Poll - Torque limiter failures on 449/511

Would have been quicker if you didn't stop every 10 mins to take a photo...... ha ha.

Good work! Way beyond my skill level; I sold on Tinken's Recirc kit to avoid having to do that.

Well you did a great service to the rest of documenting the repair...Mahalo

wont help...i had a close look how the engine is assembled. That thing will fail !!! its made to slip in tough situations and it will. After time depending on riding it will fail. Mine just failed with 4000km. Breather installed

Many more will fail also. Just Google or Bing- "BMW G450X Torque Limiter Failures". Or a combination of those words.

Better yet, check the G450 Riders Forum for the same thing. This has been going on since late 2009 - early 2010 on the G450X. I've replaced 3 myself between my 2 engines.

https://www.facebook.com/groups/219900571553501/

write up is Uploaded in form of a PDF file on our Facebook page.

Too bad about your torque limiter, running too little of oil does a number to them. The heat and exhaust blow by kills them. You have to keep them submerged in oil for them to last. My breather kit allows you to do this. I have 73.2hp going to mine without an issue and I have removed mine to retest breaking pressure which is still spot on. And to the best of my knowledge, none of my customers who installed my system from day one have had a TL failure.

9880sts,
Thanks for showing us the common replacement screw to reattach the side cover. It can be done in the frame with out engine removal if you go about it right, Right? Please reply if that is correct. Good news for all the Husky 449/511 Riders who will eventually have to do this at some point during the lifespan of the bike. Nobody wants to pull an engine if not necessary.
You guys are lucky. My G450X engine has to come out to do this same job but it is a little easier to drop it out as there is no cradle built under the engine in my frame.

Also thanks for disassembling the worn out Torque limiter itself also so everybody gets a chance to see this internal mechanism upclose. It's doesn't take a rocket scientist to see it's nothing special. It sure is appreciated by the "do it your selfer" to see the internals of this part broke down instead of just taking someones word for it about whats in there or if it's worn out. I like to see whats broke or warn out when, or before, I'm going to be replacing parts myself. It makes me feel better when I'm spending my cash to know it's going to be right, by knowing whats wrong. Internal parts aren't the only thing that can go wrong either. Unless you have done it yourself you don't know.

All assumptions aside, I see you were running The Breather Kit system so was your oil level always checked and kept full also.

That's what a good technical forum is all about, the sharing of information. For others to have that information and now understand so they may be able to do the job themselves when the time comes.

Thanks again, I hope this will ease the fear of others that may be holding them back from doing this repair to their own bikes either now, or in the near, distant future.

He was running the half system with the tee fitting.

@9880 - Did you happen to check the TL when you fried your engine at 1900km and didn't rebuild until 1000km? I see you were using 200cc of oil every 100km of use.

Reason why I ask is because when we rebuild our engines, the TL is tested and replaced if it fails the break away test. I think it is a good idea for others to do for future reference.
Also for future reference, if you tow other bikes, especially up hills with your 449, it is going to put a tremendous load on your TL.

Well Tinken , i was allways running more Oil from beginning. 1200-1300ml. Yes it was using OIl for about 6-800km
Towing Bikes uphill wont help and i knew that. But i was feeling a bit of slip in tall gears allready anyways. Wasn't such a issue in 1-3 gear .
I never tested the TL when i did my rebuild after i dusted the Piston rings. I suspected the limiter several times, especially when you test ride oder bikes after they want to check the Flexbars or the Suspension Set up. I always went off these bikes and thought damn they pull up good.

I am not Complaining ... i think overall we can be happy to have on in there and not shear of gears or dogs. When you ride the Kymco Engine and shift a gear up or down accidentally, which happened a few times, you will notice that this is still a smoother shift the on a other bike. The TL takes some of that first grip away.

On the other end, the Clutch basket and hub looks great after 4000km .you wont find that on any other bike.

Torque Limiter's also used in Equipment we repair (John Deere) and you better off replacing them then changing Gears or Shafts.

2011 model frame. I didn't actually know there is such a difference ?! can you post a couple more Pics ?

Breather Kit. -- if i would have a Motard, your Kit is the one i would Install... Yes Zip ty did a good Job with it and when you go High revs with min 1150ml oil, a little bit of Oil still comes up. But its really not a lot.
As for the Bush rider , no need for so far. My Box is dry and it does it's job. The Breather on the Rocker arm Cover is nicely made. I wish some dealers in OZ would stock it and make it available for more riders.

I am going to try to shim the Limiter up by a few hundreds of a mm. Maybe get the Torque setting to 245Nm. Now after i had it open , i understand how it works and it may possible to get it going again. ??? Don't know yet , but i will try. The Mechanic talks and wants to test things.

Have the pressure plates sand or bead blasted. When I make new ones, I'll ship a few to my AUS friends. If you have a test fixture, test to 204Nm (150ftlbs), if greater, okay to install.

So Helmut, would you still like my spare one, or will you do a rebuild of the old one & test it first?
I'll try & knock up a jig & test it when I get home from the mine-site I think.

Hi david, yes i would still like to have yours..
I get the Test device from my Husky Dealer. This is going to cost me another Box of Beer. I got big trouble to find the right sized shims for it.

I've been riding my TXC449 in supermoto service on asphalt. I always wondered why, when banging down gears, the back wheel wouldn't lock up, almost like the bike has a slipper clutch. Now I know I'm exercising the torque limiter. I'm assuming I should stop doing that?

There's no 100% cure and I wouldn't be afraid of it, eventually it is going to wear out. Abuse it to loose it I always say. Kelly got his to last 6k miles by running really thin oil in a cooler climate. It is what it is until I can convince Ty to manufacture my new one.

Why not shim the original up to raise the breakaway force slightly higher.... Maybe 275 Nm or 300 even.