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I have had an 05 400 from new and luv it. I just purchased an 04 650 and I am reading about a cvt "stopper" bolt that might need to be replaced with an updated bolt. I found the new and the old part numbers for the bolt, but I am not sure where it"s located on my bike. Can anyone link me to an illustration? Thanks in advance. Douge36843 ps, are questions just supposed to be one topic per question?
 

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It's on the right hand side of the bike right behind the exhaust pipe. Go in a line from the front of the seat down under the bike behind the exhaust. Feel along the bottom of the CVT housing and you will feel it.
 

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It's between the Tupperware and the exhaust pipe directly under the the vents on the Right hand side.

Here is DIY video on proper way to do it.

Burgman 650 - DIY - CVT Primary Pulley Bolt Replacement - YouTube
This is a very helpful video (one of many on LeDude's site). I bought a 2007 Burgman 650 with 2,300 miles on it last month (now 3,200+ and climbing) and decided to take a preventive step and replace the Pulley Stopper Bolt. Cost was $6 and replaced it in 5 minutes in the dealership parking lot (in case something went horribly wrong). Video gave all the info needed for easy fix.
 

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FINALLY got around to replacing mine at 51K+ miles... (yeah, I know guys... but hey, the good news is...)

Picks of bolt

:p I replaced it with a 2011/12 bolt (black-ish one... my original was gray). We'll see what that looks like in another 50K miles, lol!
 

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FINALLY got around to replacing mine at 51K+ miles... (yeah, I know guys... but hey, the good news is...)

Picks of bolt

:p I replaced it with a 2011/12 bolt (black-ish one... my original was gray). We'll see what that looks like in another 50K miles, lol!
51K? What about all the horror stories I read about on other forums about all of the Burgmans' CVTs self-destructing after 20K???? :p

I just bought a 2007 Burgman 650 last month with 2,300 miles (now 3,700 miles) and was pretty sure that this probably happened to 1% of the bikes but it gets blown out of proportion. (I still replaced the bolt with a new one since it was only $6 and a 5-minute fix).
 

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EXACTLY!! And like I said, over 51K miles of HARD riding... and when I say HARD, I mean... just ask around Baltimore, MD about the "Scooter", "Scooter Man", "BlackMoon" or "Moon" who wears all black and has a metallic blue (or some remember it as white) Burg and runs with and like a sportbike (and I'm talking 900cc's and up!)! Too many KNOW me now to be missed.

BurgPnoMan, I have an '07 also, bought in '08 new (which, at 2300 miles, your's basically is).

I've been engine-braking it regularly in turns and stops, through inner-city streets, up and down highways, over and under the "buck and a quarter" mark (if you know what I mean), and everything else you can throw at her. Now, she's even been Dark-Sided a few years and about 25K miles (if I remember the numbers correctly... I am getting old now, lol!), which is "supposed" to put even more strain on the CVT and bolt. To be honest, looking at it, there is actually not much damage to the bolt (compared to some others I've seen with less mileage). It's nicked about a half to a full millimeter on each side, no more. The last few pics show this best. (click camera on left side of screen to see actual album and picture botes.)

That said, oil changes regularly (and that's with synth from the 600 mile mark) of Tranny, Engine AND Rear have been essential. Never had any excess metal shavings (trace amounts is, sadly, normal) in any oil.

Can / Will the bolt eventually fail? ABSOLUTELY!
Is it worth the effort to replace it? ABSOLUTELY!
Is it worth taking a chance on running yours 50K+ miles before changes? ABSOLUTLEY NOT!!

Like the guys have said... $6 and 5minutes... if that.

But are the claims of Burgs being "problems waiting to happen" true in general? NO!!!
 
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