re the Diesel noise
Hi there,
Bob asked me in an eMail about this noise, here is my reply to him maybe it is of help to you.
"Hello Bob,
yes I have also had this problem - in fact there is no one that I don't know over here (reflected in our own Burgman Forum
http://www.an650.de) that hasn't had this problem.
The noise comes from one of the gears in the drive chain - you know where the 5 gears run horizontaly to the rear wheel. The first of these gears develops too much play (tolerance) and at idle revs causes a dull clicking sound. When the revs come up and the load on all of these 5 gears sets the rear wheel in motion the noise disappears. Apart from being annoying there are no dangers involved.
Well I took a print out of all the other guys experinces from our Forum to my dealer. Since I had the only Burgman he had sold - he compared my machine to a new one on the show room floor to form a reference. Mine was noisy the new one wasn't. He then sent a fax to Suzuki Germany requesting a special gear extrating tool and the replacement gear.
I arranged to have the repair done at the time of my 6000 km inspection.
This was to meet him half way since at the inspection all the plastic tunnel cowlings etc would be removed anyway.
When the inspection date came and was carried out I watched the proceedings. They removed the aluminium (cast) casing which houses these 5 gears, using this special tool extracted the main gear which came off easily and repalced it with the new gear (was very difficult to get on). This went to proove that this initial gear was under tolerance from the word go and within the first 1000km it started this clicking sound as we all know it.
The whole job took about 15 minutes to do - old gear off, new gear on. This was all done under waranty.
After that the noise was gone - however only some of the guys in our Forum report that the noise comes back at about 12000km - I haven't had this problem yet but makes me think that maybe the material used to manufacture this gear (cog) is not up to scratch. Maybe the first generation of these gears was like this and subsequent series are better.
Well that is all that I can tell you about this problem.
Take care and stay upright.
Bevan"