Category Archives: Project: BMW Xcountry

BMW Xcountry ~ Xtra fuel and Xrack

Xcountry index page

“frequent refuelling interruptions are not the journey”

The Xmachine is a pretty economical bike – over the last 2500 miles I’ve averaged nearly 74mpg (26 kpl) with backwind best of 83.5 (29.5kpl) while cruising at 70 where possible. Even then, with the 9.5-litre tank the light comes on at around 120 miles with a potential range of 150 miles before you suck crap into the fuel filter and start pushing. Not enough on a bike like this.

crgr-can

The simple and cheap solution is a 5-litre can on the back (left). I managed fine like this with the even-smaller tanked CRF-L in the US last year as there were no larger tanks available.
But on the faster X bike the refuelling interruptions are not the journey.

zank

My original plan was to either build a 6-7 litre tank onto the bash plate, nice and low and out the way. Others have fitted side tanks (left), another good way of keeping things low, but none gets around the need to stop at 120 miles unless some sort of pump is organised (the one left may be auto sucking, see below).

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h&benginebars

Then I thought fit a 6.6-litre Rotopax can (left, 3rd along) either under the bash plate with added protection, or one each side of the engine on H&B crash bars (right). The 6.6 can is 9cm thick which would cost clearance, be less work than building in alloy but still require decanting.

HOT-ROD

Those were my plans until AMH-contributor Walter Colebatch suggested to fellow xfan Erik from Hot Rod Welding in NL that he may like to supply an Xtank and an Xrack for my bike, as well as hard part xplates to project the underparts (see bottom of page). Erik runs his own XCh and happened to know the X series’ production volume. The first batch of Xbikes – Cha, Co and little Mo – were all built at once in 2006 and flogged from 2007, then the Xcountry was built in China for 2008. All up the run amounted to 13,000 bikes. Good to know.

Xtank

The €500 Xtank fits in the crook of the RHS subframe – mine is the regular 6.5-litre size (a wider 9.5-litre version also available for not much extra cost, pic below. And fyi I regularly got 6.7 litres in mine).
The tank hangs from the former back handle mooring points and then plugs into the diagonal beam, adding a bit of support to the subframe while being less wide than the pipe on the other side. Better still, all it needs to flow in series with the main tank is the main tank’s black breather pulled off and the clear xhose plugged in.

xtank3.jpgThat black breather happens to suck and once sucking on the Xtank’s fuel pick up at the base of the Xtank, it will create a syphon and drain that tank before seamlessly moving onto the main tank. Result: 200 miles doable without thinking and a potential range with 9.5 + 6.7 = 420km or 260 miles which happens to be my ideal suggested fuel range in AMH. That will do nicely.

xtank4

The tank requires removing the chain guard which sits quite high, and even then it’s said the chain can hit the tank on hard compression of a bottomed-out shock. That’s no longer an issue for me, and even then, I’m sure my shagged-out OE shock bottomed a couple of times without touching the underside of the xtank.

If your injected bike runs a subseat tank and has a similar sucking breather, this principle of a second tank working on a suction feed may be worth investigating on non Xbikes.

xtank2

Xrack
Although I prefer soft luggage I still believe a light side rack is worthwhile to keep bags in position come rain or shine. For his Siberian travels, Walter C also got Erik to build him a rack to keep his excellent Magadan bags (now in MkII form) out of the back wheel. The racks, 2.2kg for both sides, follow the standard formula of mounts near the pillion footrest, the back of the subframe plus a link underneath to stop them caving in. I like that Erik doesn’t just flatten tube ends and drill a hole through – he does a proper job. And the back cross brace mounted behind the number plate performs the useful function of reducing lethal number plate waggle over rough ground. I’m sure without support that thing would have broken off at the first sight of corrugations.

