So we've all heard/seen the 650 xchallenge...let's see your XCOUNTRY!

Discussion in 'Thumpers' started by Olas, Dec 3, 2007.

  1. keepshoveling

    keepshoveling Long timer

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  2. Sh4ft

    Sh4ft Beater

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    My overflow reservoir hose was routed to about the same area as the weep hole, once I routed the hose to outside the skid plate I could tell my problem was the water pump seals as I was leaking coolant mixed with a little oil. The water pump shaft was scored, mainly on the coolant seal side, the shaft just spins in the seals and will eventually wear out - no matter what.

    Once I got the inner clutch case off to replace the entire water pump assembly I was surprised to see that the weep hole was not a solid tube through to the space between the water pump seals, you can only see this if the inner clutch/water pump cover is off. As a result, if you are losing coolant/oil through the seals it isn't a guarantee that it will only escape from the weep hole. If you put your fingers behind the case behind and to the rear of the weep hole you can feel the cavity where coolant and/or oil can be present because there is a gap in the weep hole tube back there. I have no idea of the rationale behind this decision by Rotax, my case didn't appear to be damaged.


    [​IMG]


    Also, I noted this:
    - Bleeding the coolant is an exercise in patience. I had to loosen then tighten the bleeder screw in the cylinder head twice - once during the initial fill, then again after I had topped off the radiator. There was still a lot of massaging of the hoses and just plain waiting for the thing to quit burping. Once the coolant level in the radiator stayed static I topped it off, filled the overflow reservoir to about half way and it's good
    snooker likes this.
  3. c-m

    c-m Long timer

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    I'm currently in Iguazu about to leave for Salta.

    The shock I had made up in the UK is terrible. They must have got the spring rate wrong or something, but it's not going to hold up once I'm im Bolivia.

    Anyone know of any xCountry xChallenge, xMoto shocks kicking around South America at all?
  4. Dutchgit

    Dutchgit Completely clogless

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    You're best off with the airshock if you can find one.
  5. Zeus99

    Zeus99 Been here awhile

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    Wow, thanks keepshoveling for a great video thread!

    I had the same thing as Sh4ft. The coolant was leaking much more where the bunch of arrows are pointing in his diagram than from the weep hole.
  6. Jim Lad

    Jim Lad Adventurer

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  7. keepshoveling

    keepshoveling Long timer

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  8. Jim Lad

    Jim Lad Adventurer

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    Well I got to within 60 - 70 meters of a bear but happily not while camping. Anyone know of a kevlar tent for next time?:-)
  9. Zeus99

    Zeus99 Been here awhile

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    I was just putting my bash plate back on after removing it.
    While tightening the front screw, the one that attaches the bash plate to the frame just behind the front wheel, it all of a sudden started turning freely even though it was still nowhere near tight.
    So I took it out and there was a slight metal shaving between the grooves.

    Did I just destroy one of the screw holes on my frame??? :becca

    If so what's the cure??
  10. Dutchgit

    Dutchgit Completely clogless

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    Drill it out, tap a bigger thread. You'll be doing that again in a few years.
    snooker and Zeus99 like this.
  11. jckid

    jckid Been here awhile

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  12. leafman60

    leafman60 Long timer

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    Thanks for giving us a notice about that thread and thanks for posting it! Great pics!

    Who needs a 1200 to travel long distance! Sometimes less is more!

    I am impressed, however, that anyone could ride that far on the stock XCountry seat.



    .
    keepshoveling, Jim Lad and cgguy09 like this.
  13. cgguy09

    cgguy09 Scientiæ Cedit Mare

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    Hey there,
    Going down my list of changes on this bike. Finally got the bendy lever installed along with a rear rack! My Sachs shock is in good order. However, I feel the same way most other people on this thread do. At 195 I'm not doing the bike many favors. Since the problem is the spring, is there a recommended brand/spring to put in it's spot. I have a few bike shops around me who I'm sure would like my money (including a BMW stealership) I did some looking around online and didn't find any threads on the concept. I don't know if it's an off the shelf thing or if there is a specific spring I'll be needing.

    I've been pretty lucky with shocks in my life, my Rockster game with Wilbers & those things are smooth as milk.

    Thanks for the input!


    -cFogs out!

    BT
    NNNN
  14. TobyG

    TobyG be happy :)

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    Instead of just tapping a larger thread,
    you could give a thread insert a try, I've grown fond of Baercoil inserts (pretty much the same as Helicoil, but without the hefty price tag).

    Thread inserts do make sense especially in aluminium, as the steel inserts are much more durable than a thread cut directly into aluminium.
  15. Zeus99

    Zeus99 Been here awhile

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    Thanks Dutchgit and TobyG!

    I'm very happy to hear that the damage is reversible.
    Steel insert do make a lot of sense and yesterday I was thinking of doing something like that.
    I was pretty pissed how I damaged the hole yesterday because the screw was nowhere near tight :nah

    TobyG can you tell me did you use a thread insert at the same spot, where the skid plate screws in and if so which ones did you use?
  16. TobyG

    TobyG be happy :)

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    No, not exactly. Maybe because I don't have a G650X, my bike is more like the grandfather of the G650X, a F650GS converted to Enduro.

    [​IMG]


    Anyways, back to topic, I've used it on the front bolt of my bashplate (a single M6 bolt) and it's holding up for over 2 years now,
    additionally I've used thread inserts on my mountainbikes' forks, as the previous owner overtorqued some of the bolts.

    So far, I didn't have any negative experiences with thread inserts.

    As I'd said before, I am using Baercoil inserts, which are effectively the same as Helicoil.

    There is a few more options, such as Wuerth Time Sert, Ensat, Baerfix, but these are really only necessary for critical, load bearing bolts.
    And they have one big disadvantage, the pilot hole you have to drill is much larger compared to the Helicoil/Baercoil system.
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  17. Zeus99

    Zeus99 Been here awhile

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    WHoa!
    Your bike looks amazing!
    Did the Touratech seat make it a little narrower while standing on the pegs?
  18. TobyG

    TobyG be happy :)

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    Thanks :shog

    The seat is a modified F650 Rallye seat and yes, it is slightly more narrow than the other 2 seats I have for the bike,
    but the main reason I am using this seat is the 3 storage compartments (click for pictures) built into the seat that I am using for tools and some cold/rainy weather clothes.
  19. Zeus99

    Zeus99 Been here awhile

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    Nice! :) Never enough storage space.
  20. Bli55

    Bli55 -

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    Great info, haven't thought to check that area myself!

    At least that should confirm where the water's going...But that I changed the water pump set at ~10000km for the first time, and water is still disapperaing somewhere! A little over 20000km on the odo now.
    It is not inside the oil. I doubt it leaks inside the combustion chamber. :becca

    It didn't even look too bad, the shaft:

    [​IMG]

    And I used double-lipped SKF seals instead of included standart ones.

    [​IMG]

    And definitely pressed the water-side seal correct way around:

    [​IMG]

    Is nobody else having to top off their overflow from time to time?
    Maye its just a normal water loss rate for these bikes...(wishful thinking)

    As for the warped convers...:baldy How could I possibly check for this?
    snooker likes this.