Clutch mechanism failure (Again!)

[Losttheplot]

Are we saying that the forward and backward movement of the rack in the housing causes this excessive wear? Unless I'm being a bit thick, the pinion only moves a few mm to engage and disengage the clutch. This tiny movement can cause so much wear and then failure? Seems hard to believe. Can anyone confirm this? Prepping for a Siberia trip this summer so

Yes. My clutch cover wasn't worn badly, in fact there was only slight sideways movement in it , but after wrecking 2 sets of shafts in quick succession, i didn't want to risk it.

Since changing the cover i haven't had any more problems.

Believe what you like, a clutch cover is around £70, as are the 2 shafts that will need replacing are also the same amount.

If the shafts do jam up, as mine have done on 2 occassions, it will be a workshop job to remove the clutch cover. it can be done by the side of the trail, but it's not what i'd term "mechanically sympathetic"

 

[magno]

Ordered an updated clutch cover,bearings, gasket and seals today. Hopefully I won't be going back in that part of the engine again anytime soon once fitted.

Thanks for your help.

 

[levis]

Could someone show a picture of the new clutch cover with the bush?

 

[Losttheplot]

Could someone show a picture of the new clutch cover with the bush?

See post 7 of this thread.

 

[levis]

oops! sorry It's was little bit blurred but still notice clearly the shape of the bush.
Thanks for your picture.

 

[levis]

oops! sorry It's a little bit blurred but still notice clearly the shape of the bush.
Thanks for your picture.

 

[tatters_2005]

I,m currently having some issues acquiring the correct replacement clutch cover, Ordered a replacement cover last week from BMW which was showing on the system as a updated part number (l was clear that l needed the updated cover with the steel insert) but today when l went to collect it the cover it was a older one without the steel insert.

Been told it will be looked into and they will get back to me, but l just don't understand why BMW would be still stocking a part that is obsolete.

 

[Losttheplot]

I,m currently having some issues acquiring the correct replacement clutch cover, Ordered a replacement cover last week from BMW which was showing on the system as a updated part number (l was clear that l needed the updated cover with the steel insert) but today when l went to collect it the cover it was a older one without the steel insert.

Been told it will be looked into and they will get back to me, but l just don't understand why BMW would be still stocking a part that is obsolete.

Have you tried Vines in guildford? they were very helpful when it came to sorting out my clutch woes.

 

[drimcong]

CLUTCH HOUSING cover 1 11147700331 ~2008
CLUTCH HOUSING cover 1 11147699389 original

which part have you got?
if a dealer orders the old part, it will be sold as long as it available.
a dealer sold me the old clear flawed platic for a scarver instead of the improved black.
because he could.
Josey

 

[tatters_2005]

Have you tried Vines in guildford? they were very helpful when it came to sorting out my clutch woes.

This was vines of Guildford.


It appears that the old clutch cover was ordered when l clearly stated l wanted the updated clutch cover with the steel insert. "C11.14.7.699.389" (old cover) when it should of been "C11.14.7.700.331" (new cover) Its not the guy who ordered it for me fault but the ordering system should of had the new part number listed not the old one.

 

[JohnnyBoxer]

Mine's fitted with the updated cover and although I never experienced a problem, I fitted it as a precaution, because the cost was only about £75

 

[magno]

part ending in 331 is the part you need. Just got one for mine. As an aside, the new chinese manufactured part is utter rubbish compared with the original Rotax cover. New one is poorly cast and paint finish is crap compared with the proper austrian version. I just hope that the poor quality finish does not mean the tolerances for the rack and pinion for the clutch actuation are poor as well.

 

[magno]

You will need to get new seal, needle roller bearings and a circlip too. Not worth reusing the original for the price of these parts. Details in earlier post in this thread.

 

[Timpo]

If I can use your picture Magno please......
I have whipped my cover off and it has wear as LTP has described. So, I intend to bore the alloy hole out and make a small steel bush and press it in the hole to return it to the 12mm diameter that it should be. Hopefully it should save me a few quid......

To add, I had a shock today too, as I counted 7 fibre and 7 steel clutch plates, yet the parts fiche pictures show 8 of each on the diagrams.......

T.

 

[viv]

To add, I had a shock today too, as I counted 7 fibre and 7 steel clutch plates, yet the parts fiche pictures show 8 of each on the diagrams.......

T.

I found the same thing...

http://advrider.com/forums/showpost.php?p=15498616&postcount=19


Viv

 

[Nobu]

Repair of Clutchcover

Hallo from Germany
see this may be interesting
http://www.michaelbense.de/g650x/forum/viewtopic.php?f=5&t=3177&p=35956#p35085

nothing is impossible, a member of the german G650X forum did a great job and manufactured a bushing for his own X-Country.

Greetings from South Bavaria
Nobu

 

[Timpo]

Hallo from Germany
see this may be interesting
http://www.michaelbense.de/g650x/forum/viewtopic.php?f=5&t=3177&p=35956#p35085

nothing is impossible, a member of the german G650X forum did a great job and manufactured a bushing for his own X-Country.

Greetings from South Bavaria
Nobu

Yep Nobu, that is my plan too.....

 

[Bliss]

How are the news on that bushing?

As i gathered from google translate of above topic, he used a ready available bushing, which was also teflon lined, I found something like this in UK and was wondering if there is something I need to consider when adapting this??

http://simplybearings.co.uk/shop/Be...acked+Plain+Bush+12x14x25mm/product_info.html

 

[Losttheplot]

How are the news on that bushing?

As i gathered from google translate of above topic, he used a ready available bushing, which was also teflon lined, I found something like this in UK and was wondering if there is something I need to consider when adapting this??

http://simplybearings.co.uk/shop/Be...acked+Plain+Bush+12x14x25mm/product_info.html

Just be careful that the steel bushing hasn't been hardened, if it has it will make life rather interesting if you try to machine it, though i don't think it would stop you grinding a cut out with an abrasive wheel to allow the shafts to mesh.

Just watch it doesn't get hot as this may destroy the fancy coatings.

 

[Bliss]

OK, there's a problem...

My engineering friend has started to bore out the hole, but he can't do it because the needle bearing is interfering and we haven't accounted for that!
Does anybody know if it must be removed before doing this job.
How do you remove that clutch cover needle bearing anyway??

Also, only bushing I found had a split running down the entire length, but the picture from Nobu's link shows a full piece bushing.
Do you know where such a bushing can be found?

Nobu, can you help with any of the above or put me in touch with X-Treiber from that forum?

Thanks all!