Video

To remove the cvt you have to remove all the bodywork and remove the engine from the frame,it's a big job .

From what I understand there are issues with the cvt bolt which goes through the engine which makes a rattling noise,there is a conversion available from someone in Poland but offhand I don't know exactly who,the later models have a longer bolt which cures this problem,have a look at my other videos,I think I mention it there. The primary pulley stop bolt which I talk about here will only cause problems if it isn't changed.

Sorry no,I've not had any issues with electronics on the bike so unfortunately can't help.

Good,I'm pleased I've been able to help Burgman owners,my apologies to everyone, I've been mown out with work over the last 12 months and haven't had the time to post any more videos nor have we ridden the bike much,hopefully that's going to change as I have now decided to retire to concentrate on the Lambrettas I have.

Just buy one from Suzuki,Primary pulley stop bolt, it's a tenner and if you don't replace it soon then it will wreck the engine

Yes but if its something you don't know about to start with then it isn't something anyone would think of doing, I tend to think that the designer of anything knows more than I do so they know better than me. However ....... ,I have thought about using a capscrew and machining a spigot on the end which would then go into the primary pulley deeper than the original Suzuki item ,however that all depends on how much extra it would go in without causing any damage. I've been too busy of late machining barrels,liners etc for the Lambretta engines I build to get the chance to have a look at the old cvt,all I've done so far is take the old primary pulley out of the bag it's in and ponder how it comes apart. I had the bright idea of drilling the hole for the stop bolt 180 degrees from the original worn one and making it deeper,then I can see how long I need to machine a capscrew as the new stopbolt but that is far as I've got. I could repair it without stripping it but the steel sleeve is worn which would rattle when in operation. This wouldn't stop the cvt from working but it is annoying. At the moment all this is irrelevant as all I want to do at the moment is ride the bike,repairing the original cvt is something I intend to do but only to see if it can be done which might then save other owners the cost of the new replacement parts.

Which one do you mean?

My phone number is below but I'm off on holiday in the morn so leave it for a week,I think the bolt is M12X1.5mm x 140 but at the moment I couldn't be 100%.

Mines a 2009, I did one which was a 2013 and the bolts were identical on both models, the shank on the end of the bolt could do with being maybe 2mm longer as it only locates into the pulley by 2mm. At the moment all I want to do with mine is ride it,I had too many weeks last year wanting to set fire to it.

@@bobmonkhouse50 hahaha yes I love riding mine! I just had a 2 year old battery go dead on it. I have heated grips and a powerful stereo that puts a drain on the batteries. Fortunately for Amazon I got a new one the next day! I bought a 4 year warranty also for 6.99. That will be a lot cheaper than buying a whole new battery. Well good luck and enjoy riding!!

Bad knees? I know the feeling.🤣 Hopefully your Burgman will be trouble free for the next few years,it seems a bit mad for a ten quid bolt to cause so much damage but hopefully I've brought it to a lot of people's attention and saved them the heartache I've had. All I need to do now is slow down a bit, the last time we were out on it I spent rather a lot of the time at 100mph+ and have been nervously waiting for the brown envelope to arrive,nothing so far and its been nearly two weeks.😁

Don't despair, how many miles has the bike done? I've found there are three possible problems,the stop bolt can be replaced in a few minutes and only costs a tenner,the other two problems may or may not arise,the stand switch is again an easy job and all it requires if it's working is to spray it with wd40 or similar every few months or maybe spray grease to keep water out. The pulley position sensor is a bit less accessible but not much more, certainly less than an hour, cost of a brand new switch from Suzuki is around £200.

I’m sorry for the super late response, I’ve not received any notification I had a reply. I’m now 1 year into ownership, yes I’ve replaced the bolt and will never forget to do so again. Unfortunately for me spells in hospital and general bad pain have kept my riding low but when I do get out it’s fantastic, for me a reverse gear like the gold wing has would be a boon, that’s only because of my issues. I pray that I’m allowed to keep plugging away with the odd ride it does so much for my general mood. God Bless Bro.

Oh I forgot to say it’s done 23 thousand but it has a full main dealer service record for what that’s worth, with all receipts

What do you want to know? I'll help if I can but as I say I'm not an expert on these things.

No,the 400 is completely different, it's the usual variator on the 400,the belt should be about fifty quid and is much easier to change. My apologies for the delay in replying, comments aren't coming up in my email account for some reason.

@@bobmonkhouse50 No not at all, I am grateful for this answer, very valuable information!!!

I'll do a couple more this year, I've been stuck working on my daughters house for months so haven't had the time to do anything bikewise for months,we did less than 500 miles on the Burgman last year but we'll be making up for that this year.

