1200 gs 04 full rebuild

[Pauly S]

Hi All, i'm looking to do a full rebuild on the motor after it dropped an exhaust valve,i'm looking to fully strip it to ensure there is no debris in the cases.
Question is...what special tools are needed if any?
Ive got the usual full tool kit with compressor,nut guns, torque wrenches extractors etc.
many thanks Paul

 

[beermonster]

You might have more luck on the US site mate

 

[Pauly S]

which one?

any recommendations?
cheers Paul

 

[MIKE R]

You might have more luck on the US site mate

Probably

http://www.advrider.com/forums/forumdisplay.php?f=3

Mike

 

[socket086]

it might be faster and cheeper to put a second hand motor in,
it is the way i went as when i worked out the cost of parts it made sence.
i kept the engine and over the last two years have got most of the parts cheep so i will have a back up engine as i run two gs's.

 

[DrFarkoff]

Did it bust thru the piston?? If not piston barrel head NOT like this one!

Now Mine

LINK to Slideshow

 

[patzx12]

I went through the piston but didnt do a full strip.
I took of the front cases and rigged up a hose onto the end of a vacume + long airline and a magnet on a stick. Poked everywhere. rebuilt put in the old oil and filter i saved from my othe bike ran it for a day, changed the oil again and checked it for bits. Still going strong

 

[Pauly S]

yep...

Did it bust thru the piston?? If not piston barrel head NOT like this one!

Now Mine

LINK to Slideshow

Its done exactly the same..so its gonna get ripped to bits, and I'llpull out the shyte left in the sump, new barrel, conrod,piston,new head,and while its to bits its gonna get new valves in the other head.
I had to painfully explain numerous times.... that the engine has to come to bits to remove the swarf and wreckage that was left in the sump, theres bound to be summat in there, with that level of carnage.
Also i do wonder, are the new valves any better than the old ones?And are there any decent aftermarket valves for direct replacement which would be tougher?
cheers Paul

 

[Pauly S]

You may have been lucky..I never am..

I went through the piston but didnt do a full strip.
I took of the front cases and rigged up a hose onto the end of a vacume + long airline and a magnet on a stick. Poked everywhere. rebuilt put in the old oil and filter i saved from my othe bike ran it for a day, changed the oil again and checked it for bits. Still going strong

How would you have felt if a wee bit of ally jumped in the camchain and mashed itself to death in there,and snapped the chain in the process ,Then you prob would have had the valves whacking the pistons, and bending, like a car does,when the cambelt breaks.
I dont know if the 1200 is a non contact engine, anyone know?
personally i'll go on the safe side.
Also magnets dont pick up alloy..

 

[flatdog]

How would you have felt if a wee bit of ally jumped in the camchain and mashed itself to death in there,and snapped the chain in the process ,Then you prob would have had the valves whacking the pistons, and bending, like a car does,when the cambelt breaks.
I dont know if the 1200 is a non contact engine, anyone know?
personally i'll go on the safe side.
Also magnets dont pick up alloy..

Certainly not best practice.
I reckon he's been lucky it's still running TBH.