xtank5

Erik and Walter also seem to have adopted the ‘sheep rack‘ platform idea which I mentioned in AMH6. That is, a substantially wide rack, not these skinny ‘flower pot stands’ like I had on my CRF-L, or nasty edged CNC plates that have become all the rage because they look flash and are cheap to mill. With a roll bag across the back you want a  w i d e  base to spread the load and reduce rubbing. Plus it can make a good table or work surface.
Ingeniously, Walter and Erik went one better and designed the tail rack to come forward round the back of the seat (right). Again, this compels you to mount stuff as forward as possible, at the very point where you don’t want weight hanging out back. The 1.7kg tail rack doesn’t interfere with passengers and makes a good solid grip when you end up with the bike in a ditch.

xtank1

On the right side (left) you’ll see the side rack sticks away from my xtank so there’s room to fit the larger 9.5-litre Xtank (below) should you wish, or just slot stuff behind it. The whole rack assembly comes in at just 3.9kg. These light racks are designed only to support and secure soft bags. They wouldn’t be suitable for mounting hefty ammo boxes, but Erik can build you a light, soft bag rack for any bike. On the right, a rack he made from some trans-Africa CRFs.

hotplates

Left and right are Erik’s hard parts to protect the vulnerable rear brake assembly in particular.
As for panniers, the MkII Magadans would be the obvious choice, but my contract penalises me from using the same thing twice. I have an idea I’ve been wanting to try. More about that later.

Erik at Hot Rod supplied his Xparts in return for an advert in AMH.

BMW X Country – Introduction

XCountry Index
• Stage 1 mods
• Swapping the subframe
• X-tank and X-rack
• Suspension
• Tutoro chain  oiler
• Midsummer update
• The Spanish Plain
• 10,000 mile review 
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Time and need for a new project bike so next on my list is the BMW G 650 Xcountry (that being the correct BMW appellation). I snatched a 2008 model off ebay for £2300 with just 6300 miles and seemingly in great nick. Even with just a month of tax, for that sort of money it’s hard to think what else comes close.

strada

Over the last few months I’ve been watching the discounted prices on the similar and recently discontinued Husqvarna Strada (right; similar to the Terra I rode in Morocco). But at least for the moment the reduced prices never added up to more than about £4500-5000 for a low mileage ex-test bike that still weighs a good 20-25 kilos more than an XCo.

I like to think the X bikes are belatedly becoming recognised as an under-rated travel bike for the simple reason that, compared to the post-Funduro F650s and the current G-GSs which followed after a two-year hiatus in the UK, the X bikes were powerful and light. With bathroom scales I combined the upright wheel weight on my ABS machine (as I did with my GS500R) and came up with 163kg with a full tank, very close to the official wet figure. Deduct the 9 litres (6.5kg) and you get a more broadly comparable 156.5kg dry. The only accessories my bike has are plastic hand guards so let’s call it 155.5kg. Compare that to the following claimed dry weights.

  • BMW XChallenge 149.5kg
  • Husqvarna TE630 151.5kg
  • BMW XCountry ABS 155.5kg (verified)
  • Yamaha XT600R 170kg
  • TR650 Terra ABS 176kg
  • Suzuki GS500R 181.5kg (verified)
  • BMW Sertao and G650 GS 182kg
xbikeadvertYou probably know all this but I’m going to say it anyway. Ready, here goes: the Xs were only sold in the UK from 2007 to 2009 using the same Rotax engine in three models: the XChallenge was pitched as an off-roader 18/21-inch wheels and taller air suspension (below left), the XMoto was a blacktop canyon basher with 17-inch wheels (below right), and in the middle below, the XCountry was a retro/street scrambler with 17/19-inch wheels and normal suspension. For me the XCo was always the best compromise for a dirt-capable travel bike and from the figures below, the best selling model. No dodgy air shocks, a much lower seat (see image below left), a steel rear subframe (or so I thought) and a do-it-all 19-inch front wheel. You know how I feel about 19s.
bmw-650x-xersesprod
xcospex

