SERVICE
Motorcycle/ATV

GV/AN/UH No. 059

Date: January 24, 2025

Fuel Pump Warranty Extension

for 2014 - 2022 Burgman 200/200 ABS Scooters
Affected Models:

2014 - 2022 UH200/A (Burgman 200/200 ABS)

Affected Departments:

Management, Service, Sales, Warranty, Parts, Accessories

Attachment:

Customer Letter (warranty extension announcement)

Reference:

Burgman 200/200 ABS Service Manual (99500-31523-03E)

Suzuki Motor Corporation (SMC) is announcing a ten-year warranty repair coverage on the fuel pumps of 2014
– 2022 Burgman 200/200 ABS scooters. Normally, the warranty repair coverage period for the Burgman 200/200
ABS scooter is one-year.
What is the problem?
It has been determined that operating or storing a Burgman 200/200 ABS scooter in an area where salt water
from certain atmospheric phenomena may accumulate onto the fuel pump, the fuel pump discharge port resin
material may deteriorate from extended contact with compounds present in the salt water. This deterioration,
combined with bending stress from the fuel pump outlet hose, can cause micro-cracks to form in the discharge
port resin material. In the worst case over time, the micro-cracks may enlarge into a larger crack that passes
completely through the fuel pump discharge port structure. In this case, fuel leakage can occur from the crack.
What is Suzuki doing to solve the problem:
To ensure customer satisfaction, SMC has decided to extend the warranty period for the fuel pump on the
2014 – 2022 Burgman 200/200 ABS (UH200/A L4 - M2). The extension will provide warranty coverage for
a pump-related leak for ten years (unlimited mileage), starting on the original date of purchase. A new
rubber protective cover has been developed, that combined with a new fuel pump assembly, a new fuel hose,
and other related parts, will help resolve the salt water-related fuel leak.
What Suzuki Motor USA, LLC (Suzuki) will do:
Beginning the week of February 10, 2025, Suzuki will mail notification letters to owners of potentially affected
scooters for whom we have information (see pages 7 and 8 of this bulletin). This letter informs customers of the
fuel pump warranty extension and instructs them to contact a Suzuki dealer if a fuel leak occurs to schedule an
appointment to diagnose and repair the fuel leak.
What your Suzuki dealership will do:
Before performing a fuel pump repair on a scooter, first verify the repair needs to be performed by diagnosing the
cause of the fuel leak. Use the Vehicle Master Inquiry function on Suzuki CONNECT to determine the original
date of sale to verify warranty coverage for the repair. Then order the required parts as listed on page 2 of this
bulletin and perform the repair as recommended on pages 4 - 6. After repair completion, return the scooter to
the customer and submit a warranty claim as listed on page 3.
If you have a question regarding fuel pump warranty repair eligibility or a technical concern, contact TECH-LINE
at (714) 996-7480 or call your Suzuki Technical Service & Parts Manager (TSPM).
Links will function when bulletin is viewed in Suzuki CONNECT

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Ordering parts for the fuel pump repair:
Beginning the week of February 17, 2025, parts can be ordered via Suzuki CONNECT. You will select the
shipping terms. Please note that there are two parts lists, depending upon the model year of the Burgman
200/200 ABS scooter (the model/year unique parts are in the red-shaded cells).
Model / Year

Part name

Part number

Quantity

UH200/A, L4 - L6

Pump Assy, Fuel
Packing, Fuel Pump
Cover, Fuel Pump
Hose Comp, Fuel
O-ring, Injector
O-ring
Gasket, Exhaust
O-ring (OD: 2.4 mm, ID: 33.7 mm)
Clamp
Clamp
Nut, Crankcase Bracket

15100-03H21
44596-03H00
15211-29K00
15810-12J30
15717-03H00
15716-03H00
14181-46E10
09280-34004
09407-14407
09407-17403
09319-3112A

1
1
1
1
1
1
1
2
1
1
1

UH200/A, L7 - M2

Pump Assy, Fuel
Packing, Fuel Pump
Cover, Fuel Pump
Hose Comp, Fuel
O-ring, Injector
O-ring
Gasket, Exhaust
O-ring (OD: 2.4 mm, ID: 33.7 mm)
Clamp
Clamp
Nut, Crankcase Bracket

15100-03H21
44596-03H00
15211-29K00
15810-29K20
15717-26J00
15722-21H00
14181-46E10
09280-34004
09407-14407
09407-17403
09319-3112A

1
1
1
1
1
1
1
2
1
1
1

(Burgman 200/200 ABS, 2014 - 2016)

(Burgman 200/200 ABS, 2017 - 2022)

NOTE: Replacement of the fuel pump requires replacement of the engine coolant. The engine coolant capacity
(excluding the reservoir) is 1.4 US qt. (1350 ml) for the 2014 - 2022 Burgman 200/200 ABS models. Be sure to
have the necessary coolant available before you begin the repair.
•

Suzuki ECSTAR Long Life Coolant (1.0 US qt.)

990A0-02E00-01Q

*Sold in case of 12

Parts identification:
Refer to these images to distinguish between the
original and counter-measure fuel hoses.

