Hey guys, it's been a while and sadly I'm still not riding my bike. Things came up and I haven't had time to put it back together. I have finally put the clutch assembly and the gearbox back and I wanted to turn it on to make sure the gears are shifting properly before I install the final drive and everything else. Well, I had taken it all apart by removing the entire back end and the frame of the bike entirely. Well when I put the essential stuff back together (I.e the full tank, fuel lines, air filter, etc) and tried to crank it up it only tried to turn a couple of times and then it just died. You can just hear the starter click.
I have had my battery on a battery tender all this time and I didn't have any problems before taking it apart. So here is my question, will the bike run without everything being put together or do I need to install the frame and everything else for the system to be properly grounded for it to work?
I'm really not sure what's going on. Another thing I noticed is that when you turn the key, usually the entire cluster of lights should turn on, well not anymore. I can put the blinkers on or high beam and the lights work, but they don't turn on as they did before.
I realize this may be confusing but any help you may have will be greatly appreciated. Thank You!
Clutch slipping in high gear
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lguardiola
- Basic User
- Posts: 62
- Joined: Wed Nov 28, 2012 2:48 pm
- Location: Savannah, Ga
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lguardiola
- Basic User
- Posts: 62
- Joined: Wed Nov 28, 2012 2:48 pm
- Location: Savannah, Ga
Re: Clutch slipping in high gear
Hey guys,
I am still in need of some assistance trying to figure out what is going on with my bike.
I put the essential stuff back together (I.e the full tank, fuel lines, air filter, etc) and tried to crank it up but it only tried to turn a couple of times and then it just died. You can just hear the starter click. It sounds like a bad battery, but I replaced it and still gives me the same issue. I continued trying to get it running and I ended up burning out the starter. A new one is on its way (not one with a BMW stamp on it, those are $550, so just got an after market). Before I took the bike apart I had no issues with it firing it up so I wouldn't think its the starter but it might have been on its way out. Either way, it needs one now. I'll put it back together and see if this fixes the issue.
Another thing I noticed is that when you turn the key, usually the entire cluster of lights should turn on, well not anymore. I can put the blinkers on or high beam and the lights work fine, but they don't turn on as they did when you turn the key. I have checked the wiring under the cluster to see if there are any broken wires but haven't had any luck yet.
Any tips you may have are greatly appreciated.
Luis
I am still in need of some assistance trying to figure out what is going on with my bike.
I put the essential stuff back together (I.e the full tank, fuel lines, air filter, etc) and tried to crank it up but it only tried to turn a couple of times and then it just died. You can just hear the starter click. It sounds like a bad battery, but I replaced it and still gives me the same issue. I continued trying to get it running and I ended up burning out the starter. A new one is on its way (not one with a BMW stamp on it, those are $550, so just got an after market). Before I took the bike apart I had no issues with it firing it up so I wouldn't think its the starter but it might have been on its way out. Either way, it needs one now. I'll put it back together and see if this fixes the issue.
Another thing I noticed is that when you turn the key, usually the entire cluster of lights should turn on, well not anymore. I can put the blinkers on or high beam and the lights work fine, but they don't turn on as they did when you turn the key. I have checked the wiring under the cluster to see if there are any broken wires but haven't had any luck yet.
Any tips you may have are greatly appreciated.
Luis
Re: Clutch slipping in high gear
4 amp fuse? mine is pink # 2 from the left I think.
mike Mojave CA
'04 ROCKSTER
'04 ROCKSTER
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CycleRob
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Re: Clutch slipping in high gear
lguardiola,
After you PM'd me several days ago and pointed out there was no response to your serious problem, we progressed to a 32 minute phone call that really straightened things out! From the detailed descriptions I got from you I determined the starter was overheated by excessive duty cycles and the armature's commutater bars were melted/smeared together, causing a short between many coil windings and finally to just between the brushes themselves. The symptoms mimic a low/dead battery. Since the new battery gave the same weak response as the old battery did, that confirms the starter is ruined. Take the end cap off the starter and you'll see those melted/burned parts. Keep the old battery charged as a spare, get a new starter and fully charge the new battery.
On the phone you mentioned the slave was replaced and it needed to be bled. Here's a link to a greatly detailed slave bleed post on Jan 20, 2016, beginning at the 4th paragraph: viewtopic.php?p=251882#p251882
Phasing the drive shaft, here are a few links to help you:
viewtopic.php?p=190366#p190366
http://www.4crawler.com/4x4/CheapTricks ... ml#Phasing
About testing the clutch and slave, you do not need the motor running to do that, even with the rear frame section removed. Use a length of wooden board to support the FD so the rear tire is just off the ground. Then you can up-shift gears while cyclically turning the rear wheel. When you get to 6th gear, pull in the clutch lever and try to turn the wheel. Use 6th gear as all the other gears will try to spin the clutch faster, making the tiniest bit of friction stronger.
