (Right)

When install the front axle, be careful not todamage the oil seal lip.Never use force to install the front axle.If it cannot be installed by hand, it is not cor-rectly aligned.

Before tightening the front axle, turn the frontwheel ABS sensor until the stopper on the frontwheel ABS sensor bracket and the stopper ofright fork leg come in contact as shown.

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DATE: Oct. 12, 2007

PAGE: 4 OF 19

Set the front brake caliper so the brake disc plate isinserted between two brake pads.

A: PadsB: Disc plateC: Brake caliper (Right)

RIGHT LEFT

Install the front brake caliper with reflex reflector(Right).Remove the front brake caliper mounting bolt (Left).Reinstall the front brake caliper with reflex reflector(Left).

A: Brake caliperB: 8 × 28 mm flange bolt (Caliper mounting bolt)C: Reflex reflector

RIGHT LEFT

Tighten the front brake caliper mounting bolts to thespecified torque.

Front brake caliper mounting bolt:26 N·m (2.6 kgf-m)

A: Brake caliperB: Flange bolt (caliper mounting bolt)

CLAMPRoute the front wheel ABS sensor lead wire as shownin the photograph.Clamp the front wheel ABS sensor lead wire and frontbrake hose union using the strap.

A: Strap L:140 mmB: Front wheel ABS sensor lead wireC: Front brake hose union

Make sure that both the right and left calipermounting bolts are tightened with the specifiedtorque.

NOTE:Cut off the excess strap as shown in the photo-graph.

OUT SIDE

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DATE: Oct. 12, 2007

PAGE: 5 OF 19

WINDSCREEN[Page: 19, 20 Paragraph: 4]Fit the rubber cushion to the windscreen brace.Fit the spacer to the windscreen.

A: Rubber cushion (with nut) 5 mm L:15.0 mmB: Windscreen braceC: HoleD: Collared spacer OD:14.0 mm ID:5.5 mm T:5.0 mmE: WindscreenF: Hole

[Page: 21, 22 Paragraph: 1 through 3]Set the windscreen to the windscreen brace using thescrews at the correct position.

A: WindscreenB: Windscreen braceC: 5 × 16 mm screw

Tighten the screws to fix the windscreen.

A: WindscreenB: 5 × 16 mm screwC: Collared spacer OD:14.0 mm ID:5.5 mm T:5.0 mmD: Rubber cushion (with nut) 5 mm L:15.0 mmE: Windscreen brace

Align the windscreen cover boss and the hook with thewindscreen hole.Push up the windscreen cover by hands and fit thewindscreen cover.

A: Windscreen coverB: HookC: BossD: Windscreen

NOTE:Adjust the horizontal position of windscreen byaligning the right-hand and left-hand of wind-screen A and bracket B slots.

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DATE: Oct. 12, 2007

PAGE: 6 OF 19

RIGHT LEFT

Tighten the screws while pushing down the wind-screen cover.

A: Windscreen coverB: 5 × 16 mm tapping screw

A: Windscreen coverB: HookC: Windscreen

PILLION SEAT[Page: 21, 22 Paragraph: The next of 4]Fit the cushion and bracket to the seatrail.

A: CushionB: HoleC: Bracket

Install the bracket using the Allen bolts.Fit the rubber grommet into the bracket.

A: BracketB: 8 × 45 mm Allen boltC: Rubber grommet

NOTE:Push down the screen cover until it is stopped.

Fat

Thin

FRONT

MOTORCYCLE

DATE: Oct. 12, 2007

PAGE: 7 OF 19

Fit the fitting nut to the pillion rider handle cover rear.

A: Pillion rider handle cover rearB: Fitting nut

Fit the pillion rider handle cover rear.

A: Pillion rider handle cover rearB: Cushion

Install the pillion rider handle cover rear using thescrews.

A: Pillion rider handle cover rearB: 6 × 12 mm screw

Fit the pillion rider handle cover front.

