G650 Sertao - 1st gear keeps popping out - Please help

[timob]

Hiya,

I have a 2012 Sertao with 6100 miles on the clock. As I have seen on these forums the G650 does have a somewhat agricultural gearbox between 1st and 2nd, so I have just made do however I have a problem now as I get this (last 500 miles or so in particular):

Symptoms:
At standstill, select 1st makes the usual clunk and bike makes a small lurch forward, its always done this however when I attempt to ride off its actually in neutral (although neutral light doesn't always light). Shift down again still clunks and may or may not actually be in gear. The only way I have been able to reliably engage 1st is to do above but leave my foot gently pressing down on the gear lever as I let the clutch out.

All other gears such as 2nd and upwards are as sweet as a nut.

What I have tried:
- Changed oil and filter as needed doing (about 1500 miles ago) used Castrol Power One 15W50 as per BMW dealership. I was hoping this might make the clunks better, but no difference.
- Adjusted clutch freeplay as Chaingangs FAQ on f650.co.uk http://faq.f650.com/FAQs/ClutchAdjustmentFAQ.htm . I have taken up pretty much all cable slack so that the friction zone is almost all the way out on the lever to get maximum clutch disengagement (this helped a little). One thing I have noticed is that Chaingangs FAQ clutch lever (gearbox end) dimension A is 47-52mm however mine has a dimension of 43mm with the clutch lever all the way out i.e would be smaller if I pulled the clutch lever in to the Release Point. Does the G650GS have a different A dimension to the F650's?

If I moved the clutch lever (gearbox end) above one spline outwards then there is not enough slack in my cable to get any free play at the hand lever end even with the adjuster all the way in.

Any ideas as its somewhat of a danger as unless I have my foot resting down on the gear lever when I start off then I ain't going anywhere.

Thanks in advance.

 

[Timolgra]

It's either fully in first gear or not regardless of any clutch adjustment or fault so I'f suggest further investigation as to why it's not fully engaging the gear, perhaps a bent fork selector being the most obvious cause.

 

[timob]

Hiya. Thanks for the reply. It's been a while since I took the gearbox apart on a bike (23yrs)so are we saying the whole engine/gearbox has to come out, split and checked?! Is there a fork selector for each gear hence why the other gears are fine?

Is there anything else I could try before I get to this stage?

Thanks

 

[Timolgra]

Yes you'd need to split the engine (if that's the fault) although I've not split a 650.
Have a look at this pic which shows a damaged/worn selector on the left, this may have been cause by stamping too hard on the gear lever (possibly as a result of poor clutch adjustment or just because the box is pretty agricultural).

Also have a look through this section
http://faq.f650.com/FAQs/Gear_Shifting.htm

 

[timob]

I was really hoping not to have to take the whole thing apart. I will try living with it for a bit and adjusting the the way I change gear (less clutch pulled in according to that guide), leaving my foot slightly pressing down until the clutch is all the way out - not easy doing a hill start and the rear brake pedal though...

Any other ideas?

Thanks

T

 

[Dansin]

Not always possible but they're usually easier to click into first when you're moving. Either before you come to a halt or rocking the bike.

It sounds like it should be a stretched clutch cable, not adjusted properly or the fork selector.

 

[Timolgra]

I was really hoping not to have to take the whole thing apart. I will try living with it for a bit and adjusting the the way I change gear (less clutch pulled in according to that guide), leaving my foot slightly pressing down until the clutch is all the way out - not easy doing a hill start and the rear brake pedal though...

Any other ideas?

Thanks

T

Use the front brake for your hill starts

 

[MickDB1]

Just make sure yer gearchange lever is not fouling owt on its movements and the clamp on the splined shaft is tight as well
I have not read of this problem on any forum yet

 

[timob]

Hello

- Gear lever is not fouling the bike or loose on its shaft.
- clutch adjustment has 1-2mm at clutch lever end.

Could any Sertao/G650GS owners measure this distance A on their bikes. I really don't think it will make much difference what the clutch lever at the gearbox end and the clutch lever handlebar is set to as its the overall freeplay that's important? i.e. the distance A depends on the stretch in your cable and clutch plate wear and is less important than the degree's rotation of the clutch splined pinion for clutch disengagement?

This is from the F650 repair guide

 

[timob]

The total distance difference at the clutch gearbox lever end when clutch lever is out and pulled in is 10mm does that seem right?

Thanks

 

[Dansin]

Mines an F but I can't imagine it'll be different to the G. Will have a look later.

 

[MickDB1]

The distance on my 2013 Sertao for A is 39 mm - but that is with the cable fitted - and it works the clutch as it should I reckon. The dimension B on my bike is a very loose 2 mm.
HTHY

 

[timob]

Thanks for the reply Mick, that's basically the same as mine. I had a good play around with the clutch lever (on both ends) and I am happy this problem is not caused by poor clutch adjustment. Which is not good as it means the flipping thing needs a good taking apart and new fork selector and possibly other parts. I will have to try to keep going and put it down for a winter over haul job as I am rather skint since I got back into this motorbiking again ; )

I like the comment about doing hill starts using my front brake instead (so I can keep my foot pressing down when letting the clutch out) - have you seen how many steep hills there are in Sheffield ..... Some of them are so steep and gravely that the back brake is the only option.

If anyone has any other suggestions to check (other than sanity) please, please let me know.

Thanks

 

[MickDB1]

Every Sheffielder I have ever met assures me Sheff is like Rome = Built on 7 hills.
I will have a look on another forum or 2

 

[MickDB1]

Up to now
Change oil if its been yonks since last change
Check chain tension

http://faq.f650.com/FAQs/Gear_Shifting.htm

HTHY and keep us informed please

 

[Gardnep]

Up to now
Change oil if its been yonks since last change
Check chain tension

http://faq.f650.com/FAQs/Gear_Shifting.htm

HTHY and keep us informed please

Don't worry too much, I have an almost new 5000k G650GS that has been doing the same thing since birth. Told the service about it but they said I just had to be more decisive on the shift. Bit disconcerting when it happens half way round a corner. Probably just an undocumented feature like engine stopping at the lights.

 

[timob]

Hi thanks for the reply. I have found this prob can be much reduced if you barely pull the clutch in for engaging 1st. To be honest I have no faith in it when I really need to go off a busy junction so leave my foot pressing down in the gear lever.

I love this bike and this is my only gripe however it really does ruin the experience. If anyone has the answer then let me know otherwise I will have to live with it.