At a bike show one time I asked the BMW Motorrad marketing bloke why they’d been a flop but he couldn’t pin it down to one thing. Perhaps it was just a ‘perfect shit storm’ of too high asking price (around £7000 back in 2007 when a Tenere went for £4500); spartan equipment levels, lukewarm reviews, not such great looks and whole lot of teething problems. They included clutch covers which led to early wear of the unit, premature battery failures and all sorts of starter solenoid/non-starting/charging issues. The full list is here and it put me off buying a well equipped XCh when I was in the US in 2013. The thought of being stranded out on a southern Nevada track was just too galling. I got a Honda CRF 250L and never looked back. But I did miss the satisfying stomp of a 650.

bmw-650x-seat-heights
LoncinG650XCo

The 2009 XCos was the only makeover that any of the three models got. They used engines still made from parts manufactured by Rotax in Austria, but the engines and the entire bikes were assembled by Loncin in China. Some of these bikes had hot-starting issues, but $50 replacement exhaust decompressor fixes that. The main difference on these Loncin XCos was the yellow paint job as well as a lower seat with less suspension travel, softer springs and adjustable levers. You can see above how much lower a Mk1 XCo is compared to the two other models. A more useful improvement included a steel rear subframe.

steelsub 46 51 7 716 439

Blink and you’ll miss the fact that the XCountry was the only Xbike that came with pillion footrests and too much wayward pillioning on the original alloy subs common to all three models brought up cracking issues so a steel version was quietly slipped on. As is well known, Touratech sell a replacement steel subframe for all the early Xbikes (separately from the pannier rack, also shown below right). It weighs 4.7kg against the original alloy’s 1.9 – another example of overzealous weight savings on the X range, though of course it depends very much how you load and ride your Xbike. The yellow XCo’s steel subframe bolts onto an earlier alloy model without a hitch.

When BMW finally pulled the X plug prices crashed at what were seen as overpriced turkeys. I see from the papers that came with my bike that after just over a year at the BMW Off Road Centre in Wales, it had any scratched or bent bits replaced and was sold in 2009 by Vines for just £2600. Since then it’s clocked up a thousand miles a year and just got a new clutch fitted. Presumably it was the usual problem of ruined clutch fixed by an updated clutch cover plate with a proper bearing or steel bush to support the actuating mechanism.

Sounds like a nightmare but I’m prepared to take a chance; unusual as for me reliability is a high priority for the sort of riding I do. My plan is to use the bike to support my Morocco tours later this year and then take it on a longer desert trip of its own.

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XCo, first impressions
I picked up the bike in flood-struck Somerset and rode down to flood-struck Cornwall which has been the source of some phenomenal pictures over the last week. I then rode it back to London, all up about 600 miles. Rain gear report here.
Out of the guy’s house it felt a bit odd, not much up front, but everything worked as it should and by the time I’d sat in the pouring rain and headwinds for a couple of hours I was warming to the bike despite being a little underdressed myself. The Metz Tourances were rock solid in the wet, and the unscreened bike sat easily at 70mph while returning about the same mpg (average over 600 miles was 72.7mpg or 25.7kpl or 60.6US or 3.88L/100km).

blackcountry
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Mirrors were good, so surprisingly was the stepped seat with the hump far enough back. Hand and foot positions suit me too, though the levers felt a bit far away, dash info is basic with a huge speedo read-out. I have yet to meddle with the setting buttons.
Front light seems a bit lame, the gear lever doesn’t click n’ snick like my mate’s 45,000-mile old Transalp (below right), though there’s notably no driveline lash on the BMW, and that is an annoying Jap characteristic in my experience. I can’t fault the glitch-free fuelling and engine sounds reassuringly whirry rather than rattley; quieter than my 1000-mile old Tenere. Looks wise, the XCo is a bit ungainly; along with the massive cat the front end looks odd though may well be remedied or subdued with blackened fork uppers (right). Apart from black rims – good to see on the XCo – the quickest way to improve the looks of a bike like this is to lever on some knobbly rubber! Suspension is pretty firm, especially round town, though I’ve not meddled with that yet either. They say a Hyperpro spring can help out back.