After you PM'd me several days ago and pointed out there was no response to your serious problem, we progressed to a 32 minute phone call that really straightened things out! From the detailed descriptions I got from you I determined the starter was overheated by excessive duty cycles and the armature's commutater bars were melted/smeared together, causing a short between many coil windings and finally to just between the brushes themselves. The symptoms mimic a low/dead battery. Since the new battery gave the same weak response as the old battery did, that confirms the starter is ruined. Take the end cap off the starter and you'll see those melted/burned parts. Keep the old battery charged as a spare, get a new starter and fully charge the new battery.
On the phone you mentioned the slave was replaced and it needed to be bled. Here's a link to a greatly detailed slave bleed post on Jan 20, 2016, beginning at the 4th paragraph: viewtopic.php?p=251882#p251882
Phasing the drive shaft, here are a few links to help you:
viewtopic.php?p=190366#p190366
http://www.4crawler.com/4x4/CheapTricks ... ml#Phasing
About testing the clutch and slave, you do not need the motor running to do that, even with the rear frame section removed. Use a length of wooden board to support the FD so the rear tire is just off the ground. Then you can up-shift gears while cyclically turning the rear wheel. When you get to 6th gear, pull in the clutch lever and try to turn the wheel. Use 6th gear as all the other gears will try to spin the clutch faster, making the tiniest bit of friction stronger.
`09 F800ST
Member since Sept 10, 2001
"Talent, On Loan, From God" --Rush Limbaugh--
Member since Sept 10, 2001
"Talent, On Loan, From God" --Rush Limbaugh--
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lguardiola
- Basic User
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- Joined: Wed Nov 28, 2012 2:48 pm
- Location: Savannah, Ga
Re: Clutch slipping in high gear
Thanks for your input. I started putting it back together this weekend as I wait for the Started to arrive. I have a quick questions in regards to the pivot pins on the rear wheel fork. The manual states to use loctite when installing it but I also remember seeing a one of Chris Harris videos on youtube stating that not to use any loctite on these pins. What do you all think?
Also, it seems like one of the pins requires using a special tool from BMW to install. Any input is helpful.
Thanks,
Luis
Also, it seems like one of the pins requires using a special tool from BMW to install. Any input is helpful.
Thanks,
Luis
Re: Clutch slipping in high gear
I use locktite on the threads and normal torq tools will fit the pins.
mike Mojave CA
'04 ROCKSTER
'04 ROCKSTER
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lguardiola
- Basic User
- Posts: 62
- Joined: Wed Nov 28, 2012 2:48 pm
- Location: Savannah, Ga
Re: Clutch slipping in high gear
Hey guys,
Just a little update. I got the new starter earlier this week and spent all morning yesterday putting the bike back together. I installed the starter, the swingarm, final drvie, and bolted the frame back to the bike. I installed almost everything back except for the rear light assembly and the few fairings on either side. Once I rechecked that everything was wired up and connected, it was the moment of truth. I turned the key and wished for the best....and to my surprise, she fired up just as she had never had an issue. It was the best feeling to finally hear that engine again after over a year of it sitting in my garage.
I'm still not sure what the issue was. Not sure if it was just the starter or if it needed the frame to be bolted on so the entire system could be grounded properly. Either way, she is up and running. I took her out down the neighborhood and all gears shifted smoothly (only went up to 4th gear). Everything felt good. I was nice to hear that engine when you open up the throttle.
Now I just have a couple of things to finish up to finally have it ready for riding. I want to thank you all for your help as this was the first time I have taken it apart to this degree. There was a point where I wasn't sure if I would be able to finish it, but it's good to have it back and running. I'll make sure to upload a picture here once I have her ready.
Thanks for all your help!
Luis
Just a little update. I got the new starter earlier this week and spent all morning yesterday putting the bike back together. I installed the starter, the swingarm, final drvie, and bolted the frame back to the bike. I installed almost everything back except for the rear light assembly and the few fairings on either side. Once I rechecked that everything was wired up and connected, it was the moment of truth. I turned the key and wished for the best....and to my surprise, she fired up just as she had never had an issue. It was the best feeling to finally hear that engine again after over a year of it sitting in my garage.
I'm still not sure what the issue was. Not sure if it was just the starter or if it needed the frame to be bolted on so the entire system could be grounded properly. Either way, she is up and running. I took her out down the neighborhood and all gears shifted smoothly (only went up to 4th gear). Everything felt good. I was nice to hear that engine when you open up the throttle.
Now I just have a couple of things to finish up to finally have it ready for riding. I want to thank you all for your help as this was the first time I have taken it apart to this degree. There was a point where I wasn't sure if I would be able to finish it, but it's good to have it back and running. I'll make sure to upload a picture here once I have her ready.
Thanks for all your help!
Luis