Drive Belt replacement - Suzuki Burgman Forum
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Old 08-17-2010, 08:06 PM   #1 (permalink)
Ino
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Default Drive Belt replacement

Okay, heres the situation, I'm not mechanically inclined and its way past time (according to the manual) for me to change the drive belt. My local mechanic has doubts on wanting to tackle this job, either he feels that he does not have the expertise to do a good job and he has only seen one super scooter such as this, mine. Now he can do the basic stuff which is good for me (ie, tires, etc).

My question: Anyone live in California with a Burg 400 that has taken to their local dealer or shop that has successfully replaced their drive belt? If so, please let me know the shop or dealer. I feel its worth it to take the burg to a place that have seen a couple of these scoots and can do a good job.

Thanks in advance for any assistance.
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Old 08-17-2010, 09:44 PM   #2 (permalink)
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Default Re: Drive Belt replacement

I know you were looking for a recommendation for a different mechanic, but you may wish to show your current mechanic some of the tutorials and videos we have for the procedure. It wasn't nearly as hard and complicated as I thought it would be and I'm not a mechanic.

Chris
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Old 08-18-2010, 01:00 AM   #3 (permalink)
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Default Re: Drive Belt replacement

The key is the electric impact gun, then it is simple. Without it, flippen impossible. GREAT videos.

Bob Weis
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Old 08-18-2010, 07:35 AM   #4 (permalink)
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Default Re: Drive Belt replacement

Your mechanic maybe concerned about damaging the plastic panel that has to come off. Apart from that it is a reasonably straight forward procedure. If you do tackle it yourself then be sure to number the bolts that hold the CVT cover on as they are various lengths. Check out the threads and videos is good advice.

Cheers,
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Old 08-18-2010, 11:27 AM   #5 (permalink)
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Default Re: Drive Belt replacement

Ino, if you've had the final drive oil replaced, then that's all the body panels that need to come off.

I think in one of the videos, it showed the entire left side body panel coming off. It isn't necessary. Under the mat for the passenger's footrest, there are two screws, two bolts and a body pin to remove. From there, pull that out enough that the tongue of the panel will slip under the metal brace on the body and it holds it out of the way enough to get your hands in. From there, it is simply removing the five bolts that hold the plastic outer CVT on, and the 10 or so bolts under that that hold the inner CVT on. All that has to come off if the final drive fluid is changed at 7500 miles.

From that point, it is one nut holding the variator on. (Just make sure when reassembling it to turn the variator several times to get the belt seated prior to torquing the nut down.

Chris
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Old 08-18-2010, 12:12 PM   #6 (permalink)
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Default Re: Drive Belt replacement

You can do it without removing any of the body tuperware. Only plastic that has to come off is the CVT cover. After that it's not a big deal. So have you ever had the oil changed in the final drive ? by the book it's every 7,500 miles. I change mine every 10k.
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Old 08-18-2010, 12:21 PM   #7 (permalink)
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Default Re: Drive Belt replacement

Ino,
I, too, feel mechanically inept. With the generous and patient help and encouragement from Daboo (and Mitch's videos) I was able to do the job. With the electric impact wrench from Harbor Freight ($49) I was able to skip using the variator tool.

You also might want to consider replacing the roller weights with 18gram DrPulley's, while you're at it. I really like the performance change. If you can afford it, you can also replace the OEM with a HiT clutch. I'll be doing that soon. If you do a site search on both of them; you'll see some positive reviews.

I'm not the best to give advice but if you have questions, I still have the pms from Daboo which might be helpful.
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Old 08-18-2010, 01:31 PM   #8 (permalink)
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Default Re: Drive Belt replacement

Guys,

Thanks for the input but I to be perfectly clear, I am a "rider" and the only thing I'll do is change oil and basic pre-ride checking and tightening, beyond that I prefer the techs with the know how and correct tools to dig into the burg.

I may have found the dealership that has serviced and repaired about a dozen burgs over the years and its only about a two hour ride away, I can make a nice day of the ride. I'm just pleasantly surprised the drive belt lasted this long .
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Old 08-19-2010, 02:49 PM   #9 (permalink)
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Default Re: Drive Belt replacement

I am in Mira Loma.

Bring it to me and I will show you how to do it. I have the tools. Time is short but it should take no longer than 30 minutes. If you are changing your drive belt, how is the clutch, clutch bell, and final drive oil?
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Old 02-15-2011, 09:38 AM   #10 (permalink)
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Default Re: Drive Belt replacement

Where are the videos for replacing the drive belt on a 400 that are referred to in this string of threads?

Thanks..Tom
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