This is a fantastic tutorial.. easily one of the best I've seen.. Coherent, and covers all the points I was wondering about. It demystifies the process to a very large degree. Thank you. Please make more.
This was really helpful. I struggled for ages trying to get the clutch cover past the oil return pipe with no success. Once I dropped the exhaust from the engine like you suggested t was easy. Thanks for posting.
Thank you. This seems to be about the only vid that goes through the removal and reinstalling of the cover WITHOUT cutting through and replacing oil return pipe. Although my direction is the water pump shaft replacing, this is a huge help!!!! Thank you
Amazing video. Extremely well presented. You should do more of this... (Maybe you do on a different channel.) I don't need to change my clutch, but I could not stop watching and listening to your superb direction. Cheers! BTW you are right re corrosion comments below. My G650GS frame coating is already failing after 3 years 40,000km garage stored, but kept outside within a semi-marine environment at work... doing some remedial work on that issue.
Excellent instructional video...followed your instructions step by step and had no issues. Thank you for taking the time to do this and share. Most appreciated. :)
Excellent , I replaced the water pump and once I had every thing back the clutch wouldn't engage, watching your video I learned about being patience and LINE UP THE SHAFT IN THE CENTER OF THE CLUTCH. Well for first timer I m learning the hard way. Thanks for your video. Planning or do you have more of them. Mario from Chile.
Mario Lemoine Thanks, Mario! I'm glad the video is helping the DIY enthusiasts out there. I will be posting more videos, but not of the F650 as I have sold it. My main ride now is an F800ST..
I will have a car shop manufacture a "Steelflex" line to replace the oil tubing. I assume that will make the undoing and shifting the exhaust redundant next time.
Great video. I noticed that when the cover finally went on, you had the pull lever on there, then the next shot it is off. Did you skip explaining something there? I have a DS650 ATV that uses this same engine/gearbox. I have broken two of the clutch lever shafts trying to gently install them. The gears themself are chipping off with little to no effort. Hoping you might have a tip or two.
I didnt have to drop the exhaust on mine. Great video. Never seen a yellow 2 spark. Whats the year of this F650? You can use a blob of grease to hold the clutch spline in place to make installation of the cover easier.
coletrain6000 It is a 2004 model, and has since moved on to a delighted new owner. I cannot recommend these bikes enough, from learners to seasoned tourers.
I wonder how much force did you apply to pull the hose off from oil tank. I was about to do it myself, to change the rigid line for a flexible one just to find out, there isn't enough space to wiggle it off and wiggle new one on. At least I thought there isn't any. I wanted to disconnect all the hoses while the tiniest of them all has some weird clamp. I chickened out and bailed the idea of changing that line until getting all hose screw clamps/tool for that small one.
I never use excessive force when faced with a mechanical stumbling block, so I can tell you that the hose definitely did not get any brutal treatment in order to be removed. If the end of a hose won't slip off its insert, try a little penetrating fluid and gently press a very large flat screwdriver at ninety degrees to the pipe, applying pressure all around the edge on the end lip of the hose until it loosens. I hope this helps you at some point in the future.
I have an 03 cs have adjusted my clutch back and forth with very little luck need to get this taken care of looks like I could easily do myself at home? My bike only has 3500 miles any suggestions
Thanks for sharing this! Most enlightening. That gs looks so weathered... Would you say it's only superficial? I sure hope I can keep my 2011 G for years to come.
It's a pleasure! I'm happy to hear that the video is fulfilling its purpose of helping keen bike maintenance enthusiasts out there. Corrosion is a big issue with these bikes I'm afraid, so keeping them sheltered is essential if you want them to stay clean. I have since restored a lot of the finish on this particular bike and it is kept under cover. Keep the curiosity alive.
Hi, I've followed yours step thoroughly but the cover seems to be stuck on the gear lever splines.. It's been 2 says i've tried everything i could think of. Can you help me? The shaft is not corroded and i'm using quite a lot of prying pressure and small hammer but no luck.
If your clutch cable is moving the actuation arm (the exterior aluminium bit which turns the inside shaft), then your problem is internal, I'm afraid. By removing the casing you can compare your clutch mechanism with the one in my video and hopefully identify the problem. Enjoy, I always do!
Ah, the nut and washer on the countershaft were missing. I went looking for them, but I have no idea when or where they fell off. Lucky the sprocket came loose in front of my house and that no major badness occurred before that.
