Clutch drag

[GB.]

Starting to use my Xchallenge a bit more now and it seems the clutch is dragging, the symptoms are hard to find neutral, put it into first and it sometimes creeps forward. Now the bike has less than 3000miles on it, but I have no doubt it has had a hard life being an ex off road schools bike. The clutch cable is out of adjustment. The bike is an 08, I hear there is a different or updated clutch cover? Can anyone shed any light on this, new clutch cable, new plates or later casing?

 

[Losttheplot]

This might be a daft question, but have you tried adjusting the slack out of the cable? there should be an adjuster under the rubber boot where the cable goes into the clutch lever. if there is no more adjustment left, pop the silver actuator arm off the top of the clutch cover and move it back a teeth or 2 on the splines.
that should sort it.

 

[coyotedave]

My XCountry had the same symptoms.

New clutch and the most important bit, 09 outer casing. This has cured the problem.

Not sure if the XChallenge is the exactly the same as the XCountry. Worth checking it out.


Cheers Dave.

 

[GB.]

What is the difference in the covers?

 

[GB.]

Right I just looked on RealOEM and the challenge only goes up to 2007, so I looked on the G650gs fische for a 2009 and that's the part number?

 

[Losttheplot]

What is the difference in the covers?

The difference may well be a steel bush in the center of the case, the original case on my XChallenge didn't have this, meaning the clutch centre shaft ran directly on the aluminium case. This would wear and eventually cause the teeth to mis-mesh and jam up. Do a search on clutch casings in this section, it's topic that has been done several times.

That said going on the symptoms you describe, i think the cable has just stretched and needs adjusting before you throw money at it.

 

[GB.]

Might lay it on its side and pop the cover off, anyone got any pictures of what I should or shouldn't have?

 

[chrisjk]

This article should help - engines are the same on Xcountry and Challenge

http://mattsnook.com/bmw/bmwXCountry/ClutchSideCover/index.htm

 

[GB.]

Thank you, I will read that when I get home from work.

 

[Losttheplot]

Might lay it on its side and pop the cover off, anyone got any pictures of what I should or shouldn't have?

Have a look here:

http://www.ukgser.com/forums/showth...-failure-(Again!)?highlight=XChallenge+clutch

The above thread shows the various parts of the clutch, and also the centre of the clutch case showing the bush insert.

And be careful when lying the bike on it's side to check the clutch. Oil has a habit of running into the alternator casing on the other side of the engine, and when the bike is stood up and started again this oil gets blown into the air box, and makes a huge f***ing mess . DAMHIK!

 

[GB.]

Thank you, will probably do an oil change at the same time

 

[GB.]

Well, had a look at the clutch cable tonight and it has been fried against the header, so a new cable and a reroute is required.

 

[bighair]

GB
Any chance you could help ?
http://www.ukgser.com/forums/showth...yone-with-an-X-try-this-for-me-(clutch-issue)
It maybe the answer to your problem could be the same ?

 

[GB.]

I put new plates in mine from ebc, not perfect but much better.

 

[bighair]

I put new plates in mine from ebc, not perfect but much better.

What kit No did you use ?
The reason I need some info on the reserve travel is that mine has none, it basically has topped out when you pull the lever in, whether that is also part of the original cover wear issue (the bore on my clutch cover is ok and the rest of it checks out and the operating lever is set right ) but if the operating boss from the clutch can not travel any further it is stressing the cable and the cover and boss in my view. (I am thinking the cover is not deep enough or the boss is not far enough away in the at rest position ?
I need to take the cover off again but need a new o-ring first and measure the boss bore etc.
As the later parts are different maybe they also have a bit more travel ? but with out the old an new side by side it is hard to tell , but when all the previous rotax units had loads of reserve travel why mine (or possibly the X series has little or none ) is a bit of a mystery.

Also the later clutch stack height is about 3mm less which would give more travel to the operating arm in theory as it could be further from the operating shaft , but I do not know if the centre (hub) is the same dimensions ?
I am assuming that the outer cover was the same apart from the metal sleeve modification ?

 

[GB.]

Mine was CK5636 for the dakar. Your problem sounds more than worn plates to me but I'm no expert.

 

[bighair]

Hi
Thanks for the EBC No you used , my plates are fine , I am just trying to find out now about why the operating arm has no reserve travel once the handle bar lever is pulled in , when all the others models using the rotax lump do .

 

[Losttheplot]

Have you checked the springs on the clutch basket are still in spec?