Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > BMW Tech
BMW Tech BMW Tech Forum - For Questions specific and of interest to BMW riders only.
Photo by Hendi Kaf, in Cambodia

I haven't been everywhere...
but it's on my list!


Photo by Hendi Kaf,
in Cambodia



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 26 Nov 2011
Registered Users
Veteran HUBBer
 
Join Date: Jan 2010
Location: London
Posts: 286
Dead clutch on G650 X-country

I've had a major issue and now i'm stuck in Bangkok with a broken bike. I have the BMW X-country G650 and the clutch has died. It's died in impressive fashion, it vibrates, can't find neutral and drags. This is apparently a common fault on these bikes. A bit of time on google has shown up what the fault is. I had a full service done by a guy in London and he warned me about this issue, i went to my local dealer as I have always had issues with my clutch and they said they didn't know anything about it. Well it turns out it was a recall item and the bike needs a new clutch housing and actuator assembly as the lighter magnesium one has a design fault. Added to that, when I got the bike it had the 33bhp restriction kit fitted so I'm guessing the previous owner was a learner and they are hard on clutches. So I'm in touch with my local dealer back in Tonbridge in the UK and they're looking into it but I'm not holding out a lot of hope.
Can anyone offer any advice? I'm stuck in Thailand in the middle of a trip and need to get moving asap. My actuator assembly has totally failed and BKK BMW are estimating 3 weeks delivery of new parts and the cost is insane, it's cheaper to have them sent from the UK. Even if I repair it it's likely to fail again so I'm hoping to get the recall done over here. Is there a good BMW dealer I can get help from? Should I contact BMW directly? How would I do that?
Thanks, guys.
Reply With Quote
  #2  
Old 26 Nov 2011
Registered Users
Veteran HUBBer
 
Join Date: Jan 2010
Location: London
Posts: 286
The matter is now resolved, hopefully permanently. After googling it I went in this morning with a raging hangover to look for damage. None. Nothing anywhere, the teeth were perfect, everything was fine. Then we found it, the bearing that the actuator arm runs in had moved. Knocked it back into place and the vibrations are gone, the clutch is silky smooth. I have no idea how it could have moved in the shipping crate. My only guess is that the spigot that comes out of the top of the housing was pushed hard in the opposite direction by one of the guys building the crate (or me, I guess). The design of the clutch and this basket is identical to the BMW G650gs/F650gs so i guess this could happen to them too.
BMW have replied to my emails about the recall work and are looking into it for me and I think it's best to pursue it and try to get this unit replaced before it happens again. In any case, the bike is purring and i'm a happy little Jack. Thanks to everyone who would have replied and I hope my experience has been of some use to others.

Last edited by Jtw000; 26 Nov 2011 at 10:31.
Reply With Quote
  #3  
Old 26 Nov 2011
Gold Member
Veteran HUBBer
 
Join Date: Dec 2007
Location: Bucks, UK
Posts: 642
Glad you're all sorted, what model year is the bike ( my wife has a XCO 2009 and the clutch has never felt 100%).
It's a bit late now but I had a problem with my clutch (XCH) so sent a message to BMW UK (cars) via the customer service form on the website, I was in India at the time, got a reply saying it had been forwarded to Germany.
After a few emails to and from BMW Germany a new clutch cover and rack and pinion was arranged to be shipped to Athens as that was the closest BMW dealer, by this time we were most of the way across Pakistan.
When we got to Greece weeks later (on a Sunday) the parts guy came to the shop on his day off, arranged a hotel and took us there.
Picked the bike up on Monday afternoon all fixed FOC

Cheers
Pete
__________________
Vietnam, Cambodia & Thailand 2016
Buenos Aires to NYC 2012-2013: www.facebook.com/curryhunt
India and back 2009-2010:
Reply With Quote
  #4  
Old 26 Nov 2011
Registered Users
Veteran HUBBer
 
