650 Info Not In Manual

The Information Your Suzuki Manual Doesn't Tell You

This is a collection of information that should helpful to any Burgman 650 owner, but is not included in your owner's or service manual. Most of these are the result of other owner's experience, mistakes, and collaborations.

Primary Pulley Stopper Bolt

There is a bolt in the CVT that is essential to its function. Possibly through insufficient engineering, the end of this bolt can get sheered off, allowing the entire Primary Pulley assembly to malfunction. This could result in failures in other components, like bearings, causing >$1,000 of damage. This bolt should be inspected periodically, although at this time we don't know what contributing factors there are to the bolt's failure. Checking it or replacing it is an extremely easy job to do, and the part costs ~$5.
Discussion:
http://burgmanusa.com/forums/viewtopic.php?p=417960#p417960
Instructions for inspecting / replacing bolt:
http://burgmanusa.com/bkb/650+CVT+Info#Primary_Pulley_Stopper_Bolt

---

ABS Ring on Rear Tire

The sensor ring on the rear tire of Executive models can easily be bent out of specifications during a tire change. With a sensor rotor clearance of just 0.3 - 1.5 mm, sometimes the bend is not even visible. Some have had to resort to taking it to a dealer where it is hooked up to a diagnostic computer, or replacing the ring(~$103). A simple solution is to remove the ring before taking it to get the tire replaced, or at least warning the mechanic of the issue.

Threads:
http://burgmanusa.com/bkb/650+ABS#ABS_fault_light

---

Fuse Panel Tether

A piece of plastic beside the locking glove box covers the fuses and air filter access. What the manual doesn't tell you is that this will go flying away from your bike if that glove box is ever opened while in motion. A replacement is approximately $15! Fix this problem by adding a tether to the panel. Even if it comes loose, it will still be attached to the bike and you still have access to the fuses and air filter.

http://burgmanusa.com/bkb/650+Body+Panels-Tupperware#Fuse_Panel_Tether

---

Centerstand Switch

Having problems with the bike not shifting out of first gear? Most likely, the switch for the centerstand is stuck in the depressed position, a relatively common situation. The centerstand switch, which is exposed to road debris underneath the bike, often accumulates grime and periodically needs to be cleaned. The centerstand switch's purpose is to prevent damage to the CVT when the bike is on the centerstand, and thereby has no rotational resistance. When the centerstand switch is "stuck", the ECU thinks the bike is still on the centerstand and prevents the CVT from shifting up to a higher gear.

To fix: With the bike on the side stand, get down on the right side and look for a metal plunger facing the rear. Make sure it is fully extended. Routinely clean this plunger to prevent it from being stuck closed, especially if you drive on gravel or dirt.

Tutorial:
https://docs.google.com/View?docid=dgndw664_1097d62dpvgm&pageview=1&hgd=1&hl=en

---

Parking Light Feature

---