Help :Please can anyone with an X try this for me (clutch issue)

bighair · Jun 7, 2015

Hi
Had a look at our X Country (07) clutch everything checks out ok . (original type cover)
But it is hard to select neutral and does go in with a bit of a clunk (they all do that sir).

All I am asking is if somebody or a few owners could do the following:

You will need a 24mm spanner with the clutch lever pulled in and the spanner on the operating arm can you move the operating arm any further ? (basically no reserve travel)
Please no excessive force on the operating arm take care.

Mine does not , my F650gs (2000) does by a fair amount and so does my funduro.

Also a long shot does anyone have an early cover and a later cover to hand could you measure the depth of the hole where the operating mech moves in and out .

If you know if yours is the later clutch cover or early would be helpful .

Thanks :thumb2

jtw000 · Jul 4, 2015

They really all do that! It was a known issue and the later XCs had a modified clutch housing. My guess is that cover from any BMW Rotax would fit and sort out the problem. I fitted a heavy duty EBC clutch with 10% heavier springs. Problem went away for me.

Timpo · Jul 4, 2015

Your clutch actuation arm attaches to a pinion inside the cover, which inturn runs on a gear rack that acts directly to the clutch pressure plate to disconnect the plates when operated. There will be wear in the gallery that the gear rack shaft runs, the original European engines have the shaft running on the alloy casing. The 'fix' is to fit a new 'Chinese' cover, these has a steel bushing where the gear rack shaft runs.
The wear in your casing is allowing the rack and pinion to fall out of mesh, so effectively losing the stroke of the mechanism, causing the clutch not to dis-engage enough for a smooth neutral selection.
So, a new cover (11147700331), a new rack (21217709526) and pinion (21217700306), an upper (21217700120) and lower (21217701501) needle bearing, a seal (21217700173), and a cover joint (11147700194) if in poor condition. Part numbers in brackets.
Take a look at these parts diagrams:-
http://www.realoem.com/bmw/enUS/par...08-K15-BMW-G_650_Xcountry_08_0141,0151_&mg=21
http://www.realoem.com/bmw/enUS/sho...W-G_650_Xcountry_08_0141,0151_&diagId=21_0156
http://www.realoem.com/bmw/enUS/sho...W-G_650_Xcountry_08_0141,0151_&diagId=11_4082

Any problems, give me a shout. :thumb2

Best of luck.
Timpo.

Losttheplot · Jul 4, 2015

Timpo said:
Your clutch actuation arm attaches to a pinion inside the cover, which inturn runs on a gear rack that acts directly to the clutch pressure plate to disconnect the plates when operated. There will be wear in the gallery that the gear rack shaft runs, the original European engines have the shaft running on the alloy casing. The 'fix' is to fit a new 'Chinese' cover, these has a steel bushing where the gear rack shaft runs.
The wear in your casing is allowing the rack and pinion to fall out of mesh, so effectively losing the stroke of the mechanism, causing the clutch not to dis-engage enough for a smooth neutral selection.
So, a new cover (11147700331), a new rack (21217709526) and pinion (21217700306), an upper (21217700120) and lower (21217701501) needle bearing, a seal (21217700173), and a cover joint (11147700194) if in poor condition. Part numbers in brackets.
Take a look at these parts diagrams:-
http://www.realoem.com/bmw/enUS/par...08-K15-BMW-G_650_Xcountry_08_0141,0151_&mg=21
http://www.realoem.com/bmw/enUS/sho...W-G_650_Xcountry_08_0141,0151_&diagId=21_0156
http://www.realoem.com/bmw/enUS/sho...W-G_650_Xcountry_08_0141,0151_&diagId=11_4082

Any problems, give me a shout.
Best of luck.
Timpo.

When mine failed the shafts showed no wear, apart from the broken teeth. All the wear was in the cover. IIRC the new clutch cover comes with bearings and seals fitted already.

Timpo · Jul 4, 2015

Losttheplot said:
When mine failed the shafts showed no wear, apart from the broken teeth. All the wear was in the cover. IIRC the new clutch cover comes with bearings and seals fitted already.

LTP, IIRC....the Euro covers came with bearings, but the Chinky one didn't.....but I guess the OP should check, and also double check my part number ramblings too, as my head is cider-pickled!

Losttheplot · Jul 5, 2015

Timpo said:
LTP, IIRC....the Euro covers came with bearings, but the Chinky one didn't.....but I guess the OP should check, and also double check my part number ramblings too, as my head is cider-pickled!

I didn't know that! I must have had a euro cover then, as mine came with the bush and the bearings and seals fitted already.

Might be worth the OP checking the clutch basket as well, to make sure the teeth on the clutch plates haven't worn the basket to the point they don't slide freely in the basket when the clutch is disengaged. Not heard of this happening before on a X bike, but an issue on some mx bikes that have had hard use.

Sounds like the mechanism is operating fine, Bighair, have you had the clutch plates out? i wonder if the steel plates have got cooked and warped (might be showing signs of blueing)?

bighair · Jul 5, 2015

Plates and steels look fine nothing untoward.Basket nothing wrong.
I asked about the lack of any extra movement of the operating arm after the clutch lever is pulled in because both my other 650 engine BM's have loads .
I know the outer cover is of a different design , but I would have expected some additional travel on the arm but none. This would / will cause a problem if the operating mech has topped out thrusting it onto one outer wall of the bore of the outer cover in turn causing the wear reported and fixed ? by the steel insert.
BM change a lot of the clutch in the later model G , and would like to find out if the inner basket is any shorter due to the thinner clutch stack this would have then in turn moved the clutch away from the outer cover giving more travel (that is my way of thinking).

Help :Please can anyone with an X try this for me (clutch issue)

bighair

Active member

jtw000

Registered user

Timpo

North Wales TRF

Losttheplot

Well-known member