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Old 09-04-2010, 09:31 PM   #1
Lost Rider OP
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Wicked 800GS Blown Clutch Replacement Surgery - DIY

*EDIT*
If you want to skip to the DIY photos, go here or page 3...

http://www.advrider.com/forums/showp...4&postcount=37







OK boys and girls I finally did it. I done broke the GS in a way at won't let me continue my journey....

I know, I know, you were expecting to find this snazzy write up from some expert know it all already done and here for you to digest, to think about and plan for a while before you're out of warranty and needing to replace your own clutch.

Wrong!

Now, granted there can and will be a nifty little write up here about how easy it is to replace the clutch with the nifty BMW clutch kit, but before that can happen I need some help.

See, I just rode most all those trans-con-tour dirt rides rapped into one-on-shoestring-budget rides that is generally My Style. After many miles of punishment, and having nearly 40,000 miles on the clock, a steep loose single track on the Oregon coast did me.... The GS plays a dirt bike on television pretty well, but in reality is finally fed up with my shenanigans, as why the clutch slips if I'm anything but mellow on the gas. At least she's nice enough to warn me gently instead of just blowing up in the middle of fuck all nowhere - where I feel like ive been for a while.

Obviously I have some time on my hands here, since it's Saturday on a holiday weekend, I won't be seeing any parts until wenesday at best. ( being the ahead of the curve as Ive been on the GS, no dealer stocks those kit, yet)

So while I prepare to change out my clutch, in the woods, I need some help.

Will any good souls who have the service manual DVD take some screen shots of the whole clutch changing thing and send them to me?
Please?
I wont have the BmW crank shaft tool to lock it, but figure in-gear and hold the brake should do that if its even needed... I only have basic tools out here, and from what I remember (yes I studied this for this day) it's a straightforward procedure with nothing special needed... It can be done in the woods...


This should be fun right? I mean, at least I'm in the US and can get the parts relatively fast, and currently have ATT Edge service on my idevice, the weather is great, and I have YOU! ADVrider.com....

Let's do this together!
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Lost Rider screwed with this post 09-21-2010 at 10:12 AM
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Old 09-04-2010, 10:08 PM   #2
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Maybe I missed it.. but do you want them Emailed and to what addy?
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Old 09-04-2010, 11:30 PM   #3
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Old 09-04-2010, 11:49 PM   #4
kkug
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You might not need any special tools if you are just replacing the plates.

I am curious did some dealer have a clutch kit in stock or did you order it days ago ? Did you get rid of the yellow bike?

Good luck !
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Old 09-05-2010, 12:08 AM   #5
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Quote:
Originally Posted by kkug
You might not need any special tools if you are just replacing the plates.

I am curious did some dealer have a clutch kit in stock or did you order it days ago ? Did you get rid of the yellow bike?

Good luck !
Hopefully not, but am open to suggestions if anyones been here before me.


No, no dealer has the kit in stock. I'm number one, I'm number one, I'm number one! maybe not number one, but I do have a big mouth.

I would imagine next year as more folks rack up the miles and have subsequent clutch failures it will be a commonly stocked item, until then, pay for expedited shipped from the BMW parts warehouse, drop shipped to your campsite.
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Old 09-05-2010, 07:53 AM   #6
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Chitown ... you hoser... quit breaking stuff...

Joel says that BMW has beefed up the clutch as of ~02/10 production models:

http://www.advrider.com/forums/showp...2&postcount=19

Here's a start on the docs you need ... yell if it ain't enough:

http://www.advrider.com/forums/showt...ghlight=clutch

It does seem BMW has gone thru SEVERAL revisions on the design...
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Old 09-05-2010, 08:52 AM   #7
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PM'ed ya.

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Old 09-05-2010, 09:04 AM   #8
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Awesome, nice to know I'm not going where no man has gone before... The photos really help too.

So it does seem that I should, in theory should be able to do this with minimal tools, and the info I get from you folks.... I was thinking a six pack before, but after seeing all those little parts and plates I better get a twelve pack

Any other suggestions I should order besides the kit? Washers, or other hardware?

Thanks for all the pm's and support!
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Old 09-05-2010, 12:07 AM   #9
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Quote:
Originally Posted by ChiTown
I wont have the BmW crank shaft tool to lock it, but figure in-gear and hold the brake should do that if its even needed...
In gear with the brakes activated may not hold the crank since the clutch is slipping. I don't know what the torque spec is on the clutch basket nut but it's likely more than your clutch will hold (especially in it's current state)
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Old 04-09-2013, 08:04 AM   #10
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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!
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Old 04-09-2013, 02:31 PM   #11
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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...?

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Old 04-09-2013, 03:01 PM   #12
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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...

Quote:
Originally Posted by JRWooden View Post
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...?
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Old 04-09-2013, 05:21 PM   #13
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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
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Old 04-09-2013, 07:01 PM   #14
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All input is appreciated.

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

Cheers!
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Old 05-24-2014, 02:54 PM   #15
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Thank You very much for this thread!
I have had lot of help from it and dont think i would have gotten everything correct without Your posts here!
I have manual clutch now for a change, until my EFM Autoclutch arrives (have had it earlier, now waiting for new one as warranty replacement)...kinda weird feeling to use normal clutch.
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