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xcoxtank

The machine looks like it has a better than average build quality, something I can’t say for last year’s CRF-L or of course the Suzuki before it. Biggest nag is the 9.5 litre fuel tank which at the above fuel consumption is good for just 150 miles (244km) though I’ve yet to calibrate the BMW’s speedo and odo against a GPS. Something will have to be done about fuel range. The 6.5-litre Xtank (left – XL version) looks neat in that it uses what little dead space the X has and could be integrated into a rack, but costing nearly £70 a litre it’s more of an RTW investment. I’m mulling over various other ideas to improve the X’s fuel range.

Less weight: it’s as simple as that
Best thing by far is the power and the weight. They say it makes 53hp which is 3.05 when divided by the 162kg weight. The very similar Husky Terra (186kg/58hp) which I tried a year ago and also enjoyed running in Morocco is 3.2 – less good by a factor of 0.15. Write that down!
The Terra felt more cammy and crisp, though that could partially be down to the noisier pipe. In Morocco the Terra’s fuel consumption over 1000 miles was 67.9 mpg. So the significantly lighter and slightly less powerful BMW is more efficient and may well match a Terra on performance if not noise. One thing’s for sure; it’s nice to have that surge of power after running the otherwise excellent CRF-L up on the high plains.
And like I say, compare that power and weight to the current G650GS/Sertao, both claiming 48hp at 192kg which equals a staggering 4 – you read it right: FOUR or about 30% less good/more bad than an XCo. Mark my words, soon they’ll all be analysing bikes like this.

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Looking more closely at my mud-splattered bike to fix a front wheel puncture, you can see where they made efforts to save weight. The front wheel nut is barely half a centimetre thick, the spindle wall is thin and doubtless other stuff like the front mudguard and fuel tank were all pared down to lighten the scales.
There’s not even anything to attach a hook or loop to on the back and I saw a picture of a broken swingarm on advrider which makes you wonder. You occasionally hear about failed alloy sub-frames too, but that won’t be unique to this or any travel bike. See this thread and how the XCh was loaded on page 2; you’ll probably agree with the comments which follow.

As for handling and roadholding, the bike inspires more confidence than I can currently deliver. Much of this is down to that 19-inch front and Tourance road tyres and ABS brakes which I’m still not sure are working but read somewhere that they are ‘unobtrusive’. All in all I’m pleased to be more impressed with the XCo than I expected to be. Just as long as the electrical gremlins keep away I hope to stay that way.

advxch

WTF is happening to this Country?
It’s going to be a shame to plaster over that 163kg but the thing needs the usual functional junk to become a travel bike. Even with its XCh bias, this adv thread (right) will be useful while this one is all XCo and is over 500 pages long. One night soon when there’s nothing on telly I might wade through it.
The fuel range was mentioned above – I like frontal and low tanks; time will tell. Meanwhile a mate has sold me a full metal bash plate off his XCh. I’m waiting for new clamps from the US for the fat bars to re-use my q/d Spitfire windscreen from my CRF-L. A brief stand on the pegs found the bars were not too much of a stoop (and the legs/knees slotted in better than a Sertao) but some bar risers may help.
Front guard needs an extender if not replacing with a full length item; crap was thrown all over the bike from both ends. And some sort of rear rack is needed as well as engine bars on which I’d like to mount extra fuel cans. I see now my hand guards are only plastic but my CRF’s Barkers are going spare. I also have an LED light which will hopefully spare the 280W charging system once I  disable the headlight for day riding. Plus the Trail Tech Computer to fill up the data gaps on the dash. And as ever, a plate needs welding on the side stand for soft terrain support. That lot shouldn’t add up to more than 8 kilos.  Would be nice to save that on an alternative silencer but scanning this lengthy adv thread, X-Man Walter C finally nails it: noise ≠ power. The best you will do is lose 3.4kg off the 5.6kg stocker with an SR Racing stainless pipe for a cool €600. This late 2013 thread shows all the optional pipes as well as cat removing instructions.

First though, I ought to run my X for a while to make sure it doesn’t spit back in my face.

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