BMW G650X Challenge Thread Index

Discussion in 'Thumpers' started by GB, Apr 24, 2008.

  1. PaulyD

    PaulyD Been here awhile

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    Dec 9, 2014
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    help! I replaced my clutch friction plates and springs with the EBC ones, and I replaced the clutch cover with a TR650 one, for the updated cover, I looked everything over to make sure it was the same before installing.. everything is installed, and now I can't get the clutch to disengage. At first I thought that maybe the splines on the cover shaft and the shaft on the basket weren't lining up correctly, so I pulled the cover, looked it over, and reinstalled. the clutch pulls fine, albeit a bit heavier with the new springs. I tried to rotate the piece that the cable hooks onto to get some more throw, but the results are the same.. any ideas? The TR650 cover has been used on the g650x before with no problems..
    edit: I should also mention that I've messed around with the cable adjustments at the lever as well.
  2. MJS

    MJS Long timer

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    Since you say the clutch pulls fine but a bit heavier, I'll assume you can feel the proper resistance of the clutch springs. Did you soak the friction plates in oil before installing? I put them in a zip-lock bag of oil for a day before installing.
    keepshoveling likes this.
  3. PaulyD

    PaulyD Been here awhile

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    Correct, I can feel the resistance of the springs. I didn't soak them but for maybe five minutes... The clutch feels completely normal when pulling the lever, it does disengage somewhat, to the point where I can push the bike a bit, but definitely not completely disengaged
  4. Dutchgit

    Dutchgit Completely clogless

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    Did you put them in the right order ?
    Steel plate goes in first, a friction plate goes in last before the cover.

    [​IMG]
    keepshoveling likes this.
  5. PaulyD

    PaulyD Been here awhile

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    I did, the only thing I changed was I swapped the position of a steel plate. The spring length was the same, my thought currently is maybe the springs are just too stiff and not allowing the clutch to fully disengage.. If I have time tonight I may put the stock ones back in and try that
  6. keepshoveling

    keepshoveling Long timer

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    Are you sure you have the clutch release fork lever on far enough back?
    Dutchgit likes this.
  7. PaulyD

    PaulyD Been here awhile

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    I certainly believe so, I played around with a few different positions, to get the farthest throw. I even unhooked the cable, moved it so I could get a pair of pliers on it to twist it by hand, twisted it as far as it would go and still nothing..
  8. PaulyD

    PaulyD Been here awhile

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    so, I pulled it apart again, the new springs were maybe twenty thou longer than stock, so I put the stockers back in even though that shouldn't have made a large difference.. I also double checked that everything was in the correct order.. reassembled everything yet again, and the same thing... I decided to fire it up in neutral to get oil flowing, and it seems fine once running, it can be in gear, pull the clutch and the bike pushes fine. strange. I think I'm going to put some miles on it and see what happens..
  9. keepshoveling

    keepshoveling Long timer

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    Let us know if it ends up being fine after getting some more oil circulating. That'd be some interesting information. When I replaced my clutch plates I soaked them for a day before and didn't have the same issue.
  10. Butters

    Butters Kwyjibo

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    I took my cover off to inspect it (was fine) and when I put it back on the clutch was dragging regardless of how I adjusted it. So I ordered a new cover, installed it, and it still was dragging. Turned out the throwout bearing wasn't seated properly. Might be your problem. I posted some pics about it in this thread a year or two ago.

    Edit: I forgot I had them on Picassa
    [​IMG]
    [​IMG]
    jonnyc21 and keepshoveling like this.
  11. PaulyD

    PaulyD Been here awhile

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    Will do! I plan on reinstalling the HD springs as well, so I'll put some miles on it, pull it apart and re inspect it when I put the new springs back in.

    very interesting! the clutch doesn't seem to be dragging unless it's not running, and has been sitting for a little bit. it shifts fine, and neutral is certainly easier to find than with the old cover. I did see a wear spot on the old cover, the bike only has 6k miles on it.
  12. Butters

    Butters Kwyjibo

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    Yep. I don't know how wide spread of a problem it is, but it made my brain melt for awhile. My clutch had a very slight drag before I took it apart, which is why I was inspecting the cover. When I put it back together I clearly did something to unseat the bearing even more. It is a snug fit, but definitely not immovable. Even though I had the older style, it actually was in perfect shape. I guess the new cover is a good preventative measure, but I would have preferred to save the money until I needed it. On the plus side, I never would have found the unseated bearing.
    PaulyD likes this.
  13. jonnyc21

    jonnyc21 Trials Ninja

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    I had the same unseated bearing issue with my clutch as well as the clutch cover issue. Fixed both and love my clutch again. :thumb
  14. eaglescan

    eaglescan Borrego rocks

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    I found the wear problem starts at about 25000 km. It was near impossible to see ,until measuring the hole . I went through 3 actuating shafts and 2 more years before finding the problem. Cover bushed and still good, now 750000 km.
    crash a-ron, PaulyD and Dutchgit like this.
  15. PaulyD

    PaulyD Been here awhile

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    My bike was getting a little tough to get into neutral every once in a while, and I came across the complete husky cover for just under $60 shipped so I couldn't pass it up
    crash a-ron likes this.
  16. jjmead1

    jjmead1 now THAT"S a bike!

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  17. Yukon Ho!

    Yukon Ho! We can go ANYWHERE!

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    Does the Husky (tr650?) cover require modifying the shaft? (...on an '07 XCo?)
    Where'd you get the cover, PaulyD?
  18. PaulyD

    PaulyD Been here awhile

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    nope! the TR650 cover is the exact same as the updated '09 xcountry cover, bolts right on, no mods needed at all.
    I bought it on eBay, used. luckily it included everything, so all I had to do was bolt it on and go. I took a few pictures I will upload in a day or two
    Yukon Ho! and crash a-ron like this.
  19. Reg York

    Reg York Boet

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    Hi, something to check is a spring on the shaft they call a Diaphragm Spring, Our end of the world we have found that these need to be replaced especially when we have had issues with the covers and breaking shafts..... In South Africa this part cannot be bought separate but part of the clutch kit from BMW.... you guys may be more fortunate with the bigger markets......
    In My city of Port Elizabeth we are fortunate enough to have a guy who has become quiet inventive in reproducing/re purposing these which seem to be working.... at this stage...
    PaulyD likes this.
  20. treps

    treps n00b

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    Sorted. Thanks all
    Reg York likes this.