Broken ring - Suzuki Burgman Forum
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post #1 of 39 (permalink) Old 03-07-2017, 04:33 PM Thread Starter
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Broken ring

The engine stalled while stopped at a traffic light last week and would not start (2013, 400). When I got it home I found good spark, fuses were ok and a shot of starting fluid while cranking had no effect. Looking for a reason for poor compression I checked valve clearances, within tolerance but toward the tight end. Digging deeper I found the top ring broken and the bore gouged pretty bad. Sometimes you can find a complete engine on ebay for about what Suzuki wants for a cylinder and piston. Not sure what my next move will be.
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post #2 of 39 (permalink) Old 03-07-2017, 04:37 PM
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****, that sucks. How many miles on it?


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post #3 of 39 (permalink) Old 03-07-2017, 04:43 PM Thread Starter
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9000 but I've only put on the last 2000.
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post #4 of 39 (permalink) Old 03-07-2017, 04:49 PM
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9000 but I've only put on the last 2000.
that sucks even more ):


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post #5 of 39 (permalink) Old 03-07-2017, 05:31 PM
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That is a shame about the broken ring, very unusual for one of these engines, since you have the top end all apart, you might as well buy the parts to fix it, if eveything else is OK with the engine. Use standard piston if the bore can clean up with a glaze removing hone, OR have it bored out to clean up the gouge. If you chose to bore, buy an oversize piston first and hand it to the machine shop, so that they can bore and fit the cylinder to match the piston with proper clearance.

You can buy a standard piston with rings and wrist pin (83mm bore) for $35.99 w free shipping here:
https://www.aliexpress.com/item/Moto...2-237841289718
They also have OVERSIZE piston/ring sets if you choose to bore out the cylinder.

They also have the cylinder base gasket and Cylinder head gasket for $14.24 w free shipping here:
https://www.aliexpress.com/item/Moto...0-1d16f851b775

Always double check parts to be sure that they fit your make, model and year.

I have bought a few things from them, and what I have bought has been good so far. I bought a drive belt for $114, I'll be putting it on in a week, and the deals on starters and such items look to be unbeatable prices.
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Last edited by E.D.; 03-07-2017 at 05:44 PM.
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post #6 of 39 (permalink) Old 03-07-2017, 08:47 PM Thread Starter
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Great information, thanks. That gouge in the cylinder is .61 mm deep (.024 in) as close as I can measure. Having the cylinder bored and honed to that depth will have an aluminum piston running in an uncoated aluminum cylinder. Will that work ok?
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post #7 of 39 (permalink) Old 03-07-2017, 08:55 PM
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Might want to try nikasil plating for the cylinder, a bigger bore piston kit is available from Vertex.
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post #8 of 39 (permalink) Old 03-07-2017, 09:29 PM
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You Must have had A Defective Ring That's All, Manufacture Error

Bolzen, there Big Bore for are 400's, Don't look like theres room for Much but 450cc

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post #9 of 39 (permalink) Old 03-07-2017, 10:50 PM
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I dunno all sizes available. Should consult the manufacturer.
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Last edited by Bolzen; 03-07-2017 at 10:53 PM.
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post #10 of 39 (permalink) Old 03-08-2017, 04:42 AM
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You can check with the machine shop and see if they can do the cylinder coating, or it they know where to send it to get it done.
I have not seen the cylinder bore myself, so I was wondering if it is an aluminum bore or a steel lined bore? If it is aluminum, I would certainly see the need for the bore coating. Myself. I love steel cylinder bores, as they tend to give less trouble and long service life.
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2006 Burgman AN650 K6 White (The White Knight)
2008 Burgman AN400 K8 Red (The Red Baron)
1977 Honda CB 750 Silver
1977 Penneys 50 Moped Red
1974 Yamaha 360 MX Yellow
1973 Yamaha 80 MX Silver
1972 Honda QA 50 Red
1971 Kaw Bighorn 350 Enduro Brown
1970 Kaw H1 500 Red
1968 Kaw 120 Scrambler Red
1968 Kaw 120 Scrambler Blue
As far as the cages go, I've had all kinds,
but Toyota's Rule, no doubt!
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