► Recalls and software updates

[twisticles]

I just put my 800GS through its 24 month service before the warranty period ran out.

Bear in mind that my bike was laid up for about 4 months in the UK when I moved to Singapore before I imported the bike over. During that time it was covered under a car port, the December 08 to April 09.

THe following work was done as part of the servicing:

• 
  Spark plug change - they were sparking OK, but the nuts had corroded badly
  Oil/Filter change (to 15w40 semi-synth)
  Coolant change (don't need de-icer in the tropics )
  Brake fluid change (not required at 24 months but it was brown )
  All the usual servicing stuff

At the same time they discovered the following:

• 
  Rocker head gasket leaking
  Front wheel bearings shot

Still waiting for the bearings to arrive, about 1-2mm play in the front wheel...don't notice much on the TCK80s

And the following service campaign items were fixed:

• 
  Brake caliper bolts
  Front axel replaced (mine was a March 08 bike, but the dealer said it needed doing )
  Fuel level sensor
  Radiator hoses replaced (these hadn't been a problem since the 12 month service when SLM scraped the paint off, but its done now)

So, having had the $5000 'registration fee' waived for a self-import bike, the grand total of all this work? Cost me a princely 117 squids (S$252). I can live with that

New farkles on the way...wunderlich risers just added, touratech seat on order, dynabeads going in, fat foot, and a new pair of conti trail attacks in an attempt to keep up with superduke riding friend. I think a pair of Steel Ponies are on the horizon...

 

[twisticles]

A word of note on the rocker head gasket leak...I am pretty good about inspecting the bike, and I missed this. Didn't notice any appreciable drop in oil level either.

If you haven't had this problem, do check your bike. From the side of your bike, stick your fingers in the side hole in the plastic at the top of the cylinders and poke around the front of the engine at the top behind the radiator. If you feel oil there, get it checked out.

Its worth trying to wibble your wheels sideways to check your bearings too.

 

[GS Biker]

A word of note on the rocker head gasket leak...I am pretty good about inspecting the bike, and I missed this. Didn't notice any appreciable drop in oil level either.

If you haven't had this problem, do check your bike. From the side of your bike, stick your fingers in the side hole in the plastic at the top of the cylinders and poke around the front of the engine at the top behind the radiator. If you feel oil there, get it checked out.

Its worth trying to wibble your wheels sideways to check your bearings too.

My gasket was exchanged in Dec. Subsequently, it started leaking again. SLM have now said that they going to replace the top cover...booked in for tomorrow. In three weeks it’s lost nearly a pint of oil. Like you, I never noticed it leaking but smelt the burning oil on the exhaust at a set of lights the one day and lone behold. Still running fine though and love riding the thing.

 

[Greggers]

Well, my warranty runs out about now, and it's due a 12k service...

My dealer originally said they'd do the leaky cam cover under warranty and check valve clearances while they were there ... Evidently the gnomes at BMW have cottoned on to this practise and will now charge for the service and do the warranty work while they're there...

From now on I'm self-servicing, first job on the list a leaky cam-cover gasket... then check valve clearances, then buy a diagnostic reader..

G

 

[twisticles]

From now on I'm self-servicing, first job on the list a leaky cam-cover gasket... then check valve clearances, then buy a diagnostic reader..

G

I'm with you on that Greggers, if only to learn how to do it away from a BMW dealer. I think I can handle most of the servicing tasks, but I'd be lost trying to check valve clearances.

 

[Greggers]

Ahhh -- I'm running a DYO Maintenance workshop tomorrow ... Wanna come? ahhh - Singapore - hmmmmm next time maybe lol..

Seriously though, doing clearances should be fairly simple, the arse-ache comes in getting the bodywork off, then the gubbins underneath like the battery and air filter box, Once they're off, the top of the motor is relatively accessible. From there it's just a question of taking the cover off and checking the clearances - at 12k I'd be very surprised if there's an issue.


<a href="http://s123.photobucket.com/albums/o292/Greggynormous/?action=view&current=f800gsvalveadj.jpg" target="_blank"><img src="http://i123.photobucket.com/albums/o292/Greggynormous/f800gsvalveadj.jpg" border="0" alt="Photobucket"></a>


if adjustment is needed then that's where it starts getting a little complex. This motor uses little 'cups' (BMW call them 'oil-sinks' for some reason) that sit on top of the valve stem, almost like a miniature combined bucket and shim arrangement, so the clearance is controlled by the thickness of the bottom of the cup. You need to measure the valve clearance first, work out how far out of tolerance it is - then get the existing 'cup' out, read it's thickness and work out what the new 'cup' thickness should be to get you back to tolerance .. then when you've done that for all the valves, trot down to your local BMW dealer and buy/order the appropriate cups, re-assemble everything, don't be shy with the gasket goo, and Robert's your mother's proverbial brother...

G

 

[twisticles]

Oh well you put it like that...

 

[jimbob59]

There is a note in the manual that I think is important ...

Basically is says that when you are messing with the "oil sinks" you should be sure to plug the oil return passages with rags so as to avoid a loose oil sink falling into the bottom of the engine....

fine advice I think....

 

[Biking Viking]

Ahhh -- I'm running a DYO Maintenance workshop tomorrow ... Wanna come? ahhh - Singapore - hmmmmm next time maybe lol..

Seriously though, doing clearances should be fairly simple, the arse-ache comes in getting the bodywork off, then the gubbins underneath like the battery and air filter box, Once they're off, the top of the motor is relatively accessible. From there it's just a question of taking the cover off and checking the clearances - at 12k I'd be very surprised if there's an issue.


<a href="http://s123.photobucket.com/albums/o292/Greggynormous/?action=view&current=f800gsvalveadj.jpg" target="_blank"><img src="http://i123.photobucket.com/albums/o292/Greggynormous/f800gsvalveadj.jpg" border="0" alt="Photobucket"></a>


if adjustment is needed then that's where it starts getting a little complex. This motor uses little 'cups' (BMW call them 'oil-sinks' for some reason) that sit on top of the valve stem, almost like a miniature combined bucket and shim arrangement, so the clearance is controlled by the thickness of the bottom of the cup. You need to measure the valve clearance first, work out how far out of tolerance it is - then get the existing 'cup' out, read it's thickness and work out what the new 'cup' thickness should be to get you back to tolerance .. then when you've done that for all the valves, trot down to your local BMW dealer and buy/order the appropriate cups, re-assemble everything, don't be shy with the gasket goo, and Robert's your mother's proverbial brother...

G

Been there done that.........

Regarding the gasket, don't bother buying a new one, the recall ask for the new gasket to be glued in place, Rotax actually were cheap on the sealant, I assume you lot have got a black adhesive sealant around your garage somewhere just use it to glue the gasket in place, I have the recall procedure somewhere, remind me to scan it and post it here. One small advice, while you have the rocker cover off, check the tension of your headbolts, I came across a "loose" head bolt last time.

cheers
Eythor

 

[Greggers]

I never buy anything new unless the old one is FUBAR ...

Gasket Goo is King

I use Loctite 574 a nice bright orange one so you can see where it is...

G