The Suzuki Burgman 400, a maxi-scooter known for its comfort, practicality, and smooth ride, has carved a niche for itself amongst commuters and touring enthusiasts. However, like any machine, it's not without its quirks. Understanding the common issues faced by Burgman 400 owners can help you anticipate potential problems, make informed purchasing decisions, and keep your scooter running smoothly for years to come. Let's delve into some of the challenges owners have reported, offering practical advice and potential solutions.

My Burgman Just Doesn't Feel Right: Handling and Suspension Woes

One of the most frequently cited concerns revolves around the Burgman 400's handling and suspension. While generally comfortable, some riders find the stock suspension lacking, particularly when carrying a passenger or luggage.

  • Squishy Suspension: The Burgman's suspension is often described as soft or "squishy." This can lead to a feeling of instability, especially at higher speeds or on uneven roads. The rear shock, in particular, is often criticized for being under-damped.

    • Solution: Upgrading the rear shock is a popular and effective solution. Options range from aftermarket shocks with adjustable damping to progressive springs that offer improved performance and control. Consider the YSS or Bitubo rear shocks. Fork oil changes with heavier weight oil can also improve front-end stability.

  • Wobbling at Speed: Some owners report experiencing a wobble, particularly at speeds above 60 mph. This can be disconcerting and potentially dangerous.

    • Solution: Start by checking tire pressure and ensuring the tires are properly balanced. Next, inspect the steering head bearings for play. Loose or worn bearings can contribute to wobbling. Replacing the bearings with quality aftermarket units can significantly improve stability. Also, make sure the rear wheel is properly aligned.

  • Cornering Concerns: The Burgman 400, while not a sportbike, should still offer confident cornering. Some riders find it feels vague or unstable in corners.

    • Solution: Beyond the suspension upgrades mentioned above, consider investing in stickier tires. The stock tires are often adequate for general commuting, but higher-performance tires can improve grip and handling in corners. Ensure correct tire pressures are maintained.

The Dreaded CVT: Transmission Troubles

The Continuously Variable Transmission (CVT) is a key component of the Burgman 400, providing smooth and seamless acceleration. However, it can also be a source of problems if not properly maintained.

  • Belt Slippage: The CVT belt is a wear item and will eventually need replacement. Slippage is a common symptom of a worn belt, resulting in reduced acceleration and a feeling of sluggishness.

    • Solution: Regularly inspect the CVT belt for cracks, wear, and proper tension. Replace the belt according to the manufacturer's recommended service interval (typically around 15,000-20,000 miles, but can vary depending on riding style). Use only a high-quality replacement belt.

  • Roller/Slider Wear: Inside the CVT, rollers or sliders control the gear ratio. These components can wear down over time, leading to jerky acceleration, reduced top speed, and unusual noises.

    • Solution: When replacing the CVT belt, it's a good idea to also inspect and replace the rollers/sliders. Consider upgrading to aftermarket rollers/sliders made from more durable materials.

  • CVT Noise: Unusual noises coming from the CVT area, such as rattling, squealing, or grinding, can indicate a problem.

    • Solution: Investigate the source of the noise. It could be a worn belt, damaged rollers/sliders, or a problem with the clutch. A thorough inspection by a qualified mechanic is recommended.

Electrical Gremlins: When the Lights Go Out (or Stay On!)

Like many modern vehicles, the Burgman 400 relies on a complex electrical system. Electrical issues can be frustrating to diagnose and fix.

  • Battery Drain: A common complaint is a rapidly draining battery, especially if the scooter sits unused for extended periods.

    • Solution: Check for parasitic draws, such as aftermarket accessories that are constantly drawing power. A failing battery can also be the culprit. Consider investing in a battery tender to keep the battery charged when the scooter is not in use.

  • Stator/Regulator Rectifier Failure: The stator generates electricity, and the regulator rectifier regulates the voltage. Failure of either component can lead to battery drain, poor performance, and even a complete breakdown.

    • Solution: Have the charging system tested by a qualified mechanic. A multimeter can be used to check the stator output and the regulator rectifier's voltage regulation. Replace faulty components with high-quality replacements.

  • Sensor Issues: Various sensors monitor engine performance. Malfunctioning sensors can trigger warning lights and affect engine operation.