A: Pillion rider handle cover frontB: ClickC: Cushion

Make sure the pillion rider handle cover rear fitinto the groove of cushion.

Make sure the pillion rider handle cover front fitinto the groove of cushion.

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DATE: Oct. 12, 2007

PAGE: 8 OF 19

Fix the pillion rider handle cover front using the fasten-ers.

A: Fastener

Align the hook retainer and boss of back rest assemblywith the bracket.

A: Back rest assemblyB: Hook retainerC: BossD: BracketE: HookF: Rubber grommet

Push the back rest assembly down and insert the bossinto the rubber grommet.Arrange the line of back rest assembly.

A: Back rest assemblyB: Line

REAR VIEW MIRROR [Page: 23, 24 Paragraph: 1]Extend the rear view mirror with the rear view mirrorfolding switch after completing the battery servicing.

A: Rear view mirrorB: Rear view mirror folding switch

NOTE:To install the fastener, pull the center pin as Band fix the fastener by pushing the center pinas C.

NOTE:Align the mirror in the position so as to securerear view.

When operating the rear view mirror, be sure touse the rear view mirror folding switch.

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DATE: Oct. 12, 2007

PAGE: 9 OF 19

WARNING LABEL(FOR E-19 CC AND E-19 CD SELECTION)[Page: 23, 24 Paragraph: 2, 3]Select the appropriate language label for your country.

Stick the label selected for your country.

A: For E-19 CC selectionB: For E-19 CD selectionC: Warning label (General warning)D: Warning label (Windscreen)E: Warning label (Engine starting)F: Warning label (Loading capacity)G: Front trunk lidH: Trunk

LICENSE PLATE (EXCEPT FOR E-28 MARKET)[Page: 23, 24 Paragraph: 4]

A: Washer OD:13.0 mm ID:6.5 mmB: Rear fender

NOTE:For E-19 CC selection: seven kinds of labels, Eng-lish, French, German, Spanish, Portuguese,Dutch, and Italian, are supplied together with M/C.For E-19 CD selection: four kinds of labels,Finnish, Norwegian, Danish and Swedish, aresupplied together with M/C.

NOTE:When sticking the new label, remove the origi-nal label.

NOTE:When installing the license plate, use the wash-ers as shown in the photograph.

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DATE: Oct. 12, 2007

PAGE: 10 OF 19

3. SERVICING

BATTERY [Page: 31, 32 Paragraph: 2, 3]Charge the battery with a battery charger.

After charging the battery, install the battery in themotorcycle as follows.

[Page: 33, 34 Paragraph: 1, 2]1. Install the battery in the battery box.2. First connect the + lead to the + positive terminal

of the battery.3. Connect the - lead to the - negative terminal of

the battery.

A: + leadB: - lead

For charging the battery, make sure to use thecharger specially designed for MF battery.Otherwise, the battery may be overchargedresulting in shortened service life.Do not remove the cap during charging.Position the battery with the cap facing upwardduring charging.

Turn off the ignition switch when connecting ordisconnecting the battery lead wires.When attaching the wiring harness batteryleads to the battery terminals, observe the cor-rect polarity.

NOTE:The terminal bolts and nuts are attached to thebattery.

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DATE: Oct. 12, 2007

PAGE: 11 OF 19

Install the battery cover and fix the fastener by pushingknob.Install the starter motor relay assembly to the batterycover.Fit the coupler to the battery cover hole.Reinstall the tool set and helmet holder wire.Reinstall the cotter pin and washer.Close the seat, then press the seat to firmly lock it.

A: Battery coverB: FastenerC: Starter motor relay assemblyD: CouplerE: Hole

BRAKE LOCK LEVER[Page: 35, 36 Paragraph: The next of 3]Pull the brake lock lever and check if the wheel is cer-tainly locked.When there are abnormalities, adjust them by followingthe procedure below.

1. Pull the brake lock lever by one notch.2. Loosen the adjuster lock nut and adjuster.3. Turn the adjuster clockwise until it stops.

