Took Burgie to dealer today. Noisy clutch and vibrations

[larrykennedy]

First post on this list. Took my 2008 Red Burgman 400 back to dealer Monday, Summerville, SC. Noisy clutch and vibrations. It is under warranty and a Service bulletin addresses the problem or symptoms. They are ordering the duct kit to increase cooling. Seems to me that this is treating the symptons and not the problem. Towards the end of the bulletin it says to replace the clutch if the problem comes back. Now that makes sense. I rode my Burgie from Summerville, SC last June to Dayton, Ohio. Rode up old highway 52 that runs from Charleston, SC to Canada through N. Dakota. 408 miles the first day of a seven day trip, 606 miles tthe last day back to SC. Total of 1606 miles in sven days, noy bad for a old fat guy..
The bulletin also addresses those scoots that are not under warranty. If the owner jumps up and down and yells %*#**)% then call the tech line for "special" approval..at least that was my "understanding"
I also have a Vespa GTV for around town.

PS...my spelling suks, please bear with me.
pps. sure hope I haven't violated any rules.
Larry

[Daboo]

Welcome to the forum! (Would you please add your location to your profile so you don't have to keep repeating it?)

You didn't break any "rules"...but you made a lot of friends! Especially with the comment about the Service Bulletin and out of warranty bikes having an option. Is there a chance you can get a photocopy of the SB? It would help a lot of people here to know what the wording really says. Not all dealerships are as good as yours.

Chris

[larrykennedy]

It is Suzuki Bulletin GV/AN No. 41A of November 2, 2009. My dealer, actually the cute counter girl, let me read it. It is the how to for the dealer along with part numbers. It does address out of warranty problems and gives the number to call, and does make reference to problems being repaired that are out of warranty. Sorry, I didn't get a copy, maybe tomorrow. Will try to figure out that profile thing.....

[larrykennedy]

I have a copy of the bulletin and I'm in the process of getting it posted.

[JohnK]

Larry brought a copy of the Service Bulletin over to me so I could scan it in for all to read.

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[happytech]

JohnK - Excellent job - thanks.

[Elliott Larron]

Did any body figure out where the #1 Hose,Cooling Duct Go at, on the picture is do not show where the intake front hose connect to.. is there a full pic somewere....

Elliott,

[BirdmanA1A]

Hey Larry !
Im in the Summerville / Charleston area all the time due
to my parents living in Mt. Pleasant. I want to do a run up coastal Rt. 17
through GA/ Savannah thru the Low Country into Charleston next time I go......
My Mom was born on the Battery so we arent Yankee interlopers..tee hee hee
Who is your dealer ?
My bike at about 1200 isnt noisy, but is definitely not as smooth as it was when new.
How pronounced were your vibes when you took it in ? Mine are just barely
noticeable but its worrisome since it seems to be a degenerative type thing.

Thanks, be safe !

[happytech]

Regarding the cooling hose intake, the hose starts at the gas tank - it just kind of rests there and then attaches to the cover over the filter. Not real high tech in placement, but seems to keep a lot of the junk out of the filter.

[larrykennedy]

Send me an e-mail the next time you are here. We have a scooter club and ride on Saturdays, usually, to a place to eat.
My Burgie began to talk about the 3k mark. It seems to impove as it warms up. My dealer is East Coast, they sell bikes, boats and guns....aint it great to live in the South!

[larrykennedy]

Day 17 since I took the Burgie in....No word from dealer ...
I did stop at the Honda dealer today in Orangeburg, SC. They have a Black 2008 Used Burgman 400 for sale. 24 (yes, 24) miles on it. Salesman said the buyer decided he was to short to ride it. Asking $4500(US)..said he would probably take an offer. My guess is that $3900(US) would buy it. Sounds like a deal.

[ted clement]

Thanks Larry for the Svc Bulletin; good to know what Suz is thinking. Personally, I don't think they have a clue as to what is causing the many issues with the 07-08 clutchs and are groping for ideas that might work. The bulletin implies that it is dust getting in the CVT and the hose is designed to eliminate that. I don't buy it. The garbage I've seen in mine are brake and perhaps belt dust; black nasty stuff. I can, however, see the value of the hose if you live in a very wet or very dry dusty climate. The trade-off, I think, is that it will reduce the free flow of air to the CVT and likely make the belt and clutch run hotter.

I've had the 08 and now an 09. The 08 had the famous "squeal" just before clutch lock-up; the 09 doesn't squeal, it "shudders" instead. Began that with only a couple thou on the speedo. The "hold the brake, rev it up" method eliminates the shudder only for a few hundred miles. When it begins to shudder again I'll take it to the shop so they can see what its doing. I want to pull it off first to see if I can diagnose the problem as I don't have much confidence in the shop; they're fond of saying "thats the way its supposed to be". It has to be either the brake shoe/s or the bell is out of round.

None of these issues particularly bother me. I'll prob eventually put the HIT clutch on and be done with it, but while its still under warranty I think I'll let them have a shot at it.

