CVT problem - maybe

[Colchicine]

The directions here specify the side stand:
http://burgmanusa.com/bkb/650+CVT+Info# ... opper_Bolt

LeDude took the lower leg shield off for clarity of the video. With that removed, accessing the bolt is just as easy on the side stand. Permission granted to use the side stand!

[Ken]

Side stand is fine and no need to remove any Tupperware. I would set the brake. Don't take any chances of movement of the rear tire. A 2 minute job at most.

[Buffalo]

And do not turn on the key while the bolt is out.

[Colchicine]

I fixed that part just now, Craig. Thanks.

[SteveE]

My bolt came into my local stealership so I picked it up this afternoon. It took longer to find the proper wrench (Thanks Son ) than it did to swap it out. BTW I did it on the side stand.

[zeco]

Was curious about when Suzuki actually changed to new bolt. In the fisch, it shows new number at least back to 2007 with a red parenthesis around text saying it replaced the old number. Now this still clouds my mind to when it actually changed. I got down on the ground with a mirror and mine has the number on the head (either a 9 or could be a 6). So, I would still check it in the future. I surte is easy to get down to look at it, but it gets harder everyday to get back up. Wonder it Harbor Freight has a butt jack on sale.

Would be curious what is found when looking at older bikes by model year.

[SteveE]

My old bolt had no marking on the head, the new one has a 6 (I assume it to be a 6 as the dot makes it a six) stamped into it.

[hosejockey982]

Is this the pulley stopper bolt?

Yep...

[Dave_J]

Was curious about when Suzuki actually changed to new bolt. In the fisch, it shows new number at least back to 2007 with a red parenthesis around text saying it replaced the old number. Now this still clouds my mind to when it actually changed. I got down on the ground with a mirror and mine has the number on the head (either a 9 or could be a 6). So, I would still check it in the future. I sure is easy to get down to look at it, but it gets harder everyday to get back up. Wonder it Harbor Freight has a butt jack on sale.

Would be curious what is found when looking at older bikes by model year.

Terry, Is it a 6 from the right side? Go over on the left side and see if its a 9.

I havent pulled the one from my 03, nor have I checked the 08's one ether. I'm slipping.

[Buffalo]

The bolt I took out of my 07 was the newer silver color but it did not have any numbers stamped on it.

[Tromper]

Just an update for folks. My k6 had the gold bolt & some minor damage at 17500ish.
The replacement arrived & I installed it, torquing to about 35 NM/312 in/lb's /26 foot lb's.
No discernible difference in the minute or so I ran it, if it blows up I'll let ya know
The replacement was the silver one. I'll check it next oil change around 20k

[apapak]

HELLO I WROTE THIS POST TO INFORM YOU ABOUT MY PROBLEM WITH SHAFT STOP BOLT.


Primary pulley stopper bolt was not strong enough and almost “melt” by the fraction in the cutaway. AS A RESULT has "opened" the cutaway . (you can se the damage in pics included).

http://img218.imageshack.us/g/burgman65022010060734.jpg/

THIS DAMAGE COST ALMOST 1000 EUROS IN GREECE AND WAS NOT MY FAULT. WAS BOLT FAILURE!!!!!!!!!!!!!!

PLEASE SPREAD TO YOUR MEMBERS THAT THIS BOLT SOULD BE PERIODICALY CHECKED.
FORCE SUZUKI USA TO GIVE GOOD WILL WARANTEE.

I made my complains to SUZUKI EUROPE

APOSTOLOS GREECE

Please forgive any mistakes in my English!!!!!!

[Dave_J]

Apapak, we are aware of these problems on this forum and have a posting going on it. See: viewtopic.php?f=4&t=46913 and viewtopic.php?f=4&t=44912 .

Is your 5,000 Milage Km's or Miles? If 5,000 Km's thats 3,000 miles, too soon to have any problems but it does happen.

Thank you for posting pictures. Yes Suzuki should be paying for these failures as it is a design flaw and is known to exist. They have changed the part number to a new bolt becouse they know they messed up. So there should be a recall, paid for 100% by Suzuki.

This may get moved to that other post by a Modertor as it is in the same topic type.