4. Tighten the adjuster lock nut to the specified torquewith the adjuster held in that position.

5. Return the brake lock lever to original position.6. Pull the brake lock lever and confirm that the wheel

is locked. If any malfunction is found, go back to procedure 1.

Brake-lock adjuster lock nut: 9.5 N·m (0.95 kgf-m)

A: Adjuster lock nutB: Adjuster

NOTE:Do not turn the adjuster more than the givenposition, or the adjuster may be damaged.

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DATE: Oct. 12, 2007

PAGE: 12 OF 19

FRONT BRAKE LEVER[Page: 35, 36 Paragraph: 4]Make sure the front brake lever position is correct.The standard setting of this motorcycle is as indicatedin the table below.

A: Adjuster

REAR BRAKE LEVER[Page: 37, 38 Paragraph: 1]Make sure the rear brake lever position is correct.The standard setting of this motorcycle is as indicatedin the table below.

A: Adjuster

ENGINE OIL [Page: 43, 44 Paragraph: 1]Engine oilOil quality is a major contributor to your engine’s per-formance and life.Always select good quality engine oil.Use oil with an API (American Petroleum Institute)classification of SF/SG or SH/SJ, or with a JASO clas-sification of MA.

SAE Engine Oil ViscositySuzuki recommends the use of SAE 10W-40 engineoil.If SAE 10W-40 engine oil is not available, select analternative according to the left chart.

Standard setting 3

Standard setting 3

SAE API JASO

10W-40 SF or SG –

10W-40 SH or SJ MA

API: American Petroleum InstituteJASO: Japanese Automobile Standards Organization

-30 -20 -10 0 10 20 30 40

-22 -4 14 32 50 68 86 104

10W - 30

20W - 50

10W - 40 10W - 50

15W - 40 15W - 50

˚C

˚F

ENGINE OIL VISCOSITY RATING SELECTION CHART

ENGINE OIL

TEMP.

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DATE: Oct. 12, 2007

PAGE: 13 OF 19

JASO T903The JASO T903 standard is an index to select engineoils for 4-stroke motorcycle and ATV engines.Motorcycle and ATV engines lubricate clutch andtransmission gears with engine oil.JASO T903 specifies performance requirements formotorcycle and ATV clutches and transmission.

There are two classes, MA and MB.The oil container shows the classification as shown.

A: Code number of oil sales companyB: Oil classification

Energy ConservingSuzuki does not recommend the use of “ENERGYCONSERVING” oils.Some engine oils which have an API classification ofSH or higher have an “ENERGY CONSERVING” indi-cation in the API classification doughnut mark.These oils can affect engine life and clutch perform-ance.

SPEEDOMETER (FOR LIMITED MARKET)[Page: 43, 44 Paragraph: The next of 2]Press and hold RESET button for 2 seconds to switchthe display.Select km/h and mph properly to comply with trafficregulations.Check km/h and mph display after adjusting the instru-ment panel display.

A: RESET buttonB: Speedometer display (km/h, mph)

RecommendedNot recommended

EN

ERGY CONSERVIN

G

API SERVICE SJ

SAE10W-40

API SERVICE SJ

SAE10W-40

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DATE: Oct. 12, 2007

PAGE: 14 OF 19

IDLE SPEED ADJUSTMENT[Page: 43, 44 Paragraph: 4]Check the engine idle speed.

Engine idle speed: 1 100–1 300 r/min

NOTE:If the engine idle speed is not within the speci-fied range, ask your Suzuki dealer or a qualifiedmechanic to inspect and repair the motorcycle.

