800GS Blown Clutch Replacement Surgery - DIY

I have not had dealings with any of these guys, but got their name somewhere:

http://www.realoem.com/bmw/

http://www.bikebandit.com/2010-bmw-f800gs/o/m20814#sch692892

Note that over the years BMW has modified some of the parts in the clutch assembly..

Thanks to all for the clutch change instructions. So easy, even I was able to do it.

Had some clutch slippage when I was in Mexico but was able to baby it back home (BC) and did the replacement in my garage which was better than the side of the road. Now that I have done it, could do it again on the side of the road.

Bought the parts from Sierra BMW online. Good folks to deal with - the parts guy found both old and new numbered parts in the BMW system and made sure I received the new ones.

It's great to see this thread still coming along and helping folks out. The power of ADVrider.


I will add in these guys for a good source for parts, it's a big shop and they stock a lot of stuff.

http://www.ascycles.com/

Hey ChiTown!
I was just wondering what you were up to this morning!
Are you working on any new adventures, or are you on the Roadie circuit these days?

Howdy JR!

I'm currently gigging, getting ready to bounce around on tour and hopefully make some to time to get LOST when it's over.
At least I was able to ride to rehearsals.

Excellent! Glad all is well and the odometer is ticking on up!

I hope to be trekking to my old stomping grounds - Key West - at the end of the month.
So far it seems to have been 10 - 15 degrees or so hotter here in the mid-Atlantic than it has been in the Keys....

I'm biting the bullet and getting the kit from our local yokel. After tickling his ears on "the newer kit" (mentioned in this thread but not spilling the source) I am now being offered a 25% discount. Do I take the discount? May be trading/selling the bike next year. Thanks!

Ok, did any of you happen to suffer from the symptoms described in the thread below?

http://advrider.com/forums/showthread.php?t=806022

My clutch isn't slipping, it just feels like crap. I already put 'slack' into the cable, like, a good bit.

Hooray! Clutch!

Don't know what the difference is between the new and old versions of the kit. I did notice the new springs seemed a bit longer and I presume do a better job of pressing the clutch pack together.

If the dealer is being upfront and offering a discount on the old version then sounds like he is being straight up with you. My impression is that the new kit is supposed to last longer than the old one and both will do the job for the time being.

Comments on updates here:

http://www.advrider.com/forums/showpost.php?p=13166522&postcount=19

One of the common tricks in the old days (and probably still is ...) was to put a washer or two of the correct diameter at the bottom of the wells under the bottom of the clutch springs thus giving them more preload and thus a bit more clamping pressure .... and requiring a bit firmer grip on the clutch lever.

Not sure I should ask here so mods, please move if necessary...

I did the procedure described here with a friend of mine who is a pretty solid mechanic. I am a total noob but willing to learn.

The procedure went well and the new clutch works great! Bites good, smooth shifts, etc. The only issue is when the bike is cold, when I first pull in the clutch after starting the bike in neutral, there is a vibration around the friction point. After one or two pulls it stops. Same thing, if I start the bike hot, no vibration...

Where did we mess up? Am I destroying my engine?

Thanks for your support guys!

In the "old days" it was recommended that the new fiction disks be soaked in motor oil for a while before installation.... I don't remember how long you were supposed to soak them, I always let mine soak overnight ...

Did you guys soak the friction disks or put them in dry?

I honestly don't know if BMW suggests that or not, but it might be your problem...?

Thanks for your reply JR!

Yes, we did soak the disks in oil all night before the surgery.
I made sure they were all covered in oil...

Well that was the "easy" suggestion...........

This thread might have some hints..........
The clutch design has been upgraded several times:

http://www.advrider.com/forums/showthread.php?t=578782

All input is appreciated.

I am going to read the link you posted see if I can figure out my booboo...

Cheers!

First of all thanks for the detailed pics! When my clutch blew last week this was very helpfull!

So here a little input:

Since I needed to put it all back together quickly (needed to ride 700kms home that day) I just lubed all the plates in a hurry. So maybe 5minutes of soacking in the oil... Woody told me to let it over night, well "c'est la vie", they still took me home safely.




Old ones after 30000kms


The new "kit" they even seperate the smaller ones from the bigger ones, well done BMW. Costs: 303€ plates + gasket.


Soak them full with oil


Put them all back together


and torque to specks.

After 1hour of trying to put the whole sidepanel back together I took a "plastic/foam" hammer out and hit the thing where the clutch cable goes in (didn't move before), and voilà it was all clear after that .

5 minutes is better than nut'n

It looks like you were forced to use new gasket ...

Could you tell if they used any sealant on it at the factory?
The repair manual does not call out a sealant ...

I'm going in soon on the other side cover to check my stator ... probably need spare gasket on hand .......

I didn't recall for any sealant no :0). Guys at bmw told me to use a new gasket... when I saw my old one I didn't thought it was necessary but since I paid for it you know :0)

Thanks ... spares will be on hand

Btw a bit off topic but whats the difference bteween jrwooden and woodywizard account? ) the last one owes me an answer