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2006 Burgman 400 - Silver - 8600 miles - and climbing !
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Discussion Starter · #1 ·
....the foam element is totally gone...but the plastic circular cage remains.

Stubborn screws came off after soaking overnight with PB Blaster & using Large JIS / Phillips bit on Ryobi Impact driver.

Some AN400 Pros on here say this is just to filter out bugs sticks & rocks.

Others say finer dirt & dust.

I think the truth is it should filter but allow good air flow.

This idea is a simple $.97 wire mesh kitchen sink strainer.

Perfect size to go over cage & fit flat around it. Just bore 2 screw holes thru & attach.

If you're of the 'filter it tight camp' then there looks to be room for a thin layer of foam in between mesh & plastic cage.

Some said they were gluing screen door material onto the plastic cage with Elmer's glue and 'its done stayed put' many miles.

Which only goes to show "there's more than one way to skin a cat".

(My cats retreat when they hear me say that...)
Wood Rim Circle Fixture Auto part
Tableware Dishware Grille Table Plate
Hair Eye Circle Font Electric blue
 

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2006 Burgman 400 - Silver - 8600 miles - and climbing !
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Discussion Starter · #8 ·
Very good input. Hmmm

The East Texas Powersports service manager I spoke to yesterday - he pointed out that nearly ALL their side by sides & UTVs are CVT equipped.

Think of the dust & nasty low speed & loaded conditions they operate in !

Quite the opposite of a modestly loaded, low to moderate dust @ highway speeds evironment our Maxi-Scoots live in.

He said their CVT filter layout is normally a fine mesh screen - probably quite stringent to keep dirt out.
Maybe their airflow needs over belt etc are less, so the more restrictive filter is perfectly fine.

Just thinking out loud here.

I wonder if upgrading to the Higher Performance Dr Pulley 21 sliders in our Variator will lengthen CVT maintenance intervals versus stock ones.

Obviously there are a ton of variables in this equation !

Cheers - David

PS: Is this the filter for the Majesty 400 CVT :

Plastic Camera accessory Metal Rectangle Electric blue
 

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2006 Burgman 400 - Silver - 8600 miles - and climbing !
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Discussion Starter · #10 ·
Yes good point.

Main diff I see is prob that an auto serpentine belt has lots of underhood airflow.

This belt in running enclosed and gets pinched by variator - that would be heating up pretty good, so air has to flow thru for max longevity.

I agree don't overdo filtration.

I would enjoy finding out how small scooters like 50 - 125cc Japanese & China air cooled ones handle their CVT airflow filtration.

Course I dont own one so that'll have to wait.

Unless someone here knows.

TY - David
 

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2006 Burgman 400 - Silver - 8600 miles - and climbing !
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Discussion Starter · #19 ·
If I bought a scooter and saw a kitchen strainer where the OEM CVT air filter should go (I just replaced mine a few days ago), I'd think "jeez, what the heck else have they jury rigged on this thing?"
Before you criticize, please consider:

As my title says, "improvised", implying making up for a lack of immediate local supply.

If they're not on hand when you have it apart & have a time frame on re-assembly, what else should one do ?

Several others here have said they did their own improvised method, one glued screen door material on with Elmer's, another used a wet + dry vac filter.

Quite sure owners do it, due to scarcity of part & ease of making a substitute.

BTW, mine is hidden under the black louvered grill, now hidden under the outer Tupper ware.

They're simply not visible, just as the completely toasted OE wasn't to me prior to disassembly, so how could such dissaude you ?

I only saw 2 listings for OE part 1 from eBay & 1 from Partzilla:


Seems to list every model but my 2006 AN400


That last one seems like mine.

But can't wait that long.

Best regards,

David in Hot Hot Texas
 

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2006 Burgman 400 - Silver - 8600 miles - and climbing !
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Discussion Starter · #21 ·
Dang that's very very nasty fluid.

Hope stuff isn't damaged lol.

I'm done with the tune ups & mechanical ✔ and now fluids filters all new.

Supposed to be leaving in 5 days and needed accessories are all ordered:

Cruise control throttle lock
LED Bulbs
50L Dry Bag
Windscreen Extension Diverter

Man the bike is PURRRRRING after my 70-75 mph cruise to Lufkin - a 60 mile to round trip.

I'm probably blowing out decade old cobwebs...this bike may never have been ridden hard as I just pushed it.

Idle is smoother & acceleration more fluid.

The new tires Shinkyo brand are stellar for handling & suspension confidence.

Like a whole new bike now !
 

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2006 Burgman 400 - Silver - 8600 miles - and climbing !
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Discussion Starter · #23 ·
Thats certainly looks like the one my yamaha majesty 400 and tmax 500 had.
I'm sure as I got it searching using Yamaha Majesty CVT filter.

That looks like a much more serious filtration effort than on our Burgman

I wonder why ?

Did / do you note any diff in how the CVT works on each Scooter in comparison ?

A curiosity to my engineering sense....

Somebody here was saying the Burgman has the longest Factory belt interval at 14,500 miles, so somethings working alright, in any case !
 

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2006 Burgman 400 - Silver - 8600 miles - and climbing !
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Discussion Starter · #26 ·
Very good to know gentleman.
I've got high respect for both brands & have owned several diff Yamahas & Suzuki's.

I must say that this Burgman is really enjoying coming out of retirement.

Everything that felt weird or reluctant or grabby is now gone - she feels like elastic smooth & powerful.
That rattley sound I believe has disappeared.

