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Discussion Starter · #1 ·
Good afternoon and Merry Christmas! I was hoping to elicit some expertise from the group. I have a 2013 825i with approx 9000 miles that is making a noise that I hope to repair before it becomes a bigger problem. Under heavy acceleration, I hear what seems to be a belt slap from inside the clutch cover. When I leave off the throttle and reapply, the noise seems to go away. I am on my third belt in a two year period. When I last replaced the belt, I did notice an area closer to the primary that was beginning to wear through due to belt contact. i was hoping that the old belt may have been misshapen and had caused the issue. That seems not to be the case. A second symptom is that upon heavy deceleration, the machine surges a great deal via engine braking. i have been able to determine that the wheel bearings are ok, the transmission appears to be working appropriately, and i did just replace the front drive axle carrier bearing in that it failed. When i changed the last drive belt, i also replaced the wheels on the secondary clutch.

My working theory is that the primary clutch might not be functioning properly, causing the machine to engage/disengage inappropriately causing excess slack in the belt and the observed surging. Being the shade-tree mechanic that i am, this could be way off... Any advice from the group would be greatly appreciated before i begin the process of checking this theory out the hard way...

Thanks in advance!!
 

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XUV 550 with Honda GX 630
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"...an area closer to the primary that was beginning to wear through due to belt contact. "
What is "an area"? What is wearing through?

"...on my third belt in a two year period."
That is not normal.
 

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Discussion Starter · #3 ·
Tried to take a picture, but it didn’t turn out… an area just above the hose that leads to the intake above the cover for the belt is wearing through the plastic housing…
 

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On first read I thought the primary wore, but it sounds like the plastic cover has worn through due to belt contact.

Have you:
Inspected the primary rollers and weights for wear or binding?
Checked secondary plastic slides and spring?
100% certain on belt part number?
Purchase quality belt or cheapest available fro sources unknown?
Cleaned the clutch belt surfaces before installing new belt?
Fillowed break in procedure for belt when new?
Searched forum for similar? Remember a few posts concerning belt slap in the past.
It will be interesting to learn resolution.
When the belts need replaced what is the reason? Too narrow? Inconsistent width? Glazed functional surface? Shredded? Etc…
 
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Discussion Starter · #5 ·
I have not checked primary rollers or weights, I did replace the secondary plastic rollers, but nothing else yet. Jd belt was used after cleaning surfaces and breaking in…
 

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Discussion Starter · #6 ·
i had some time today to disassemble and take some pictures... i truly hope this helps diagnose the issue. What had caused this to be a problem was the noise i assumed to be belt slap. When looking into this further, I can see where the drive belt was hitting the cover...

Automotive tire Hood Wood Automotive exterior Motor vehicle


Hood Automotive lighting Automotive tire Trunk Automotive exterior



The top of the belt had been hitting, but it didn't seem to have damaged the belt outside of when it came off, it was pear shaped, not oval as expected. I pulled the primary clutch out to inspect. I was able to notice some slide wear on the buttons, but the internal spring was intact, the clutch weights were ok and I could not identify any flat spots on the rollers.

Finger Gas Automotive wheel system Machine Electric blue

Next, i removed the secondary clutch. The springs seemed ok and i had already replaced the rollers on the transmission side of the clutch. I did notice what appears to be significant wear on the outboard rollers in addition to wear on the metal surface of the outboard secondary clutch sheave.
Automotive tire Rim Wheel Gas Circle



Automotive tire Household hardware Rim Gas Bicycle part


my thoughts as a weekend mechanic is that the outer sheave and rollers are not operating properly causing the belt to extend and slap the cover.

I would very much appreciate other thoughts as I move forward!

Thanks!
 

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I think you are onto something. This system relies on both clutches working in unison even though they are actuated by totally different means. The primary moves based on RPM while the secondary moves based on torque. If they are out of sync the belt won't be properly tensioned and could slap.
 
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