    • Solution: Use an OBD-II scanner (with the appropriate adapter for the Burgman 400) to read diagnostic trouble codes (DTCs). This will help pinpoint the faulty sensor.

Engine Quirks: Keeping the Heart Beating

While generally reliable, the Burgman 400 engine can experience its share of issues.

  • Oil Consumption: Some owners have reported higher-than-expected oil consumption.

    • Solution: Monitor the oil level regularly and use the recommended oil type and viscosity. If oil consumption is excessive, it could indicate worn piston rings or valve seals. A compression test can help diagnose the problem.

  • Starting Problems: Difficulty starting, especially in cold weather, can be a concern.

    • Solution: Check the battery condition and ensure the spark plug is in good condition. A faulty fuel pump or clogged fuel injector can also cause starting problems.

  • Overheating: While less common, overheating can occur, especially in hot climates or during prolonged periods of slow-speed riding.

    • Solution: Check the coolant level and ensure the cooling system is functioning properly. A clogged radiator or a faulty thermostat can contribute to overheating.

Bodywork and Aesthetics: More Than Just Looks

While not directly affecting performance, issues with the Burgman 400's bodywork can be frustrating.

  • Plastic Cracking: The plastic body panels can be prone to cracking, especially around mounting points.

    • Solution: Handle the body panels carefully when removing or installing them. Use appropriate fasteners and avoid overtightening. Consider using plastic repair kits to fix cracks.

  • Seat Wear: The seat, while comfortable, can wear down over time, especially in areas exposed to sunlight and weather.

    • Solution: Protect the seat with a seat cover when the scooter is not in use. Consider having the seat reupholstered if it becomes excessively worn.

Pre-2018 Model Specific Issues: Things to Watch Out For

Burgman 400 models produced before 2018 had a slightly different design than later models. Certain issues are more common in these older bikes.

  • Cam Chain Tensioner (CCT) Failure: The CCT keeps the timing chain tight. Older models are known for CCT failures, which can cause engine damage if left unaddressed.

    • Solution: Listen for rattling noises from the engine, especially on startup. Replace the CCT with an updated version or an aftermarket manual CCT.

  • Fuel Pump Problems: Fuel pump failures are relatively common in pre-2018 models.

    • Solution: If the scooter is hard to start or stalls frequently, suspect the fuel pump. Replace the fuel pump with a quality aftermarket unit.

Preventative Maintenance: An Ounce of Prevention...

The best way to avoid many of these problems is to adhere to a strict preventative maintenance schedule.

  • Regular Oil Changes: Change the oil and filter at the recommended intervals.
  • CVT Belt Inspection: Inspect the CVT belt regularly for wear and tear.
  • Coolant Flush: Flush the cooling system every two years.
  • Brake Fluid Flush: Flush the brake fluid every two years.
  • Air Filter Replacement: Replace the air filter regularly.
  • Tire Pressure Checks: Maintain proper tire pressure.
  • Battery Maintenance: Keep the battery charged and clean the terminals.

Frequently Asked Questions

Q: What is the most common problem with the Suzuki Burgman 400? A: CVT belt wear is a frequently reported issue, leading to slippage and reduced performance. Regular inspection and timely replacement are crucial.

Q: How often should I change the CVT belt on my Burgman 400? A: The recommended interval is typically between 15,000 and 20,000 miles, but this can vary depending on riding style and conditions. Always check the manufacturer's recommendations.

Q: My Burgman 400 is hard to start. What could be the problem? A: Possible causes include a weak battery, a faulty spark plug, a clogged fuel injector, or a failing fuel pump. A thorough inspection of these components is recommended.

Q: Is the Burgman 400 a reliable scooter? A: Yes, the Burgman 400 is generally considered a reliable scooter, but like any machine, it requires regular maintenance. Addressing potential issues promptly can ensure years of trouble-free riding.

Q: Can I upgrade the suspension on my Burgman 400? A: Absolutely! Many aftermarket suspension upgrades are available, including rear shocks and fork springs, which can significantly improve handling and comfort.

The Bottom Line

The Suzuki Burgman 400 offers a comfortable and practical riding experience, but being aware of potential issues is key to enjoying its benefits for the long haul. By understanding these common problems and following a regular maintenance schedule, you can keep your Burgman 400 running smoothly and reliably for many years to come.