New, counter-measure hose: 15810-12J30
or 15810-29K20
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Warranty claim processing:
Submit a warranty claim for each Customer Warranty Extension repair immediately upon completion. This
warranty extension requires you to file a warranty claim using the Long Campaign form as shown below.
Suzuki CONNECT Long Campaign Claim: A Long Campaign Claim form will reimburse you for replacement
of the fuel pump plus the additional parts (as listed by model/year on page 2), 2 quarts of Suzuki ECSTAR Long
Life Engine Coolant (990A0-02E00-01Q) and 3.9 hours of labor.
WARRANTY EXTENSION CAMPAIGN 2M99, UH200/200A FUEL PUMP REPLACEMENT
SUZUKI CONNECT LONG WARRANTY CLAIM FORM INSTRUCTIONS

CLAIM INFORMATION
CLAIM NUMBER:
ENTRY TYPE:
REPAIR DATE:
MILEAGE/HOURS:
CAMPAIGN NUMBER:
LABOR TIME:
PARTS INFORMATION
REPLACEMENT PART 1:
ADDITIONAL PARTS:
AUTHORIZATION:
FAILURE DESCRIPTION
DESCRIPTION OF DEFECT:
DESCRIPTION OF REPAIR

XXXXX,X (Dealer enters number)
VIN, Model/Frame or Control/Sequence # (Dealer chooses)
Enter date of repair
Enter mileage or hours at repair date
2M99
3.9 hours
15100-03H21 (Qty. 1)
Additional parts as listed on the model/year parts list
Only needed if additional parts (besides parts on the part list) or labor
claimed, will require TSPM authorization
Fuel Pump Replacement
Performed warranty extension repair as required per Service Bulletin

NOTES:
If the scooter is still within the original, one-year warranty period, please submit as a regular warranty
claim using the correct Defect Code.
If you encounter an unusual situation related to the Burgman 200/200 ABS fuel pump warranty extension, please
contact TECH-LINE at (714) 996-7480 or call your TSPM.

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Fuel pump repair - required tools:
The general tools and special tools listed below are required to replace the original fuel pump with a new fuel
pump, a new fuel pump protective cover, a new fuel pump hose, and other related parts.
Tool or item

Size or capability

Ratchet handle

(Typically 3/8-inch drive)

Extension bar(s)

(Typically 3/8-inch drive)

T-handle

(Typically 3/8-inch drive)

Ratchet sockets

8 mm, 10 mm, 12 mm, 14 mm, & 17 mm

Deep ratchet sockets

10 mm & 12 mm

Hexagon socket (Allen-type)

4 mm, 5 mm, & 6 mm

Combination wrench

10 mm, 12 mm, 14 mm, & 17 mm

Phillips screwdriver

#2 (mid-size bit)

Flat blade screwdriver

#1 (small blade) & #2 (mid-size blade)

Plastic hammer

(Typical tool)

Needle-nose pliers

(Typical tool)

Snub-nose pliers

(Typical tool)

Wire cutter

(Typical tool)

Torque wrench

Torque range: 0.73 ~ 73.7 lbf-ft (1.0 ~ 100.0 N.m)

Jack

(Typical shop equipment)

Shop towels

(Typical shop supplies)

Special tools
Ring locknut wrench
09941-51013

SDS-II Diagnostic tool
09904-41030

Thickness gauge
09900-20803

Thickness gauge
09900-20806

Precautions for working on the Fuel System:

WARNING

•

Keep away from fire or spark.

•

During disassembly, use care to minimize the spilling of gasoline.

•

Spilled gasoline should be cleaned up immediately.

•

Work in a well ventilated area.

CAUTION
•

To protect the fuel system (fuel tank, fuel hose, etc.) from foreign particle contamination, seal all
openings.

•

After removing the throttle body, tape the cylinder head intake to prevent foreign particle from
entering.

•

Adhere to the safety recommendations in the Service Manual.
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Fuel Pump repair procedure:
Refer to the Burgman 200/200 ABS Service Manual (99500-31523-03E) and the additional procedures listed in
the bulletin to replace the original fuel pump with a new fuel pump, a new fuel pump protective cover, a new fuel
pump hose, and other related parts.
To provide adequate access to replace the fuel pump and associated parts, the fuel tank must be removed from
the chassis. Use these steps from the Burgman 200/200A Service Manual:
A. Remove the engine assembly (see page 1D-28 in the Service Manual)
B. Remove the footboard (see page 9D-23)
C. Remove the lower leg shield (page 9D-17)
D. Remove the fuel tank assembly (page 1G-8)
• Add additional removal steps as listed below.
• Add additional installation steps as shown on page 6 of this bulletin.
D) Additional removal steps to the fuel tank removal
procedure. Remove the original fuel hose (page 1G-9):
1. Remove the fuel hose clamp bolt 1.

2. Remove the wire clamp 2 and disconnect the fuel injector
electrical coupler 3.
3. Place an absorbent cloth or similar item near the end of
the fuel hose and around the fuel pump.
4. Remove the fuel hose mounting bolts 4 and
then remove the fuel hose 5 from the fuel pump.

5. Remove the fuel hose clamp 6 from the disconnected
fuel hose 5.

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D) Additional installation steps to the fuel tank installation
procedure. How to install the fuel hose clamp to the new
fuel hose and how to install the new protective cover to the
fuel pump (pages 1G-11 to 1G-15):
1. Orient the new fuel hose 1 so the white line 3 is facing
directly upwards [a].
2. Attach the fuel hose clamp 2 to the fuel hose 1 so the
surface of the hose clamp 4 is vertical.

NOTE:
Do not install the fuel hose to the fuel pump until
you install the new protective cover (step 3, below).

3. Install the fuel pump outlet protective cover 5 on the
fuel pump outlet as shown. Install the fuel hose onto the
fuel pump and complete the reinstallation of the fuel tank
onto the scooter.

If you have a question about this warranty extension or a technical concern related to the fuel pump repair,
please contact TECH-LINE at (714) 996-7480 or call your Suzuki TSPM.
Suzuki Service Department
6/8

Customer letter on the following page >>

Burgman 200/200 ABS Fuel Pump Warranty Extension - Customer letter, page 1/2

February
February10,
10,2025
2025

7/8

Customer letter page 2 on the following page >>

Burgman 200/200 ABS Fuel Pump Warranty Extension - Customer letter, page 2/2

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END