I can see how frustrated we get with that pipe in front of the eng cover. German (bmw) engineers could had done better? or there is a reason for ?placing? in there. Replace it by a braded line could help? Thanks again
Mario Lemoine It is a DIY nightmare, but as you can see, a bit of extra time and work gets around the problem. A braided line might be more susceptible to snags in rough conditions.
thank you for nice video. I replaced the clutch plates and reassembled it. I'm not sure about one thing. I havent top up the oil yet but I tried to shift to a gear and pulled the clutch. I wasnt able to move with wheal. Did I do anything wrong? Or it should be ok, after oil top up?
Hi, apologies for only seeing this question now. If the clutch doesn't move, then it hasn't been reassembled correctly. Take careful note of how to line up the internal shaft when replacing the outer cover.
Hey there great video ! ! ! Thank you so much! ! ! I was thinking about buying one of those, but now i think again :( It's not that much of a good bike .
Hey ! First of all thanx for your time ! I took my licence on one of those , but ever since i didn't spend time riding it. I said that maybe i should think again because it looks so complex and it would be a maintenance nightmare (from a financial point of view) But it's certain that you know better... so what do you think? Are the parts too expensive??
Because this model has been around for a number of years, there are a wide range of non-OEM parts available which are reasonably priced. I'm not sure where you're based, but if you search there are a number of online retailers who provide a great service. I'm based in Ireland, so if you're in Europe I can recommend a few websites. The clutch is probably the trickiest job to do on this bike, and the spark plug connectors are in a very tight space, but other than that everything else is quite easy.
Hello budy, how are you? My motorcycle is G650 GS manufactured in 2010. I need change the clutch discs. Here in my country (Brazil) I just find the clutch discs of mocicleta F650 GS. Do you know if the F650 GS clutch discs work in G650 GS? Thank you? Hallo budy, wie geht es dir? Mein Motorrad ist G650 GS im Jahr 2010 hergestellt. Ich brauche ändern Sie die Kupplungsscheiben. Hier in meinem Land (Brasilien) Ich finde die Kupplungsscheiben der mocicleta F650 GS. Wissen Sie, ob die F650 GS Kupplungsscheiben arbeiten in G650 GS? Vielen Dank?
Itã Teodoro Hi, I'm sorry I can't help you on that one! Look at some online forums or post a question there, it might provide the answer you need. Surely you could order the correct part from the U.S.?
Great vid, I am going to cut that line at case and add a feed for a return pressure gauge. Makes my BSA look simple to work on LOL! Why did I buy a non kicking bmw mongrel single! LOL!
Little bit of resistance eh.. I can't get the cover off no matter how hard i pull. Firmly stuck..... Ok found out the asshole who fucked up my motorcycle used silicone everywhere instead of seals
Correct me if I'm wrong,but,I thought that Aprilia initially co designed the Funduro,which BMW brought inhouse later on and modified into the GS/Dakar models.........Most of this engineering is left over from Aprilia,I think>Then again Rotax ,an Austrian company do the engine....>>Either way BMW is overrated>>Still,I love my 650 GS >>It's a good bike.. Great video though..Good mechanic and teacher...
This is a fantastic tutorial.. easily one of the best I've seen.. Coherent, and covers all the points I was wondering about. It demystifies the process to a very large degree.
Thank you.
Please make more.
This was really helpful. I struggled for ages trying to get the clutch cover past the oil return pipe with no success. Once I dropped the exhaust from the engine like you suggested t was easy.
Thanks for posting.
Glad to be of some help!
Thank you. This seems to be about the only vid that goes through the removal and reinstalling of the cover WITHOUT cutting through and replacing oil return pipe. Although my direction is the water pump shaft replacing, this is a huge help!!!! Thank you
Thanks, i just did mine following your steps. Works great! Was able to do it without removing the exhaust :)
Thanks a lot, with that video I can finish the change ! Cheers from south of France !
Great tutorial, Well done. Especially since you didn't hack saw the oil line!
Amazing video. Extremely well presented. You should do more of this... (Maybe you do on a different channel.) I don't need to change my clutch, but I could not stop watching and listening to your superb direction. Cheers!
BTW you are right re corrosion comments below. My G650GS frame coating is already failing after 3 years 40,000km garage stored, but kept outside within a semi-marine environment at work... doing some remedial work on that issue.
Excellent video, well done!
Thanks for this, it is very informative and helps a lot with this tricky job.
Excellent instructional video...followed your instructions step by step and had no issues. Thank you for taking the time to do this and share. Most appreciated. :)
thank you , I've got a sloppy 1st gear its nice to see this , I appreciate it😎
I have been wondering how can I replace the exhaust manifold and the exhaust. You answered the question. I thank you!
