CVT problem - maybe

[hosejockey982]

Hey Kory, as far as I could tell, the bolts were identical. I figure if I can get another 50 000 km (prolly this year 2010) out of this bike it'll be time to start thinking about another (next yer) one. I'll prolly go with another 650 Burgman too. I already know how to maintain it and modify it to my liking.

[herbeckg]

I replaced my Bolt with a new one today. The old one has no marking on the head indicating hardness. The new bolt has the # 9 on the head. So Suzuki replaced it with a much harder one.

[RobinB]

Did they tell you the 9 means a harder version ?

If that is the case it would be easy for every to have a peak under the bike to see if thats the case.

[Buffalo]

I guess this thread has caused a run on the bolts. I ordered one from Ron Ayers over the weekend and got a notification today that the bolt is on back order.

[Colchicine]

haha, I ordered THREE last Thursday from Ron Ayers. One for me to use, one for another local Burgman owner, and one for a spare. I haven't gotten a confirmation yet so...

[Buffalo]

So your the guy that ordered up all their stock

[herbeckg]

I got mine from bikebandit.com. No problem.

[Hans Von Scrofula]

Also got mine today. No shortage here in the UK apparently.

[benbeaux]

Ordered mine last week from the local stealership.

[Buffalo]

Changed my bolt out today. Mileage is 48,731 miles. Both the bolt that came out and the new one are a silver color. The notches in the end of the bolt were very visable. My camera does not have much of a macro lens so these were the best closeups I could get.

HPIM0922.JPG (18.64 KiB) Viewed 2317 times

HPIM0923.JPG (14.56 KiB) Viewed 2317 times

Edited to add, notice the little notch that was starting to develop between and slightly below the two notches at the end of the bolt. I'm not sure what is causing that. It has a kind of half moon shape

[gdawg]

Mine is on back order. Hope it comes in soon as yours has.

[Hans Von Scrofula]

This just in from the parts guy at my local stealership.

Quote

'As from your recent visit and the gentleman who's (very badly looked after
and rusty) bike was in the other day. Suzuki have issued a new service
bulletin regarding the bolt in question, I believe the bolt now has to be
inspected for wear every 4.5k service. If worn it has to be replaced during
the service. I'm not sure if this has rolled out globally but it does show
that Suzuki (GB at least) have acknowledged the issue. Obviously a lowly
parts assistant such as myself cannot speak for Suzuki and I'm sure that
regular inspection of the bolt should be regarded as no more intimidating
than simply checking if you need new spark plugs etc. just thought I'd let
you know that feedback from dealer and customers does appear to reach Suzuki
and that they do look into such claims'

[Colchicine]

WOW, that's great information! I wish there was a way to get our hands on the Service Bulletin to see exactly what it says.

I'd also like to point that checking it every 4,500 miles seems like overkill, much like the spark plugs, etc.

[Buffalo]

Might be overkill but since it only takes about 2 minutes to do it I think I will just add it to my routine.

[Dave_J]

Now it would be nice to know it there was any room at the tip to install a longer bolt. You can have a bolt made for about $20 - $40 at about any length and hardness. I would like as long a bolt as possable with the tip surface hardened.

Like how deep is the slot in the CVT and how much of that bolt fits in that slot? Over the years I have seen "Stop Bolts" just bearly ingage the item its to stop and as the item ages they slip.

Could we install a longer bolt with a Jamb Nut to lock it in place??????

[Buffalo]

The slot in the pully that the bolt fits into is not very deep, maybe 1/8 inch. As near as I can tell the bolt bottoms out in the slot and one of longer length would not fit.

[Securityman]

Hello everyone, I had the same problem with the CVT and my mechanic he fixed me with staff € 1750 uro had to change everything without the CVT belt because he had broken a primary pulley bearing.

is a big problem and fix it had to remove the engine

[LeDude]

ordered a couple of these bolts today from my favorite local SuziQ dealer... the online inventory system said, limited supplies on hand, possible back/ordered...

There must have been a huge rush on these... I think I will replace mine every 15k miles...
Worth doing as a preventive measure for around $4.95 a bolt.

Will put together a DIY doc along with an accompanying video when the bolts come in...

good info gang, thanks...

[ybbor]

Just swapped out the bolt... and I have the same damage at only 15300 km. I am now convinced this must be an inspection every oil change you do. We have an AN650K7 as well with 12000 km and will be inspectimg shortly.

Also I did mark the bolt indicating where the front of the bike is relative to the tighten position. The notch damage appears to be the edge facing the back of the bike.

[cmn1771]

Hello everyone, I had the same problem with the CVT and my mechanic he fixed me with staff € 1750 uro had to change everything without the CVT belt because he had broken a primary pulley bearing.

is a big problem and fix it had to remove the engine

add this one to the failure list. thats about $2400 US. and about 12000 miles US. (19000 km)

-matt

[LeDude]

The bolts finally came in so I swapped mine out just out of curiosity to see what it would look like. The damage was very minimal on the bolt, nothing that could cause the bolt to fail anytime soon after 33k miles...

I made a quick DIY with an accompanying video to do the procedure, pretty straight forward, should take about 10 minutes at best:

DIY - CVT Primary Pulley Bolt Replacement

[Buffalo]

LeDude, good work on the video . Only thing is I found it funny that it took longer to watch it than it took to actually change the bolt.

[LeDude]

LeDude, good work on the video . Only thing is I found it funny that it took longer to watch it than it took to actually change the bolt.

alas such is the nature of instructional material... it's really for the new DIYers that may want to do the job... boy your are fast... under 3 minutes to do the whole thing...

I just realized that I forgot to mention to put the rear brake lock on in the video.. will edit it tonight when I get back home..

PS: Just updated the video with an annotation, like the new feature in Youtube, makes for easy quick corrections/additions.

[Buffalo]

I cheated, I didn't take of any body panels . Set parking brake, pick up wrench, unscrew bolt, screw in new bolt , torque, put tools back on hangers over work bench, about 2 minutes.

[LeDude]

I wanted to show the location of the bolt with both the tupperware on and off, so I took advantage of the effort to clean my CVT filter.

It took me about 30 minutes to do the entire mise en place, removing the right side leg cover and filiming etc...

But the bolt replacement itself shouldn't take more than 5 minutes at best.

One doens't have to remove anything to do this upgrade, just be sure not to burn yourself if your exhasust hasn't had time to cool down.