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Old 09-04-2010, 08:31 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 09:12 AM
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Old 09-04-2010, 09:08 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, 10:30 PM   #3
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Old 09-04-2010, 10:49 PM   #4
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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 09-04-2010, 11:07 PM   #5
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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 09-04-2010, 11:08 PM   #6
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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, 06:53 AM   #7
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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, 07:52 AM   #8
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PM'ed ya.

David
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Old 09-05-2010, 08:04 AM   #9
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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, 08:55 AM   #10
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Joe:

maybe for an extra $10 you wanna have the

10 21217690426 WAVE WASHER - 24,5X40X1,80.02 1 $4.05[IMG]CartView.aspx?PartNumber=21217690426&qty=1 &description=WAVE+WASHER+-+24%2c5X40X1%2c8&weight=0.02[/IMG]
11


21217690425 HEX NUT - M24X1,50.07 1 $6.00


wave washer & hex nut on hand?

Go here, then click "clutch" ....

http://www.maxbmwmotorcycles.com/fic...8&rnd=03192010
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Old 09-05-2010, 10:23 AM   #11
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Been wonderin when someone would have to do the clutch. And, of course it would be you, Chi. And on a newer bike yet! You da man. Always been worried about mine because of having to slip it in city traffic too much. Sometimes these days I'll run it up hard thru the gears and it feels like it's slippin a bit but I can't really tell. As for removing that big nut, you may need an impact gun unless you want to jamb something in there to stop the slipping clutch from turning. But I wouldn't recommend that.
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Old 09-05-2010, 04:02 PM   #12
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Try the Mitas E-09 next time. They are lasting a long time, and are knobby!
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Old 09-05-2010, 05:28 PM   #13
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ChiTown:

Actually when I look at it again that nut and washer hold the basket onto the crankshaft...
You "shouldn't" have to take the basket off so maybe you don't need those.

The tightening torque on the bolts of the pressure plate springs is only 10Nm, so you can probably get by without the little thing that locks the engine from turning over.

One other note, the comment about soaking the friction disks in oil before installing is important ...
Dry plates don't do so well ...
Last time I did one I stacked the dics in a pan ... spaced apart from the bottom of the pan and from each other by a few toothpicks, then put enough oil in the pan to cover my "tower" ... and let them soak a while ...

JRWooden screwed with this post 09-05-2010 at 05:44 PM
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Old 09-05-2010, 08:37 PM   #14
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Sorry to hear about this part of your adventure Chitown.

Your not the first. I fried the crap out of my clutch 3000 miles ago doing something stupid but fun.

The clutch hung in there till a short while ago, but with almost zero freeplay and no remaining slack. In any case, at least one dealer does stock this clutch, but I depleted said dealers stock :(

In any case, the job is fresh in my mind.

It's funny, but I'm not in much better shape then you right now.

I left Kansas city where I was visiting friends to take my son to his mothers for the school year in Michigan.

40 miles from his moms on an f8gs that was fantastically overloaded, we fell over as my son was dismounting next to a curb (he's young and short)

Long story long, shifter is bent around to 11 o'clock.

I know well what that means, but on the + side I'm in a 24 hour Starbucks parking lot, so I have the most valuable tool for any mechanical job, caffeine!

So in about 10 minutes, I am off to pull my clutch cover in the parking lot after a 600 mile ride, flatten out a piece of metal that probabley looks like a rippled potato chip, then ride another 450 miles home to STL.

in any case, I'll pm u with my # incase anything in the RSD does not make sense.

Parts for you shouldn't be more then a day or two out, but if they are back ordered or something, let me know and I'll see if I can talkthe boss into letting me pull them off of a new bike.

Good luck, glad to hear your adventurious spirit is holding up :)
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Old 09-08-2010, 09:59 PM   #15
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Thumb

Success!

With all the ADV and BMW support it was a successful operation. Actually it's quite simple, it just has a few dark arts things to do...
I'm jumping back on the TAT tomorrow in Nevada heading east, once I'm home I will do a little DIY with all the photos I took.

New clutch, fresh oil, new chain + sprockets, new knobbies.... Unstoppable!
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