I just traded my 2003 Burgman 650 for a 2005. I've only had it one week, so I cannot give a fair rating of reliability, etc. However, I expect it to be rock solid in that department just like the 2003 model. My 2003 had 22,300 miles on it without a single problem; I just did the routine maintenance such as oil & filter changes, transmission oil changes, and final gear oil changes. I only had it back to a dealer for service one time, at around 16,000 miles just to have them check the valves, etc. because I was getting ready for a trip to Michigan. The valves were still within normal tolerances and needed no adjusting. The spark plugs looked great, but I had them changed anyway because they need to be done when valves are being checked or other major work.
I probably should have kept the 2003 model; it still rode and looked like new. However, I wanted the '05 model because of a few changes this year: a new over drive in the transmission, clear turn signal lenses, ambient temperature gauge, a fuel consumption meter, and color matched panel in front between headlights rather than the black panel. Suzuki advertises better fuel mileage on the '05 model, but so far I haven't noticed any difference. I'm getting from 48-53 mpg as I did on the '03. However, it might get better when it is fully broken it.
The owner's manual doesn't do a good job of explaining the overdrive, but I found that the indicator only comes on when you use the manual mode. The display is changed so that the D for normal mode is now on the far left at the bottom with the 1-5 gear positions next and the OD for overdrive on the far right at the bottom after the 5. I have noticed lower rpm in overdrive and I am also having more fun with the manual mode. I hardly ever used it on my '03 model, but I find myself using it quite a bit now. It is easier to vary the engine speed (rpm) during break-in. The fuel consumption meter isn't worth much to me since it only goes up to 50 mpg. I wish they had made it go at least to 60mph. The '99 Hayabusa I owned several years ago was the same way, only went up to 50, and I sometimes got over 50 with it if I was careful. Some of you probably don't believe that, but it is true. I keep a record of fuel consumption on all of my vehicles and have done this for the past 35 years. I have a little book in each vehicle and record information every time I fill up, so I know what I'm talking about when I give fuel consumption figures. On my '03 Burgman I averaged 52.4 miles per gallon during the first 11,500 miles. You can subtract about 5% from whatever fuel mileage you think you are getting because that's about how much the speedometer and odometer are off. When your speedmeter reads 70, you're only going about 66.
I really like the looks of the color matched panel on the front of the '05 model and I like the overdrive in the transmission. I also like knowing the ambient temperature although I don't know for sure how accurate the gauge is; I suppose it's accurate. I probably should have kept my '03 model because there's not enough difference in the new model, although as I said, I enjoy some of the additional features. I just hope this new one is as reliable as the old one; if it is I'll be happy. By the way, after 30 years and 41 motorcycles, this is the very first time I have bought the same model twice in a row. I think that says something for the Burgman. It is a great motorcycle.