BMW G650X Issue Log (xCountry, xChallenge, xMoto)

Discussion in 'Thumpers' started by andrewgore, Jul 20, 2009.

  1. orlando_orange

    orlando_orange deslyxic tepyr

    Joined:
    Jul 3, 2008
    Oddometer:
    694
    Location:
    back in noo zillund
    not sure exactly what type of plastic the fairing is but if it is ABS then you can weld it back together - you can buy ABS welding rods and then use a decent soldering iron to weld them back together - have done it on my old bike. there's also a chemical welding method but can't recall which chemicals you need...

    for the plastic welding you basically file the cracks to make a nice groove (the ABS rods should be a triangular cross-section) until the rods sit in them nicely, then apply the soldering iron to melt it all together... takes a bit of practice but i dropped my old super tenere on the welds plenty of time and they didn't crack again....
  2. macrocephalic

    macrocephalic Adventurer

    Joined:
    Sep 7, 2007
    Oddometer:
    62
    Location:
    Brisbane
    Xmoto. ~55k km.

    I too have the warm start problem (where it will crank over forever but never fire after filling up with fuel). I've had it intermittently since getting the bike, but it seems to be worst when it's raining - I seem to always be stuck at a fuel station in the rain.

    If the bike is hot and not stopped for too long then it's fine. If the bike is cold then it's fine. It seems that the time it takes to fill up and pay for fuel is the sweet spot for making it fail.

    The other day I had it fail on me, and after cranking for a few minutes I decided to roll start it. I rolled it down a large hill, in third, and the engine was rotating at a decent speed for probably 10 seconds total - and not one fire. After pushing it back to the top of the hill it magically started again.

    The sticking injector theory is interesting. I might try a bottle of injector cleaner followed by the 2-stroke oil idea and see how it goes (I already have a new set of plugs waiting for when they get fouled).

    I'm also going to be more diligent with putting it on the trickle charger overnight (although I do ride it 5+ days a week) in a pretty warm environment.

    I'm certainly less than impressed with the reliability from a ~BMW~ (it seems to be more aprilia than bmw)
  3. Royal Tiger

    Royal Tiger Sd Kfz 182

    Joined:
    Sep 21, 2006
    Oddometer:
    1,769
    Location:
    Lehigh Valley, PA
    Having an issue. Changed the plugs among other things (non engine related) and after putting it all back together it cranks but won't fire. Fuses all good and everything looks right. Have to check spark and see if they are both firing. Didn't touch the fuel system at all so that should be good. Did all the usual stuff, side stand switch, clutch lever, etc... I'm stumped at this point. I think I'll pull the plugs and do it all over in case I missed something. I know I have the two coils right.
  4. macrocephalic

    macrocephalic Adventurer

    Joined:
    Sep 7, 2007
    Oddometer:
    62
    Location:
    Brisbane
    These bikes are incredibly sensitive to voltage from what I've discovered. If the battery isn't great then the cranking voltage will cause them not to fire - otherwise known as the G650 hot start issue. Check your battery.
  5. aprilian

    aprilian Can I change this?

    Joined:
    Feb 20, 2009
    Oddometer:
    476
    Location:
    MinneSNOWta
    Did you unplug the sensor on the air box and not get it fully seated when reassembling?


    Sent from my iPhone using iTypo.
  6. Royal Tiger

    Royal Tiger Sd Kfz 182

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    Sep 21, 2006
    Oddometer:
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    Location:
    Lehigh Valley, PA
    Battery was on a tender the whole time the bike was apart but I'll check it. Thanks.


    I'll check it to make sure. Thank you.
  7. ARozanski

    ARozanski Adventurer

    Joined:
    Apr 27, 2007
    Oddometer:
    10
    Location:
    Macungie, PA
    Hi all, I am responding to RT's replies above. His bike is at my place. He dropped it off in December, and it has been sitting since, while we work on it. The seat, side panels and top panel have been removed. We removed the air box to change the spark plugs. Both coils were removed, the connectors were kept separate so we did not mess up the installation order. I did disconnect the probe connector. The plugs were changed and everything reinstalled the way it came off, including the connector. Once that was done, we re-installed the airbox, replaced front and rear brake pads, flushed the brake lines, installed a centerstand (it did not affect the side stand switch in any way), added crash bars up front, and I just changed out the coolant. We added heated grips (Oxford Heaterz), I consolidated the three accessory power wires (power port, battery tender, heated grips) into one negative, one positive connection, so there are only two negative connections and two positive connections to the battery, accessories and main leads. The battery has been on a tender and was fully charged. I did not perform a load test. When I reconnected the battery, the dash lit up momentarily, then went off (the key was in the OFF position).

    I wanted to start the bike to circulate the coolant and finish adding the coolant (has about 150 mL to go). Turn the key on, everything lights up strong. I lifted the side stand, pulled in the clutch lever, made sure the kill switch was in the run position, and hit the button. It turned over just fine, lights stayed bright, but would not fire. It has gas.

    I have now gone over the plug connectors and coils again, all looks right. The probe is connected tight. I will charge the battery again and do a load check, but it seems fine. I didn't hear any fuel pump noise, but I don't know what they sound like on these (I am used to carb'ed bikes). We didn't touch the fuel system. All fuses are good. No messages on the screen.