My rank amateur guess is it was a formerly rogue Variator roller, now behaving after 400 miles of hard & regular use.

Today I'll try to go slow & listen for the noise or it's absence.

Yesterdays high speed run did this drivetrain some good !

In terms of reliability does the CVT present any 'road breakdown' concerns or is it mainly a 'things wear slowly out, plenty of lead time to renew' ?

TY - David
 

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2006 Burgman 400 - Silver - 8600 miles - and climbing !
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Discussion Starter · #27 ·
For example my belt seems to have no wear.
Width = 24mm
Wear out = 20.8mm per manual

Either of prior owner replaced OR ? Could still be that wide @ 8500 miles ?

Also I used Inspection mirror to see clutch faces seem to have 1.5 - 2mm of material left.

Slight blue color on bell but not bad.

RPM vs Speed are about average:
70mph = 6200 rpm.

(Would love that lower RPM Malossi / Dr Pulley upgrade @ my 1st CVT rebuild - my main riding will be 85% Hiway riding)
 

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Discussion Starter · #29 ·
OEM CVT is pretty sturdy and doesn’t give much trouble.
Belts don’t often fail early unless they are cheap knock-offs. However, like tyres, they don’t like sitting around doing nothing.

Visual check is useful but not a guarantee, it does add to confidence that it’s OK.

Belts can go bang, which is messy and can bend things sometimes. Plus if it goes while you’re exiting a bend/overtaking or it locks your wheel up it’s going to hurt. That sounds scarier than it’s intended to be (I suspect other, more compact units are more prone to locking up)
If it’s a named belt, in spec, flexible and visibly good - I wouldn’t think twice about taking it out.
Great that all does inspire confidence.

From that do I conclude that once CVT / belt is inspected visually & running fine most modest length road trips are done without packing a spare belt ?

I imagine there's enough other things that could sooner fail.

I've got my "Road Tire Flat Emergency Kit" all together.

I'm thinking that's got to be a prime concern area for motorcycle touring.

But maybe motorcycle tires are SO tough flats are a rarity.

Still be prepared...the cost of not is too high.
 

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Discussion Starter · #31 ·
Yes & Amen Brother.

Good on you for an improvised fix !

The only person you've gotta please is yourself.

I was thinking on using bedliner paint on the bellypan & L+R leg shields.

My bike was laid down by a ham fisted kid and has some scratching on R side, plus the inevitable use & wear marks.

The bedliner treatment should renew & toughen the lower parts.

Did you see the post where a guy did that ?

Was also thinking on an overall color change.

Mine is "boring silver"...no offense if yours is.

I just prefer more lively colors.

This Scoot shouldn't be hard to do cause all the pieces - most anyhow - are simply removed for painting.

Sounds like a great winter project lol !

You got a great budget deal, sounds like.

Wouldn't those final drive parts be modest cost - ? Due to that they're common wear parts ?

I've no idea I'm sure they're Suzuki OE, are they spendy ?

Cheers - David in East Texas
 

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Discussion Starter · #33 ·
Wow scary to roadside, bedside tale !

I wonder what revs were at that point ?

Did you have a Tach ?

Maybe engine & CVT we're past their limit lol.

Boy, your story has me recalling the 1970 Vespa 2 stroke Scooter we had in 1980 - I'm quite sure it was a 3 speed with a clutch on the left, you'd rotate the right handgrip to shift.

I wanna say therefore it was 3 gears / direct drive. No belt...and it was quick not sure if a 125, 150 or maybe larger.

BUT I rode a 50cc Vespa Ciao Moped then too and I think it DID have a small CVT running on left side.

Man I put like 8000 miles on that Ciao in 1.5 years of commuting to my school 15 miles each way.

My Dad almost did the same commute on the Vespa Scooter - the only Hiccup being it's penchant for breaking down 2x monthly - we lived 15 miles from the Vespa dealer on El Cajon Blvd...too far to be convenient lol.

Drove my Dad crazy it did....yet he loved the Vespas zippy performance & mpg.

Whereas the Ciao Moped NEVER broke...not once in 8000 miles....

Geat fun - old, dusty memories !

My Dad bought these Vespas to save us on high gas prices...some things never change....same reason I'm on this AN400.

It's so much fun to be back on two wheels again !
 

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Discussion Starter · #35 ·
Byron awesome ideas.
Was thinking similarly.
I was wondering what the Left leg shield piece goes for used or if avail, new ?

That would seem the "most likely body piece to break", due to its frequently required removal.
 

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Discussion Starter · #37 ·
Got it. Me too mostly.
If my Burg were cherry (as I'd like eventually, IF Honeymoon lasts), only then would I plop $300 for that crucial part.
For now mine are ok.
Just 1 tab broke upon removal due to me not being UBER careful. Wiser next time !

My two 4 wheeled rigs are both 2000 & 2002 Mercedes Wagon & SUV & it's same story basically on them:

Very solid - bulletproof drivetrain & chassis, with occasional electronic snafu hurdles & plastics S L O W L Y degrading.... keeping cosmetically decent is 65% of equation.

As I say, Life is SO much better with Cars & Bikes you maintain & know with NO car payment, than any other way - IMHO.

I've got neighbors who are SLAVES to their news cars & dealer - they act like their hoods are welded shut.

Okey dokey if they're happy living like that....in times of economic downturn they panic because those 2 New Driveway Ornaments are a financial boat anchor.

Ok, rant over ...God bless & ride safe...

David
 
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