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I am a complete newby to this site so please forgive me if this thread is in completely the wrong place.
I have just bought a tidy 2005 400 Burgman which is just about spot on, the only problem I have is (believe it or not) the petrol flap. If i press the flap release button, it releases the flap, but it doesn't pop up like it should. If i open it with my nail and look inside, I can see the spring intact and attached at the coiled end but the other long end is just sticking out at the top edge, and quite clearly should be hooked up against something to put the tension on the flap. the trouble is I cant work out what it should be hooked up against. there is my problem. Any help appreciated. A photo of the flap with the spring attached, taken from behind would be excellent. Cheers, Griff. England
 

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Discussion Starter #2
I am a complete newby to this site so please forgive me if this thread is in completely the wrong place.
I have just bought a tidy 2005 400 Burgman which is just about spot on, the only problem I have is (believe it or not) the petrol flap. If i press the flap release button, it releases the flap, but it doesn't pop up like it should. If i open it with my nail and look inside, I can see the spring intact and attached at the coiled end but the other long end is just sticking out at the top edge, and quite clearly should be hooked up against something to put the tension on the flap. the trouble is I cant work out what it should be hooked up against. there is my problem. Any help appreciated. A photo of the flap with the spring attached, taken from behind would be excellent. Cheers, Griff. England
i think you can remove the fuel flap without taking all the glovebox off! Does anyone know how, without breaking it?
 

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I've never tried to take it apart so not sure how it goes together. I looked in the manual and could not find any instructions on taking it apart. Suzuki does sell replacement parts for it so it looks like you should be able to disassemble it. I looked at the fiche for the parts and could not see any screws that hold it together so it is probably just a snap together kind of thing. Here is a link to the fiche so you can see what the parts look like. That might help you puzzle it out.
http://www.partshark.com/fiche_section_detail.asp?section=300349&category=Scooters&make=SUZUKI&year=2003&fveh=7244
 

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After looking at the manual some more I did find an exploded view of the front box. Looking at it I think you are going to have to take the front box off and turn it over to get to the mounting points for the hinge. Looking at the part fiche it looks like the spring hooks around the two pins you can see on the hinge part of the lid (part number 17). The damper (part number 20) slides in from the outside and is held on by the end of the spring. Then part number 18 slides up into the hinge to lock it in place. I would suspect one of the pins that the spring goes on has broken off. It's hard to tell from the drawing in the manual but there may also be a couple of screws on the back side that secure the hinge.
 

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Buffalo thanks for your info, i will give it a look. If I have to take the front box off I think I might need a manual or I will end up breaking something. I will let you know how I get on. Cheers
 

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I've never tried to take it apart so not sure how it goes together. I looked in the manual and could not find any instructions on taking it apart. Suzuki does sell replacement parts for it so it looks like you should be able to disassemble it. I looked at the fiche for the parts and could not see any screws that hold it together so it is probably just a snap together kind of thing. Here is a link to the fiche so you can see what the parts look like. That might help you puzzle it out.
http://www.partshark.com/fiche_section_detail.asp?section=300349&category=Scooters&make=SUZUKI&year=2003&fveh=7244
Thanks for the url. I wanted to get a new cover for my muffler. Found it, thanks to you!! I bookmarked the site.
 

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Thanks for the url. I wanted to get a new cover for my muffler. Found it, thanks to you!! I bookmarked the site.
There are a number of such places. If you go to the knowledgebase link at the top of the page you can find a list of them.
 
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