Join Date: Jan 2010
Location: London
Posts: 286
Mine is the 07. Like you, mine has never felt right and always seemed to be slipping. I have to say, now I've been inside it everything looks like brand new. Mine had a 33bhp restrictor so maybe the last owner was a learner and abused the clutch. It did feel 100% better when i tried it so maybe now it will be ok. Might be worth having a look inside yours, it's an easy job to do and you can see the offending bearing right in the middle of the assembly. It should be flush, mine was about 6mm down and twisted.
I should also say, the first time we fitted it back in the bearing got pushed back out by twisting the spigot the wrong way so this seems to be what happened in the crate. It all makes sense now!
Reply With Quote
  #5  
Old 26 Nov 2011
Gold Member
Veteran HUBBer
 
Join Date: Dec 2007
Location: Bucks, UK
Posts: 642
Cheers for the info, my wifes 2009 is the lower version (made in China I think? Or assembled?) but I'll check it none the less.
__________________
Vietnam, Cambodia & Thailand 2016
Buenos Aires to NYC 2012-2013: www.facebook.com/curryhunt
India and back 2009-2010:
Reply With Quote
  #6  
Old 26 Nov 2011
Registered Users
Veteran HUBBer
 
Join Date: Jan 2010
Location: London
Posts: 286
I think I have an exploded diagram here somewhere. If you're in any doubt about the part I'm talking about I can post a pic.
Reply With Quote
  #7  
Old 27 Nov 2011
Gold Member
Veteran HUBBer
 
Join Date: Dec 2007
Location: Bucks, UK
Posts: 642
A pix would be good
__________________
Vietnam, Cambodia & Thailand 2016
Buenos Aires to NYC 2012-2013: www.facebook.com/curryhunt
India and back 2009-2010:
Reply With Quote
  #8  
Old 27 Nov 2011
Registered Users
Veteran HUBBer
 
Join Date: Jan 2010
Location: London
Posts: 286


Number 18 is the offending bearing. The shaft, number 18 is pulled forward when you pull in your clutch lever to open the clutch. When you force it in the wrong direction it pulls the entir bearing out of the casing. When you open her up you can see number 15 staring right at you and the bearing you can see through the middle hole and shouldn't have a gap, obviously. I have to say she runs fine now, no slip, no hassle and the clutch feels better than ever. Must have been a problem for a while.
Reply With Quote
  #9  
Old 27 Nov 2011
Gold Member
Veteran HUBBer
 
Join Date: Dec 2007
Location: Bucks, UK
Posts: 642
nice one dude, tomorrow i'm on it
__________________
Vietnam, Cambodia & Thailand 2016
Buenos Aires to NYC 2012-2013: www.facebook.com/curryhunt
India and back 2009-2010:
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
Three Kidnapped and one dead in Timbuktu pjm300 North Africa 69 16 Apr 2019 19:00
Africa - Best and Worst Awards rupertu Ride Tales 7 20 Jul 2016 10:53
DR650 Engine Dead, Ideas? brianrossy Suzuki Tech 18 4 Jan 2012 09:37

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now
, and add your information if we didn't find you.

Next HU Eventscalendar

25 years of HU Events
Be sure to join us for this huge milestone!

ALL Dates subject to change.

2025 Confirmed Events:

Virginia: April 24-27
Queensland is back! May 2-5
Ecuador June 13-15
Germany Summer: May 29-June 1
CanWest: July 10-13
Switzerland: Date TBC
Ecuador: Date TBC
Romania: Date TBC
Austria: Sept. 11-14
California: September 18-21
France: September 19-21
Germany Autumn: Oct 30-Nov 2

Add yourself to the Updates List for each event!

Questions about an event? Ask here

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

Adventurous Bikers – We've got all your Hygiene & Protection needs SORTED! Powdered Hair & Body Wash, Moisturising Cream Insect Repellent, and Moisturising Cream Sunscreen SPF50. ESSENTIAL | CONVENIENT | FUNCTIONAL.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.




All times are GMT +1. The time now is 14:35.