TDC locking tool.

[Noddy]

To fit 1100GS.
Could anybody let me know the dimentions of the locking pin.
Or, any hints/tips of something else that will do the job.
Got to take the head of to replace a head gasket thats leaking oil.
Thanks.

 

[ferguscawley]

Noddy

No need to get a special tool. I set the bike at TDC (by turning the wheel in 5th gear with spark plugs removed), then apply large cable tie tightly through rear wheel and around paralever (swingarm). This locks it well enough.
Anyway, the camchain sprocket will only go back on one way so its hard to mess it up. Just be sure to put a small cable tie around the chain and cam sprocket before you remove it so that it does not jump a tooth.
Piece of cake really.

Do a search under cylinder head removal etc under my name and you'll see pics of what I mean.

Ferg

 

[ferguscawley]

Go here

http://www.ukgser.com/forums/showthread.php?s=&threadid=18299&highlight=cylinder

 

[Noddy]

Thanks for that Furgus, will give it a try. was a bit concered about undoing the timing chain sprocket.
I tried everything to undo the exhaust studs and finally heated them up with Oxy/A, photos show the result. Bastards.
Already got the new studs but can't think of a way to remove the knackered ones, What do you recon on heating the head?

 

[Noddy]

Other side.

 

[Polarbear]

In similar situations in the past i have welded a nut onto the sheared stud, and then found it will undo with the correct size spanner for new nut. (must be a heat thing which helps to break the stud free). When this has failed and the stud has sheared again its been down to carefully drill, tap, and or helicoil.

 

[ferguscawley]

Noddy

As polarbear says, weld a nut onto each stud. Then soak (and I mean soak) the studs in WD40 overnight and then back them out. Buy new studs from BMW dealer and apply copper grease liberally when inserting them .

I would be slow to use an oxyactylene torch directly onto the head itself as you will burn the paint/laquer off. Use a heat gun if you must.

The cam chain sprocket comes off ok but the allen-head bolt is in quite tight. Use a good quality allen extension on a long bar to undo it. The cam sprocket then needs to be levered off the camshaft with a small screwdriver. It is 'keyed' so it will only go back on one way. Be sure to back off your cam chain tensioner bolt before you do this or it will be nigh on impossible to put the sprocket back on the cam shaft.

Any questions - just ask.

I am actually removing both heads on my friend's 1100 tonight to replace the pistons and replace a valve. See this thread for history.

http://www.ukgser.com/forums/showthread.php?s=&threadid=28526

Ferg