    I am at a complete loss. I will check for spark by removing a coil, placing another plug in it and grounding on the head. Assuming it has spark, what is the next step?
  8. ARozanski

    ARozanski Adventurer

    Joined:
    Apr 27, 2007
    Oddometer:
    10
    Location:
    Macungie, PA
    Okay, I can hear the fuel pump cycle with the kill switch, and I smell fuel through the TB after cranking. I removed one coil, added another plug, grounded with a wire to the battery negative, and cranked. I get one blue/white spark, then nothing as it cranks. If I stop cranking, wait, then crank again, I get one spark, then nothing.

    I have also swapped out the clutch lever, it was changed after the bike arrived at my place, and the bike has not run since. The area near the clutch switch is different between the two levers, so maybe I'll get lucky. The battery is back on the charger right now.

    I'm 99% certain this is a spark issue, something not letting the coils fire.
  9. aprilian

    aprilian Can I change this?

    Joined:
    Feb 20, 2009
    Oddometer:
    476
    Location:
    MinneSNOWta
    ARoz, you sure your new clutch lever is completing the safety circuit when pulled in. Bike won't start with that switch open - I don't know if it will crank without the switch.
  10. macrocephalic

    macrocephalic Adventurer

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    Sep 7, 2007
    Oddometer:
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    Brisbane
    My bike starts just fine with the clutch out. Startup procedure for me is, turn key, make sure bike is in neutral, DON'T TOUCH ANYTHING, then press the start button firmly. If you don't press the button firmly and it gets through 2 rotations then stops then it will be harder to start after. If you mess with the throttle during the POST then it will affect idle etc.

    That said, I still think it sounds a lot like the whole warm start issue that many have.
  11. ARozanski

    ARozanski Adventurer

    Joined:
    Apr 27, 2007
    Oddometer:
    10
    Location:
    Macungie, PA
    Solved - it was the clutch lever. Silly Tiger, using Japanese levers on a German bike :huh
  12. Butters

    Butters Kwyjibo

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    Oct 10, 2008
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    Location:
    NoVA
    :clap

    It always seems it's those simple things that take so much time/energy to solve.
  13. macrocephalic

    macrocephalic Adventurer

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    Sep 7, 2007
    Oddometer:
    62
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    Brisbane
    That really puzzles me. Last year when some bastard knocked over my parked bike and broke the clutch lever, I took the lever off my XT600 -which kind of fit- and used it for about 6 weeks until I got around to replacing it.
  14. Royal Tiger

    Royal Tiger Sd Kfz 182

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    Sep 21, 2006
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    Location:
    Lehigh Valley, PA
    Thank you so much Tony for all your help. I could never find a friend as awesome as you again no matter how long I looked.

    Thanks for the pm with things to check Marc. I went with the Suzuki lever from the XChallenge index thread and thought for $11 how could you go wrong? I'll be buying the proper set from Wunderlich this week.
  15. ARozanski

    ARozanski Adventurer

    Joined:
    Apr 27, 2007
    Oddometer:
    10
    Location:
    Macungie, PA
    You must have gotten lucky with the lever profile, there is a pronounced bump on the original, and this was lacking on the Suzuki lever.
  16. kito

    kito Been here awhile

    Joined:
    Mar 8, 2009
    Oddometer:
    281
    Location:
    cheshire , England
    any one any idea why my bike wont idle when cold but is ok when hot .
  17. Superstar

    Superstar Been here awhile

    Joined:
    Nov 7, 2007
    Oddometer:
    500
    Location:
    Texas

    Same here. Mine has (thus far) been resolved by cleaning the idle valve (wasn't dirty at all), keeping it on the tender, and running Marvel Mystery Oil in every tank.

    When I ran into the issue, it never failed to start by holding the starter button at half-throttle.
  18. macrocephalic

    macrocephalic Adventurer

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    Sep 7, 2007
    Oddometer:
    62
    Location:
    Brisbane
    The half throttle trick normally works for me as well, but occasionally not. I have an idea about putting a small secondary battery and diode in so the voltage to the ECU stays up when it's cranking - because I think that's the main problem.

    At the moment it's working fine with the idle solenoid cleaned and put on the battery tender each night. Now I need to get a second battery tender since I stole this one from my XT.
  19. Superstar

    Superstar Been here awhile

    Joined:
    Nov 7, 2007
    Oddometer:
    500
    Location:
    Texas
    I did the same thing...here is my second battery tender:
    http://www.amazon.com/gp/product/B000H90XDS/ref=oh_details_o03_s00_i00?ie=UTF8&psc=1

    Grab a SAE to Powerlet adapter and just charge the battery from the Powerlet port if you already aren't doing so...makes it super easy to connect/disconnect.
  20. macrocephalic

    macrocephalic Adventurer

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    Sep 7, 2007
    Oddometer:
    62
    Location:
    Brisbane
    I actually have a wall wart version of that already, it came with two battery connectors, one's installed on each bike - I'm just too lazy to climb over everything to switch it from one bike to the other every day :rofl