Suzuki Burgman 400 Problems – Is This Scooter Reliable?

The Suzuki Burgman 400 is a popular scooter for its promise of a comfortable ride and great fuel economy. With a 400cc engine producing around 30.5 hp and 26.5 lb-ft of torque, it does hold a pretty decent performance.

The popularity of the scooter, however, is marred with certain issues. Most of these are centered on its transmission which could spell plenty of issues in its performance and fuel economy. We will bare it all here to help you decide whether this is worth your money or not.

CVT Slips

The primary complaint about the Suzuki Burgman 400 has to do with its continuously variable transmission (CVT). According to affected users, major problems in this part can occur as early as 1,000 miles. This leads plenty of people to believe that maybe Suzuki is not yet ready for this kind of transmission judging from the way it's designed.

So far, the giant motorcycle manufacturer has not owned up to this issue. That means people encountering this problem are left to find the solutions themselves, so let's try to diagnose the issues here ourselves.

Aside from the possible design flaw on the part of Suzuki, CVT slippage can be caused by a lot of things, including low fluid levels, dirty fluid, or worn parts. Checking and replenishing the fluid level is the most basic solution to this.

The process is something that you can do yourself, but it's definitely time-consuming and confusing if you are new to the task because of all the parts you will come across before gaining access to the oil filler plug, check level plug, and drain plug. If you want to save yourself from all the trouble, you can turn to a mechanic to handle everything for you.

Here are the basic steps to fill up the transmission fluid:

• First off, you have to remove the lower leg panel of the bike where the transmission is located. It's the plastic covering on your left leg if you are riding the motorcycle.
• Locate and remove the transmission check level bolt in between the transmission oil filler plug and the drain plug to inspect your fluid levels. Fluid should flow out from there it if it's filled.
• If the fluid level is low, that's a sign to add transmission fluid.
• Remove the transmission oil filler plug to access the hole where the transmission fluid should go in.
• Add transmission fluid in that tight hole using a funnel or a large syringe with a narrow hose to get all that liquid in.
• Again, the fluid should flow out of the hole in the check level plug if it's already full.
• Put back the bolts and the plastic panels you removed earlier.
• Start the engine and let it run for a few minutes. You should see significant changes in how your transmission functions if the issue was only low fluid.

If you noticed that the transmission fluid coming out from the check level hole is dirty, it's a sign that you have to drain the old batch and fill it with a fresh one. This can happen if the scooter has been sitting in the garage for a long time, or if it is regularly driven in dusty or dirty conditions. Draining and refilling the transmission with fresh fluid will usually solve the problem.

Here are steps to do this:

• Repeat the process of gaining access to the transmission reservoir by removing the leg panel covering it.
• Along the way, make sure that you have placed a pan under it to catch the fluid that you are about to drain.
• In the bottommost part is the transmission drain plug, which you will have to remove. The dirty fluid should flow out as soon as you remove it.
• Wait until all the fluid is drained in the pan.
• Put back the drain plug when you're done.
• Detach both the check level and filler plugs before proceeding.
• Refill transmission with fresh transmission oil until it flows out of the check level hole.
• Reassemble all the bolts and the panels you removed earlier.
• Start the scooter and check for leaks. If you notice any, simply retighten all the bolts in the transmission reservoir.
• Test ride scooter and check for proper operation.

If that doesn't solve the problem, then the CVT system will need to be cleaned or serviced. In some cases, worn parts like the clutch, CVT belt, or pulleys may require replacements. However, if the whole system has already been compromised, the entire transmission system either has to be rebuilt or replaced.

If you're experiencing CVT slipping on your Suzuki Burgman 400, it's best to take it to a qualified mechanic for diagnosis and repair. Ignoring the problem can lead to more serious issues, so it's best to nip it in the bud as soon as possible.

CVT Squealing

This is oftentimes an aftereffect of transmission slippage. However, due to the overwhelming complaints about this issue, we think it deserves its own spot here. Aside from improper lubrication, the issue mostly stems from the CVT belt issues.

Improper tensioning of the belt is the most common source of the squeaky sound in the CVT of the Burgman. The belt should be snug but not too tight. If the belt is too loose, it will slip and squeal when under load. If the belt is too tight, it will wear prematurely and may eventually break.

Incorrect alignment of the pulleys can also cause the CVT belt to squeal. The pulleys should be aligned so that the belt runs straight between them. If the pulleys are misaligned, the belt will run at an angle and wear prematurely.

Damaged CVT pulleys can trigger squealing noises, too. The pulleys may be damaged if they have been impacted hard from collision or hard objects. Damaged pulleys will not grip the belt properly and may cause the belt to slip and squeal.

The best way to prevent the dreaded CVT belt squeal is to regularly check the tension of the belt and keep the pulleys properly aligned. If the unusual sound persists, it may be necessary to replace whichever part is causing the noise.

Faulty Clutch Bell

If your Suzuki Burgman 400 is experiencing issues with its clutch bell, there are a few potential causes. The problem could be due to the clutch itself, the transmission, or even the engine. Here are a few potential solutions to investigate if you're experiencing problems with your Burgman's clutch bell.

The first thing to do if you're having issues with your clutch bell is to check the clutch itself. Make sure that the clutch disk is clean and free of any debris. If it's dirty, clean it off with some brake cleaner and a rag. Also, check to see if the pressure plate is warped or damaged in any way. If it is, it will need to be replaced.

If the clutch is in good condition, the next thing to check is the transmission. Make sure that the transmission fluid is at the correct level and is clean. Dirty transmission fluid can cause a number of problems, including damage to the clutch bell. If the fluid looks dirty, flush it out and refill it with fresh fluid.

The last thing to check if you're having issues with your Burgman's clutch bell is the engine. Make sure that all of the engine's mounting bolts are tight and that there are no leaks in the engine itself. If everything looks good with the engine, the problem likely lies with the clutch or transmission.

These are just a few potential solutions to investigate if you're having problems with your Suzuki Burgman's clutch bell. If you're still experiencing issues after trying these solutions, it's best to take your bike to a qualified mechanic for further diagnosis and repair.

Electrical Issues

Electrical issues are very common in the Suzuki Burgman 400. The known symptoms of these include the bike not starting, the headlight flickering, and electrical accessories not working.

There are a few things that can cause these problems. A loose or damaged battery terminal is one possibility. Another is a problem with the charging system, which could be caused by a faulty rectifier/regulator, a bad stator, or a weak battery. The part or components where your electrical issues are originating should be replaced immediately.

When working on any electrical system, it is important to use caution. Always disconnect the negative battery terminal before beginning any work. This will help to prevent any accidental shorts.

If you are not comfortable working on the electrical system, it is best to take the bike to a qualified mechanic. They will be able to properly diagnose and fix the problem.

Conclusion

As far as the problems uncovered here, we therefore conclude that the Suzuki Burgman 400 certainly has major issues. The faulty transmission alone should be enough to drive away any reasonable buyer. What's worse is that it could happen with only a little mileage. Add to that the electrical problems that could potentially trigger all sorts of extra issues including fire, and it becomes more trouble than it's worth.

Don't get us wrong because Suzuki is such an amazing brand that's known for the quality of its products. For the Burgman 400, however, we will have to give this one a hard pass. Better settle for other alternatives from Suzuki or other brands.