[BirdmanA1A]

I rode my Sportster year 'round in PA.
Salty road sploodge would make the belt squeal after you hit a
puddle. We used to spray PAM on the belt, and all was OK.
I know the belt has a slightly different function on the 400,
but it might be worth a try.
When my bike starts to squeal, I'll be the guinea pig

[tsc3047]

Interesting reading the bulletin. Obviously that cooling duct looks like more of a bottle neck leading to clean air. So the focus isn't on cooling but on cleaner air. That worries me. Because every time I tore apart my case and most recently to put in the DPS it was a mess. But not from external debris but from internal belt bust, and clutch pad dust. Now I haven't had noise but I did have some shuddering at times. The DPS seems to help with smoothness because if nothing else the RPM range feels better. But when I used my blow gun on the clutch housing the shoe pads themselves each and every pore on the pad was caked with compacted dust. For the first 1,500 miles since my tear down it's been silky smooth. I don't think this bulletin will address the mess.
Cleaner air is fine, but I really didn't see the need for the long duct. It seems it would now be sucking air closer to the warm enclosed engine area just to the rear of the fuel tank, and behind the radiator. I think what they really need is better movement in the CVT case of air and a better way to expel air and dust.

[emmettken]

Thanks guys for the service bulletin. I copied it incase I need it. No squeal or shudder yet,knock on wood,but my 08 has low mileage.

[larrykennedy]

23rd day that dealer has had the Burgie. Kit has been there for two weeks but that lack a tool to work on clutch and have ordered it. Said the warehouse was located in the midwest and had been shut down because of storms and was playing catch-up.
I also purchased a 48 month SEP for the same price as Oneida Suzuki and East Coast Power Sports said they would match the price for anyone who wanted to purchase one.
I do have a Vespa to ride while the Burgie is in the shop.

[larrykennedy]

The tool that was required for the clutch change came in from the Suzuki warehouse in Pennsylvania. It was billed for $238.00 and when they opened the box it was a tube of silicon and not the spring compression tool. It seems the WH now thinks the tool is mislabeled from Suzuki. 28 days Monday that the Burgie has been in the shop....Is Toyota the parent company of Suzuki?

[Daboo]

I got my new clutch and installed it myself. I bought two C clamps to hold it together thinking this large spring would send things flying otherwise. I didn't need them.

On YouTube, I saw a guy swap out a clutch without anything other than the impact wrench and socket. He simply placed the clutch on the garage floor. Sat down on a short bench. Put his feet on top of both sides and took off the nut. I tried it for putting the clutch back together. Piece of cake. The point is, the only tool you need after you take the clutch bell off, is a 55mm socket.

There's some bearings in there that can be replaced. But if the dealership is doing that, they'll have the tools to replace the bearings.

Chris

[larrykennedy]

They had the bearing tool but it was not for a 400.

[Shadow]

I noticed intermittent shudder on my 09 as well at around 3500 km around 2000 miles. Like you I also tried the hold the brake, rev it up method with the same results. As is t now winter here I have not had the opportunity to get it into the dealer. Armed with the service bulletin and your post I'll be making a trip to the dealer as well in the spring. I find the shudder a bit annoying but I still love the bike.

[Mike99]

Hi All,
I have a 2008 K8 and have the cluthch squeal/vibration problem also. I spoke to the dealer previously and am due to go for the first service soon, so hope to get this resolved while bike is under warranty. The SB is useful and at least recognises the problem, but I note this is issued by Suzuki USA. Does anybody know if Suzuki UK has issued a similar bulletin?

Mike

[Desert Rat]

Interesting reading the bulletin. Obviously that cooling duct looks like more of a bottle neck leading to clean air. So the focus isn't on cooling but on cleaner air. That worries me. Because every time I tore apart my case and most recently to put in the DPS it was a mess. But not from external debris but from internal belt bust, and clutch pad dust. Now I haven't had noise but I did have some shuddering at times. The DPS seems to help with smoothness because if nothing else the RPM range feels better. But when I used my blow gun on the clutch housing the shoe pads themselves each and every pore on the pad was caked with compacted dust. For the first 1,500 miles since my tear down it's been silky smooth. I don't think this bulletin will address the mess.
Cleaner air is fine, but I really didn't see the need for the long duct. It seems it would now be sucking air closer to the warm enclosed engine area just to the rear of the fuel tank, and behind the radiator. I think what they really need is better movement in the CVT case of air and a better way to expel air and dust.

+1......... with Ian. I'am one of the lucky ones as mine has nerver had the noise or shudder Problem is the clutch and belt dust that stays inside the CVT housing. Even the DPS sliders can get gumed up with that dust. Had it when I pulled mine apart with the 21 gram ones that had 4,000 miles on them.
I'm going to pull my CVT cover and variator apart every oil change to clean the dust out.

[Daboo]

...I'm going to pull my CVT cover and variator apart every oil change to clean the dust out.

Good time to change the Final Drive oil while you're in there.

Chris

[larrykennedy]

Day 31 and the dealer said that the tool is in the mail...Is that anything like the check is in the mail?

[larrykennedy]

After 30+ days the Burgie is ready. The tool came in yesterday and they had it ready late today. I will pick it up tomorrow. The mechanic told me he drove it and it is a lot smoother than when it came in. Will have a follow-up report in a few days.