F800GS Engine
This engine is a work of art
Notice the rough mating surface on the bearing cap? It’s called a “cracked bearing”.
Traditional bearing caps are made 2 piece, bolted together, then bored to precise dimensions, then unbolted, bearing shells are installed, then bolted together again, at which point they never quite line up again and increased wear is the result.
Cracked bearings are forged one piece, bored to precise dimensions, cooled down to “oh my god cold” then cracked in half. The result is a perfect fit that is keyed down to the molecular level to fit back together in only one way. HIGH TECH!
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HLM bearing cap “cracked bearing technology”
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This is the HLM. This is the counter balance in this uniquely designed Rotax engine. This rod, with it’s counter weight is attached to the crank shaft between the two pistons and is opposite by 180 degrees. The result? Primary vibration is dynamically damped, something a rotating counter weight can never do.
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Here we have a CAM SHAFT. Note the missing chunks on the cam lobes facing up. This is not a casting flaw, but there by design to help oiling. It does not weaken the cam nor wear the follower as no pressure is present here as this is a valve closed part of cam lobe.
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This is the cam cap, or some might call it the cam shaft carrier.
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Magic pieces of the transmission.
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Here is an upside down view of the block with crank shaft loosely bolted in. Between the two quad bolt main bearing caps is where the HLM attaches to the crank. The lower case makes up the other two main bearing caps.
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This is the Lower engine case, complete with oil cooler and oil filter still attached. The slot in the center is where the HLM goes through.
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Magnesium HLM cover, oil strainer for main oil pump, and dry sump oil sump.
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This is the underside of the Lower engine case, complete with oil cooler and oil filter still attached. The slot in the center is where the HLM goes through. The HLM cover to the right bolts over the slot in the engine case.
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Top side of HLM cover.
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Center, Inside of oil pan, note the well braced mounting bosses. To the right is the alternator side cover.
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Block with pistons at BDC.
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Top side of the head.
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Gears, ball bearings, and driving dogs. note how perfect machining of dogs are and how oversized they are.
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For those with enquiring minds. This engine was opened up to find a noise that only occurs when the engine is fully warmed up and is only detectable at idle.
Yes I am aware this engine is not in a clean site, it’s off for hot tanking once we find out what is wrong
The verdict is not in yet, however, one thing that is known: Every bearing clearance is perfect, as new. the Nikasil coating on the bores is perfect. wear on pistons is almost undetectable. If other F800 engines are holding up like this, I would say this is an EXTREMELY long life motor. All bearings still have nearly all of their factory matte finish, they have not even begun to polish!
Amazing considering this bike has 11,000 hard miles.
I am in awe of the quality and design of this Rotax engine.
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RESULT!! ..an email..
[email protected]
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The web page was using adobe to share the images or protect them, I'm sure i've screen printed them somewhere, as there was 2/3 pages on the site.
Right emailed the chap about whats what...hopefully get a reply. It maybe that you need to have an account to view it now..each of the above paragraphs has images of parts of the engine (for those wondering if I had gone loopie).