Excellent , I replaced the water pump and once I had every thing back the clutch wouldn't engage, watching your video I learned about being patience and LINE UP THE SHAFT IN THE CENTER OF THE CLUTCH. Well for first timer I m learning the hard way. Thanks for your video. Planning or do you have more of them. Mario from Chile.
Mario Lemoine Thanks, Mario! I'm glad the video is helping the DIY enthusiasts out there. I will be posting more videos, but not of the F650 as I have sold it. My main ride now is an F800ST..
What did you do? Do you just have to reassemble? I stupidly forced it in and now the bearings are all wobbly.
nice thorough explanation and a cool Southern African accent, thanks!
I will have a car shop manufacture a "Steelflex" line to replace the oil tubing. I assume that will make the undoing and shifting the exhaust redundant next time.
Thanks ! Your a very good narrator !
Great video. I noticed that when the cover finally went on, you had the pull lever on there, then the next shot it is off. Did you skip explaining something there? I have a DS650 ATV that uses this same engine/gearbox. I have broken two of the clutch lever shafts trying to gently install them. The gears themself are chipping off with little to no effort. Hoping you might have a tip or two.
I didnt have to drop the exhaust on mine. Great video. Never seen a yellow 2 spark. Whats the year of this F650? You can use a blob of grease to hold the clutch spline in place to make installation of the cover easier.
coletrain6000 It is a 2004 model, and has since moved on to a delighted new owner. I cannot recommend these bikes enough, from learners to seasoned tourers.
Great video, very useful. Many thanks!
Thanks for the video, really useful
I wonder how much force did you apply to pull the hose off from oil tank. I was about to do it myself, to change the rigid line for a flexible one just to find out, there isn't enough space to wiggle it off and wiggle new one on. At least I thought there isn't any. I wanted to disconnect all the hoses while the tiniest of them all has some weird clamp. I chickened out and bailed the idea of changing that line until getting all hose screw clamps/tool for that small one.
I never use excessive force when faced with a mechanical stumbling block, so I can tell you that the hose definitely did not get any brutal treatment in order to be removed. If the end of a hose won't slip off its insert, try a little penetrating fluid and gently press a very large flat screwdriver at ninety degrees to the pipe, applying pressure all around the edge on the end lip of the hose until it loosens. I hope this helps you at some point in the future.
Hey, thank you for the tip. That might work. I'll give it a shot next oil change. So I guess pressing it back on was somewhat easy as well...?
Apply a tiny smear of grease to the steel pipe and the hose will slide back on easily.
Hello, Thank you for this video.. reallu usefull - Is this the same for a BMW F650GS dakar 2000
I'm not sure, but I'd imagine any differences will be easily negotiated. I thought the only difference was in the ride height.
I've heard that it's good for those new plates to leave them for 24 h in Moto Oil before putting them in. What do you think about this?
Great video! Thanks.
I have an 03 cs have adjusted my clutch back and forth with very little luck need to get this taken care of looks like I could easily do myself at home? My bike only has 3500 miles any suggestions
Very, very helpful. Thank you!
Comment savoir si les ressorts sont usés ?
Thanks for sharing this! Most enlightening. That gs looks so weathered... Would you say it's only superficial? I sure hope I can keep my 2011 G for years to come.
It's a pleasure! I'm happy to hear that the video is fulfilling its purpose of helping keen bike maintenance enthusiasts out there. Corrosion is a big issue with these bikes I'm afraid, so keeping them sheltered is essential if you want them to stay clean. I have since restored a lot of the finish on this particular bike and it is kept under cover. Keep the curiosity alive.
clearskiesahead Thanks for the reply! Well if it's aesthetic damage, I don't really mind. Maybe it's a Bavarian climate thing. Take care!
Hi, I've followed yours step thoroughly but the cover seems to be stuck on the gear lever splines.. It's been 2 says i've tried everything i could think of. Can you help me? The shaft is not corroded and i'm using quite a lot of prying pressure and small hammer but no luck.
my bike (2003 f650gs) got stuck in neutral today. Could this be what I need to do to see what's wrong? Someone mentioned a broken spring.
If your clutch cable is moving the actuation arm (the exterior aluminium bit which turns the inside shaft), then your problem is internal, I'm afraid. By removing the casing you can compare your clutch mechanism with the one in my video and hopefully identify the problem. Enjoy, I always do!
Ah, the nut and washer on the countershaft were missing. I went looking for them, but I have no idea when or where they fell off. Lucky the sprocket came loose in front of my house and that no major badness occurred before that.
Why did you change it, was it slipping or dragging?
Does the oil you add to the engine get used by the clutch plates ? On a 2013 g 650gs sertao ?