4. TIGHTENING TORQUE [Page: 45, 46, 47]

Item Part Name N·m kgf-m

FRONT FORK

A Handlebar clamp bolt 23 2.3

B Steering stem head nut 65 6.5

C Front fork upper bracket bolt 23 2.3

D Front fork lower bracket bolt 23 2.3

E Front axle clamp bolt 23 2.3

BRAKE

F Front brake master cylinder mounting bolt 10 1.0

G Front brake caliper mounting bolt 26 2.6

H Rear brake master cylinder mounting bolt 10 1.0

I Rear brake caliper mounting bolt 26 2.6

Item Part Name N·m kgf-m

J Brake caliper air bleeder 7.5 0.75

AXLE

K Front axle 65 6.5

L Rear axle nut 100 10.0

ABSORBER

M Rear shock absorber nut (Upper) 29 2.9

N Rear shock absorber nut (Lower) 29 2.9

OTHERS

O Rear swing arm pivot nut 100 10.0

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DATE: Oct. 12, 2007

PAGE: 15 OF 19

5. CABLE ROUTING [Page: 48]

A

A

B

VIEW B

SECT A – A

Pass the throttle cables between the steering upper bracket and rear brake hose.

Rear brake hose

Brake lock cable

Front brake hose

Guide

Wiring harness

Clamp

Clamp

Clamp

Clamp

Rear brake hose

Rear brake hose

Wiring harness

Throttle cable (Pulling)

Throttle cable (Returning)

Throttle cable (Pulling)

Throttle cable (Returning)

Throttle cable (Pulling)

Throttle cable (Returning)

Pass the throttle cable under the wiring harness.

Handlebar switch lead wire (R)

Handlebar switch lead wire (L)

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DATE: Oct. 12, 2007

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6. HARNESS ROUTING [Page: 49, 50]

Clamp

Clamp

Clamp

Clamp

Clamp

Continuously Variable Transmission motor lead wireHO2 sensor lead wire

Continuously Variable Transmission revolution sensor Pulley Position sensor lead wire

Center stand switch lead wire Continuously Variable Transmission revolution sensor

HO2 sensor lead wireCenter stand switch lead wire

Continuously Variable Transmission revolution sensor

Center stand switch lead wire

Pulley Position sensor lead wire

Clamp

Continuously Variable Transmission revolution sensor

Center stand switch lead wire

Box

ClampWiring harness

Headlight (R) Headlight (L)

Be careful not touch the exhaust pipe.

Exhaust pipe

Handlebar switch lead wire (R,L)Turn signal light lead wire (L)

Clamp Clamp

Clamp

Wiring harnessRelay

Meter lead

Pass the meter lead to behind the brace.

ABS sensor lead wireRear view mirror folding switch lead wire (L)

Exhaust pipe

Continuously Variable Transmission motor

Leg shield brace

Engine Control Unit

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DATE: Oct. 12, 2007

PAGE: 17 OF 19

Clamp

Clamp

Wiring harness

Ignition coil Ignition coil

Generator lead wire coupler

Solenoid lead wire

Clamp

Clamp

Clamp

Wiring harness

Starter motor

ClampIdle Speed Control branch wire

Throttle Position sensor lead wire

Wiring harness

Continuously Variable Transmission motor lead wireHO2 sensor lead wire

Continuously Variable Transmission revolution sensor Center stand switch lead wire

Wiring harness

Clamp

Solenoid lead wireWiring harness

Pulley Position sensor lead wire

Wiring harness

Clamp

Clamp

Clamp

Clamp

Clamp

Clamp

Wiring harness

Clamp

Side-stand switch lead wireOil level switch lead wire

Oil pressure switch lead wire

Fuel hose

Starter motor lead wire

Generator lead wire

Generator lead wire

Starter motor lead wire

Wiring harness

Oil level switch lead wire

Oil pressure switch lead wire

Wiring harness

Wiring harness

Speed sensor lead wire

Generator lead wire

Clamp

Clamp

Clamp

Clamp

Wiring harnessSeat switch lead wire Seat

Seat switch lead wire

Generator cover

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DATE: Oct. 12, 2007

PAGE: 18 OF 19

Intake Air Pressure Sensor

Fuse

Wiring harness

Pass the wiring harness inside of the brake lock cable.