No, I estimate the safe life of the stop bolt to be 20-25,000 miles. Maybe replace it before then but it's not a big job to take it out and check it,at 9000 miles it should be good for another 10,000. It might be worth Burgman owners to check it when they change the engine oil,its even easier to remove than the drain plug.

The problem is most likely the stop bolt unfortunately , however it could be the centre stand switch which is easy to remove and clean up try that first,the other possible problem could be the primary pulley positionsensor,these are around £200, you need to take the right hand side footboard covers off to get to it but its held in place by two M6 screws with an 8mm af head , look at one of my other videos for the pps values., If its not either of those then I can almost guarantee it'sthe stopbolt, look underneath the right hand side of the bike and lookfor a 14mm af bolt head,remove it and look at the end of it and compare it to the ones Ishow in one of my videos. If its that Its a huge job just to get to the cvt and then it's an expensive repair because the primary pulley will be knackered,the casing will also be knackered . The only alternative is to get a replacement engine. My apologies for not replying sooner, I don't tend to check my email inbox every day but I'll look out for your reply

Are you in the UK?

A 2016 bike is worth too much to scrap or break so it needs repairing, if it's done at a bike shop then it's going to be very expensive, I don't think there are many people about who would take it on,it's not a hugely technical job ,just time consuming. I'll do a video in the next couple of days and go through what you may need to do.

@@bobmonkhouse50 yes

@@dainius50 I'm not sure of anyone who I could recommend, I'm in Huddersfield if its of any use but I couldn't take the work on,I'm up to my neck in scooter engines at the moment, I'll do a quick video in the next couple of days,it rained all weekend so I didn't get the chance.

Don't let me put you off the 650 Burgman,it's a pleasure to ride and a good tourer, no gear changes and the seats are like sitting on a sofa so perfect for long distances. Look for a low mileage bike and make sure you change the stopbolt at around 20k.

@@bobmonkhouse50 I'm looking at a Burgman 650, BMW c650gt or Kymco AK550. Have to testride all 3 of them.

Sir, I've owned about 4 Burgmans and NEVER had an issue. I believe if you simply change that damn bolt at every oil change, you'll years of enjoyment. I had a Honda Silverwing, which was wonderful, BUT, I really missed the comfort of the Burgman. :)

I'll get back to you tomorrow or Monday, I'm racing at the moment

Yes,I believe its identical in all 650 models, it is heat treated ,probably a carbon steel bolt as opposed to an alloy steel like that seen in capscrews. The problem to me is that the spigot on the end of the bolt only protrudes into the pulley 2mm,if it went in the full depth then I don't think this problem would arise.

Yes it's that simple, a 14mm af socket, the only important thing to know is that you must not move or start the bike with the bolt out. I recommend torqueing the new bolt up to 30lb/ft, it's M10 in aluminium so I wouldn't go any tighter,

Yes it's simple, you don't need to take any bodywork off,put the bike on the centrestand ,look underneath the bike on the right hand side and you will see the head of the stopbolt,use a 3/8" drive ratchet and a 14mm a/f socket,undo it then fit the replacement,it's as easy as that. Make sure it's torqued up to around 30lb/ft and you'll be good for 20+thousand miles.

It stops one side of the primary pulley from routing so that the screw inside the pulley can operate to change ratios,if the blot breaks the pulley won't contract or expand and the bike is stuck in the lowest ratio,ie first gear.

Thanks, I don't know if I'll be posting anything more about Burgmans, I bought it so my wife and I could just put petrol in it and ride it, it's much more comfortable than the last two bikes we've had, a VFR800 and a VTR1000 Firestorm but riding a sports bike with one's knees under one's armpits isn't too comfortable when you're in your sixties so we decided on the Burgman. If it wasn't for the gear/ratio problems we would still just be putting petrol in and riding it and occasionally servicing it. I don't think there are any other problems with them other than the stop bolt so hopefully I won't need to do any more videos. Now I can get back on with the Lambretta stuff I haven't been able to do for the last 3 weeks. Keep up with the servicing on yours and change the bolt every couple of years or so and you shouldn't have any problems. Also sign up for the Burgman USA forum, the one in the UK appears to be defunct. Regards, Bob.

@@bobmonkhouse50 Hi , sorry to hear you might not be doing any more Burgman updates but good luck with your new projects . Ride safe and thanks again for the video .

It's a good bike and easy and comfortable to ride, so far I believe this stopbolt problem is really the only weak spot so change it and obviously maintain the bike as you would any other and it should be good for many years.