I can see how frustrated we get with that pipe in front of the eng cover. German (bmw) engineers could had done better? or there is a reason for ?placing? in there. Replace it by a braded line could help? Thanks again
Mario Lemoine It is a DIY nightmare, but as you can see, a bit of extra time and work gets around the problem. A braided line might be more susceptible to snags in rough conditions.
is there a bike more complex to change clutch discs?
+Epi Vou A very reasonable question! If there is, it will most probably be another BMW.
The BMW R1150 GS is a bike which got a more complex way to change the clutch discs
For the R1200 you need to split the bike in two... German Engineering...
Excellent tutorial more please
thank you for nice video. I replaced the clutch plates and reassembled it. I'm not sure about one thing. I havent top up the oil yet but I tried to shift to a gear and pulled the clutch. I wasnt able to move with wheal. Did I do anything wrong? Or it should be ok, after oil top up?
Hi, apologies for only seeing this question now. If the clutch doesn't move, then it hasn't been reassembled correctly. Take careful note of how to line up the internal shaft when replacing the outer cover.
Great explanation, thanks.
that was awesome - thanks heaps
Je n'ai pas compris à quoi ça sert de desserrer la visse près du réservoir d'huile
Hey there great video ! ! ! Thank you so much! ! ! I was thinking about buying one of those, but now i think again :( It's not that much of a good bike .
What changed your mind? I can honestly recommend them as one of the best bikes to learn on.
Hey ! First of all thanx for your time ! I took my licence on one of those , but ever since i didn't spend time riding it. I said that maybe i should think again because it looks so complex and it would be a maintenance nightmare (from a financial point of view) But it's certain that you know better... so what do you think? Are the parts too expensive??
Because this model has been around for a number of years, there are a wide range of non-OEM parts available which are reasonably priced. I'm not sure where you're based, but if you search there are a number of online retailers who provide a great service. I'm based in Ireland, so if you're in Europe I can recommend a few websites.
The clutch is probably the trickiest job to do on this bike, and the spark plug connectors are in a very tight space, but other than that everything else is quite easy.
Thanx for your time again i'm too based in Europe. If you find some spare time i would be interested to know about those retailers. :)
I love mine, it is fantastic 42k on mine.
muchas gracias!!!
nice good explanation.
Thanks a ton for making this video, it's going to make tackling this project much easier.
Also are you from ZA? I'm trying to place your accent. :)
Yes, proudly South African! Glad the video helped.
Hello budy, how are you?
My motorcycle is G650 GS manufactured in 2010.
I need change the clutch discs.
Here in my country (Brazil) I just find the clutch discs of mocicleta F650 GS.
Do you know if the F650 GS clutch discs work in G650 GS?
Thank you?
Hallo budy, wie geht es dir?
Mein Motorrad ist G650 GS im Jahr 2010 hergestellt.
Ich brauche ändern Sie die Kupplungsscheiben.
Hier in meinem Land (Brasilien) Ich finde die Kupplungsscheiben der mocicleta F650 GS.
Wissen Sie, ob die F650 GS Kupplungsscheiben arbeiten in G650 GS?
Vielen Dank?
Itã Teodoro Hi, I'm sorry I can't help you on that one! Look at some online forums or post a question there, it might provide the answer you need. Surely you could order the correct part from the U.S.?
Itã Teodoro são motores diferentes. A F650 monta o motor Rotax enquanto a G650GS monta o motor Minarelli. O mesmo da Yamaha XT660.
The design engineer could have made this so much easier to do.
Great vid, I am going to cut that line at case and add a feed for a return pressure gauge. Makes my BSA look simple to work on LOL! Why did I buy a non kicking bmw mongrel single! LOL!
BMW Motorcycles appear to be complicated to work on. English motors, Holden and Fords were so easy to work on.
Little bit of resistance eh.. I can't get the cover off no matter how hard i pull. Firmly stuck..... Ok found out the asshole who fucked up my motorcycle used silicone everywhere instead of seals
Glad you found the sticky problem!
You should have taken advance and painting those external parts. They are in a very bad condition
Time is a precious luxury.
There was no step by step there were info lack
My father rode a 1938 Matchless 500 single and he did everything himself.
Not the best example of german engineering at BMW.
Correct me if I'm wrong,but,I thought that Aprilia initially co designed the Funduro,which BMW brought inhouse later on and modified into the GS/Dakar models.........Most of this engineering is left over from Aprilia,I think>Then again Rotax ,an Austrian company do the engine....>>Either way BMW is overrated>>Still,I love my 650 GS >>It's a good bike..
Great video though..Good mechanic and teacher...
Such a pain in the arse bike. God video though
Good