Clamp

Set the wiring harness clamp inside.

Clamp bottom side of the wiring harness clamp.

Bent the clamp inside, not to protrude from the actuator set plate.

Battery + lead wire Battery - lead wire

Battery - lead wire

BatteryFuel hose

Starter relay

Battery cover

Seat

Trunk light switch

Trunk boxFuse

ClampRear combination light lead wire

Set the coupler in front of battery box.

Set the starter relay coupler.

Pass the wiring harness under the fuel hose.

Set the battery + lead coupler under the wiring harness.

Pass the rear combination light lead wire under the frame.

Pass the rear combination light lead wire under the frame.

Battery box

Fuel tank

To license plate light

Windscreen regulator motor

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DATE: Oct. 12, 2007

PAGE: 19 OF 19

7. SAFETY CHECK OUT [Page: 51, 52, 53]

ENGINE AND TRANSMISSION

CHASSIS

COLD TIRE INFLATION PRESSURE

ELECTRICALS

ROAD TEST INSPECTION

After completion of the setting-up the motor-cycle all the following items should be dou-ble-checked to confirm that the operation andfunction of the motorcycle are satisfactory.Now, setting-up the motorcycle and pre-deliv-ery inspection have been completed and themotorcycle can be passed to the customer.

ITEM MEASURE SPECIFICATIONSEngine oil Check/Refill 2 600 ml Fuel tank Drain/Fill 15.0 L Throttle cable Check/Adjust 2.0–4.0 mmIdle r/min Check/Adjust 1 100–1 300 r/minExhaust system LeakageFuel system connection

Leakage/Circlip

Final gear oil Check/Refill 300 ml Transmission oil Check/Refill 360 ml Engine coolant Check/Refill 1 600 ml

ITEM MEASURE SPECIFICATIONSDisc brake Clean/Fluid levelFront brake lever Check/Adjust Position 3Rear brake lever Check/Adjust Position 3Brake lock lever Check/AdjustOiling points All necessary pointsBattery Filling electrolyteWiring and cable Routing/OperationWiring connectors Clean/TightRear shock absorber Check/Adjust Position 2Tighten all nuts and bolts

Torque those listed in this manual

Cotter pins, circlip and fasteners

Check

Warning label(For E-19 market)

Select/Stick

SOLO RIDING DUAL RIDING

FRONT225 kPa

2.25 kg/cm2

33 psi

225 kPa2.25 kg/cm2

33 psi

REAR250 kPa

2.50 kg/cm2

36 psi

280 kPa2.80 kg/cm2

41 psi

ITEM CHECK FOR

Light

Lighting/AdjustHeadlight high/low beam

Tail/Brake light

Turn signal light

LightingPosition light(Except for Canada and Australia)

License light

Trunk light

Instrument Lights

Lighting

Speedometer indicator

Tachometer indicator

High beam indicator light

Turn signal indicator light

Oil pressure indicator light

Fuel injection system indicator light

Coolant temperature warning indicator light

Coolant temperature indicator

Fuel meter indicator

Oil level indicator

Oil change interval indicator

Odometer/trip meter indicator

Brake lock indicator light

Power mode indicator light

Shift indicator light

ABS indicator light

Immobilizer indicator light(Except for Canada)

Instrumental panel light

Clock

Switch Operations

Operation

Ignition switch

Dimmer switch

Turn signal switch

Horn switch

Passing light switch

Shift switch

Shift mode change switch

Power mode switch

Rear view mirror folding switch

Power windscreen switch

Engine stop switch

Hazard warning switch

Starter button

Brake switch

Side and center stand/Ignition interlock switch

ITEM CHECK FOR

EngineStarting/Acceleration/Smoothness/Noise

Transmission Operation/NoiseBrake Operation/NoiseSteering StabilitySuspension OperationControl cables Operation/Proper returnLeakage Fuel/Oil/Coolant/ExhaustInstrument panel Operation