And your English is fine, I speak American English and have a hard enough time understanding what my Daughter says.

[Colchicine]

I'm very sorry to hear about your problem, but your pictures help me understand more about the shape of the bolt after it has been worn. I plan to write a detailed article about this issue in the coming weeks and it will be posted here:
http://burgmanusa.com/bkb/650+CVT+Info

May I have permission to use your pictures in the article? They are the best that I have seen yet!

[LeDude]

apapak,

sorry to hear about the failure, but it does seem to occur, thanks for the pics, they will help a lot of people get a sense of how the bolt works and how it is held in place once inserted, it's easy to understand now how the notching is occuring :



I replaced mine at 32k miles as a precaution on my 04 STD., will probably be checking / replacing it every 15k-30k miles...



DIY - CVT Primary Pulley Bolt Replacement

what's puzzling in your case is the low mileage on your scoot if 5k is the actual ODO reading be it in KM or Miles...

somebody had hinted that Suzuki may have issued a recall notice on this bolt in Europe / England, but it was part of previous thread, not sure if Suzuki has actually done that.

all the best...

[apapak]

I'm very sorry to hear about your problem, but your pictures help me understand more about the shape of the bolt after it has been worn. I plan to write a detailed article about this issue in the coming weeks and it will be posted here:
http://burgmanusa.com/bkb/650+CVT+Info

May I have permission to use your pictures in the article? They are the best that I have seen yet!

yes you can use my pics!!!!!

We should inform burgman owners about this failure.

My bike has 31000km. here in greece a lot of burgs have the shame catastrophic problem close to 30000 to 40000km.

I think that we should check this "little think" periodicaly in every 12000 km

Thanks for your comments.

[GoldBurg]

Headed up to the mountains and I've got 30K miles (check my sig, I can't remember...) and no one has changed my bolt that I am aware of. I needed a good excuse to buy a torques wrench anyway...
Removed bolt with no problem. Sorry, pictures I took would make you question how I got the bolt out, they were so bad (the pictures, not the bolt). Wear on 2 sides almost 180 degrees apart, one side worse than the other. Almost notching a square out, but not very deep at all. The other side just faint signs of wear. New bolt on order but not here yet, so I reinstalled this one. No worries...Strange thing is, I've got an 07Exec and I've got the new hardness bolt. At least it's the silver tone and not the gold.
Will check regularly - and will purchase another camera soon...

[650Scoot]

It is rumored that the CVT Stopper Bolt may be defective and should be removed inspected/replaced. I removed mine and found the end of the bolt to be pitted and discolored. I replaced it with the revised bolt.

Supposedly Suzuki had released an advisory however, my dealen knew nothing about it.

My mechanic advised that the key should be removed from the ignition when removing/replacing this bolt otherwise, the CVT assembly will become out of sync. resulting in $$$$$$$$$$$.

What is the function of the CVT STOPPER BOLT?

Will

[Buffalo]

The function of the stopper bolt is to hold the position of the primary pully back plate when the ECM turns the worm gear to adjust the ratio of the pully. Without it the transmission could not shift gears.

[RobinB]

My dealer in Spain told me today that there is zero stock in Europe.

Delivery 8 days ???

If you think you may need one, get it on order sooner rather than later.

[malahy1501]

Finally got to mine today...minimal wear compared to others...Almost 8 years 25,250 miles...guess those "noisy" 2003's have something going for them
All wear marks were facing the rear of the bike...nearly pristine through the other 270 degrees



Bill

[NormanB]

I ordered one this week. Back order.

[benbeaux]

Replaced mine a few minutes ago. Not chewed up hardly at all & much like malahy1501's.
15,400 miles.
http://farm5.static.flickr.com/4051/469 ... 9945_m.jpg

[RobinB]

I ordered one this week. Back order.

How long did they quote you for delivery ?

[Scootermikie]

I ordered one this week. Back order.

I ordered a spare pulley bolt and 2 oil filters from the link below. Placed my order about 2 weeks ago and my order arrived in less than a week. I called them to see if the pulley bolt was in stock before placing the order.

http://www.suzukipartsoutlet.com/fiche_ ... 1748-10G10