Broken ring - Page 2 - Suzuki Burgman Forum
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post #11 of 20 (permalink) Old 03-08-2017, 11:42 AM
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The 2003-2006 400's have a steel sleeve-type cylinder, and I believe the 2007 on have nikasil coated aluminum. I've never heard of anyone boring and re-coating a nikasil cylinder although it's probably possible I'd worry then about getting an oversized piston- it doesn't seem like they're for sale anywhere. I'd say it's best to get a new OEM cylinder and piston, or buy an engine out of a wrecked bike. It looks like you'll get out for around $500 either way. Or roll the dice and get this set for $79: http://www.ebay.com/itm/BURGMAN-400-...NXNh6Q&vxp=mtr

BTW, the gasket set and 83 mm piston from aliexpress are for the 2003-2006 400, and won't fit the newer bikes.

Edit: On second thought, I'd be all over that Ebay cylinder and piston- only 7000 miles on it and it looks pretty clean. With shipping under $100. A couple of gaskets and another few hours of work and you could be back on the road for under $150. And the broken ring is a pretty rare problem- normally the 400 is a very reliable engine- I don't think it will happen to you again.

Last edited by Squeazel; 03-08-2017 at 12:03 PM.
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post #12 of 20 (permalink) Old 03-08-2017, 11:53 AM
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this whole thread makes my heart sad.....
Sad that you had this happen to you at such a young age.

(sniffles)

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post #13 of 20 (permalink) Old 03-08-2017, 02:12 PM
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Broken piston rings and 'easy-start' go hand in hand! I've Repaired 500hp marine diesels where Easy Start had been used..... NEVER EVER USE THE STUFF!

Jim

'83 Lead 80, '84 Lead 125, '52 Sunbeam S8, '09 Burgman 400 K8
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post #14 of 20 (permalink) Old 03-08-2017, 06:03 PM
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Lol, Easy Start -- that's how they call a C4-fuel-air mixture now

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post #15 of 20 (permalink) Old 03-08-2017, 06:17 PM
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Quote:
Originally Posted by captainfish View Post
this whole thread makes my heart sad.....
Sad that you had this happen to you at such a young age.

(sniffles)
Yeah makes me sad too to have this happen at such a young age. Broken Rings & Busted Things.
It reminds me of Elvis Presley, Jimi Hendrix, Janice Joplin, Buddy Holly, Ritchie Valens, J. P. Richardson(The Big Bopper), Otis Redding, Michael Jackson, and so many others!
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post #16 of 20 (permalink) Old 03-09-2017, 02:51 PM Thread Starter
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Thanks for spotting that for me Squeazel! I had checked ebay earlier and didn't see this. I think I got to it in time.
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post #17 of 20 (permalink) Old 03-09-2017, 05:03 PM
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Great! Always happy to help another burgusa member! I hope it works for you- now just a couple of gaskets from Bikebandit and you'll be on the road in a couple of weeks!

BTW- don't hone the cylinder- you don't want to break the coating. Just wipe it clean and put on a coat of oil before assembly.
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post #18 of 20 (permalink) Old 03-11-2017, 11:47 AM Thread Starter
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The jug and piston should be here late next week, gaskets were ordered yesterday and cost almost exactly the same as the cylinder/piston combo. Now I have time to clean up the head and throttle body. I have seen post about oil collecting in the airbox, mine had 175ml of oil in the bottom likely due to excessive blow-by after the ring broke. There is a drain tube with a check valve at the end that should take care of normal oil mist, I'll make sure that is clean and functioning before it goes back together. Too bad simple things like this are so hard to get to.
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post #19 of 20 (permalink) Old 03-11-2017, 03:05 PM Thread Starter
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Correction: That is not a check valve at the end of that drain tube, it's just a plug. It would seem as if a rubber duck bill would be a better idea so that any liquid could get out but bad stuff couldn't get in.
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post #20 of 20 (permalink) Old 03-11-2017, 03:27 PM
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Correction: That is not a check valve at the end of that drain tube, it's just a plug. It would seem as if a rubber duck bill would be a better idea so that any liquid could get out but bad stuff couldn't get in.
I'm sure EPA would not like that.
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