G650 XChallenge - any clutch problems?

[JohnnyBoxer]

Hearing reports that some XCountry owners are have clutch probs, due to a clutch design problem

The part numbers appear identical between the XCountry and XChallenge (checked MaxBMW parts fiche).................so if there's a problem with Country..........why not the Challenge?

The probs are well documented on the US Puma system (similar to UK VOSA)

Problems are related to running out of clutch adjustment and inability to disengage the clutch and some parts fracturing inside clutch basket

I've had no issues, have you?

Colebatch would be the one, his XChallenge has 80,000k on it

 

[Timpo]

My money is on:-
Wrong oil used and extreme dragging of clutch, causing excessive heating (then cooling when bike engine cools) and eventually, the plates fail.


T.

 

[JohnnyBoxer]

My money is on:-
Wrong oil used and extreme dragging of clutch, causing excessive heating (then cooling when bike engine cools) and eventually, the plates fail.


T.

Seems a bit more involved, what I find difficult is that this engine has sold in huge units previously and all is ok, maybe just down to the redesigned G Series slimmer casings in Magnesium

Here's the data, from Drone on ADVRider

There is a design fault with the clutch housing. The splined shaft that engages the clutch chews away at the clutch housing causing it to stick and jam. I have just had mine sorted under warranty.

Some details off the recall and parts required that have been passed onto me.

Service detail:

Clutch lever hard to pull in, bike walks when clutch disengaged, almost impossible to find neutral. Inspected Cable and found freeplay maxed out at lever adjuster and spine adjustment at cover. Inspected cable length, ok. Removed Clutch access cover and found tooth missing on pivot arm operates clutch plates. Searched bulletins and measures, found PUMA Measure US-22898888-02 ordered all necessary parts...

Parts:
Needle sleeve: T99L00N
Operating Shaft: T21500
Set of clutch Disks: T212A2
Release Bearing: T21500
Shaft Seal: T99DooTW
Gasket: T99D00TG
Clutch Rel. Fork Lever: T21500
Needle Sleeve: T99L00N
New design clutch housing


Hope this helps as there is not a lot of info out there about this problem.

 

[Timpo]

Nope, I can not relate to the problem described..... my is fine, but the bike only gets light trail use.

T.

 

[ncpierce]

Clutch lever hard to pull in, bike walks when clutch disengaged, almost impossible to find neutral.

That almost perfectly describes what mine is starting to do. Only done 2.5k miles but the first 1.5k were spent as a BMW school bike in Wales. I have my suspicions about the clutch cable so am changing that first but will delve deeper if/when I need to. I was wondering if my clutch was shot from all the abuse on the off-road course but it may not just be that.

Nigel

 

[JohnnyBoxer]

Nope, I can not relate to the problem described..... my is fine, but the bike only gets light trail use.

T.

Me neither........................but it seems to start @ 8-10,000 miles onwards or as ncpierce decribes

My dealer is onto it.....................they have seen it before - but on a F650GS Twin

 

[powroll]

Seems a shame theres a weak spot on such a tough bit of kit, is the new clutch housing inside spline just a better machined tolerance or a different material, did you change the drive gear ratio on your Xc , just wonder if this puts a greater strain on the clutch during engagement.
Have to just hope good oil eeks out the mileage over 10K before it goes bang or that it was a bad machined batch and its the luck of the draw.

 

[JohnnyBoxer]

Seems a shame theres a weak spot on such a tough bit of kit, is the new clutch housing inside spline just a better machined tolerance or a different material, did you change the drive gear ratio on your Xc , just wonder if this puts a greater strain on the clutch during engagement.
Have to just hope good oil eeks out the mileage over 10K before it goes bang or that it was a bad machined batch and its the luck of the draw.

I have no info.....................trying to ascertain the facts on something I picked up on ADVRider

 

[ncpierce]

I have my suspicions about the clutch cable so am changing that first but will delve deeper if/when I need to. I was wondering if my clutch was shot from all the abuse on the off-road course but it may not just be that.

Clutch cable has been changed but a quick play in the garage and on the drive seems that it has not yet solved the problem. I will need to get the bike back out on to the road for test ride first and then I may be investigating the clutch.

 

[JohnnyBoxer]

Clutch cable has been changed but a quick play in the garage and on the drive seems that it has not yet solved the problem. I will need to get the bike back out on to the road for test ride first and then I may be investigating the clutch.

Sounds like it's happened to you also

I'd be taking it to a BMW dealer in Jan 2011, armed with the above technical info printed off in the early part of this thread

 

[rossi]

25k miles. OK so far but the clutch cable is approaching the end of its adjustment.