A 650cc scooter puzzle to be completed..

[bdrannik]

Today I jumped on the Downtown 300 and did a 350mi/563km round trip to purchase a 2007 Burgman 650 in pieces..  It needs the CVT belt replaced which on a this model is a HUGE repair requiring complete disassembly of the bike to be done.  At this point it's about 70% taken apart to the point it needs to get to for the repair to be started:

















Here are two Internet photos I found showing a Burgman 95% ready to start the CVT repair - from this point the CVT assembly would still need to be removed from the engine/transmission and disassembled:





It will be a fun   project - I am going to strip it down to the bare frame for powder-coating and go from there.  Has 80,000mi/128,748km so will also be doing all maintenance items such as engine mounts, fork seals, spark plugs, coils, cables, valve adjustments, wheel bearings/seals, steering head bearings, brake pads/rotors, caliper seals, etc in addition to the needed CVT repair.

Project will not happen for at least a few months as I need to get it home and collect all the needed parts before getting started.

When finished it should look something like this:

[Mike Green]

bdrannik,
What a great fun project. I think I would develop an inventory of all parts that come with your purchase and then label each piece and have a corresponding number or letter on the part with the inventory. That way as you start your re-assembly you can identify what's missing and what you have. Please keep us posted with updated pictures as your project moves along. Just because this is a Kymco forum does not mean that we do not appreciate other great scooters.
Mike

[08087]

I like the way it looks as is, replace the belt and seat and ride!

I like the Big Ruckus look of a Honda can you tell.

I wish I had your ability.

[bdrannik]

I like the way it looks as is, replace the belt and seat and ride!

I like the Big Ruckus look of a Honda can you tell.

I wish I had your ability.

A "Bruckus 650", I like it!     I am also a fan of the Big Ruckus..
 
>>"I wish I had your ability":  Thanks for the kind comment but truth be told I do a lot of riding on the efforts of those that came before me and documented it all..  Although  I do have an occasional original idea once in a while..  

Thinking of painting scooter the same Diamond White Pearl as the Downtown and moving the Givi E55 box to the Burgman with a Givi V47 taking its place on the rear of the DT300i.  While the body panels are getting painted it might be ridden bare for a while..  Not sure yet - just tossing thoughts around.

And hello to Mike..  Yes I usually put related nuts/bolts/etc into seperate zip-lock baggies and label them with a black Sharpie marker as I take things apart.  I haven't done any of the disassembly to this point so it will be somewhat of a challenge fitting it all back together - I predict lots of trial and error fitments on the body panels.

[InfernoST]

You should check out this thread over @BUSA, it extremely informative with step by step pics and video. Don't be fooled, the ECVT parts required to repair it are quite costly. Good luck with the repair.

http://burgmanusa.com/forums/viewtopic.php?f=4&t=57574

[bdrannik]

You should check out this thread over @BUSA, it extremely informative with step by step pics and video. Don't be fooled, the ECVT parts required to repair it are quite costly. Good luck with the repair.

Did a LOT of research before deciding to take on the project - between BurgmanUSA and printing the repair manual I've used over 1000 sheets of paper.    The Burgman owner in your link above also has a comprehensive Burgman repair website of which I've printed about 95% of...

[gn2]

Hope you didn't pay much for it.
Looks like a fun if time consuming project, keep us updated with pics and stories. 

[InfernoST]

Did a LOT of research before deciding to take on the project - between BurgmanUSA and printing the repair manual I've used over 1000 sheets of paper.    The Burgman owner in your link above also has a comprehensive Burgman repair website of which I've printed about 95% of...

LeDude is the member in the link above and the Red 650 you pictured above belongs to Craig AKA Buffalo on BUSA. Both of these guys are aces when it comes to fixing these finicky 650's.

[jprestonian]

Best of luck with it, truly.

I cannot ever imagine myself having the time, tools or space in which to take on such a daunting task... and dang, all this to change the CVT belt?!  Holy crap. How did they ever sell the first one?
.

[blue]

All I can say is good luck.................................

[Vivo]

All I can say is good luck.................................

If bdrannink has the time and funding..... all he needs is a little luck....

[Mike Green]

bdrannik,
Any progress on re-assembly of your burgi? Man I would love to have one of those scoots. Keep
us informed of progress and please post PICTURES! Thanks,
Mike

[bdrannik]

bdrannik,
Any progress on re-assembly of your burgi? Man I would love to have one of those scoots. Keep
us informed of progress and please post PICTURES! Thanks,
Mike

Nothing as of yet.  At the end of my original post, just above the photo of the grey scooter on white background, I mentioned it would be a few months before I'll be getting to it.  I have some projects ahead of this one and still need to go pick it up and get all the parts ordered.  There will be plenty of photos when I get started on it...  

[bdrannik]

InfernoST/Keith,

Too bad the previous owner didn't see the repair in Germany before tearing it apart - would have saved me a lot of work..

[InfernoST]

InfernoST/Keith,

Too bad the previous owner didn't see the repair in Germany before tearing it apart - would have saved me a lot of work..

I hear that Brother. I believe they got the CVT out in about 2hrs.

I'm picking up my 650 this Thursday and am glad to see it can be done in such short order should the cvt fail on mine.