tearing down my 1150GS

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Hello, all! I'm currently tearing down my 1150GS to do some major work on her. If you're interested, the original post is here (on ADV). If it makes more sense to people, let me know and I'll insert the actual post here.

Bohdan
 
Hi there feller.Looks like you've been busy.
Couple of points i've learned.
No half measures with the clutch.Replace the complete Sachs unit.That one looks toasted.
Those fork top bushes are expensive (according to one of the Aussie ADVriders) unless theres play,clean,WD40 and grease them.
Good idea to check clutch pipes at slave for corrosion and bleed old fluid out.
Are you working on the brakes at all?.Stainless lines?.
Good luck.:beerjug:
 
Hi, there, Colban!

Thanks for the bits of advise! At the risk of boring everyone, but in the interests of sharing (and perhaps answering some questions before they're asked), here's the list of things I'll be doing for sure and the things I'm planning on doing:

* jobs definitely being done*
replace all fluids
replace all brake lines with stainless steel
replace clutch line (at least from clutch lever to slave), possibly with SS
replace all brake pads
replace all cables
install new handlebars (Renthal Fat Bar)
install handlebar risers (likely Rox risers)
install fuse box in tool tray to consolidate all aux electrics
upgrade aux lights (currently running Hella ff50-driving pattern, planning on swapping those out for Hella ff50-fog pattern and adding LightForce 140s or 170s)
install new fuel pump
install oil cooler fan
install fuel line quick disconnects
install Stebel Magnum horn
replace front and rear shocks
replace any items necessary to maintain safety and handling
(already found clutch needs replacement, will likely replace telelever and FD bearings, possibly front wheel bearings)
general cleaning, inspection, and lubrication
general cleaning and inspection of electrical connections
inspect (and replace, if needed) oil thermostat
replace timing chain tensioners

I still need to do a leak-down test to see if there are any engine internals that require attention.

* jobs done prior to this *
new battery
TB balance
new air filtre
new alternator belt
valve adjustment
new tyres
new plugs
new plug wires

* jobs I'd like to include *
install ADV tank
re-paint motorcycle

That about covers it. I'm sure there are some minor jobs I've forgotten about.

Bohdan
 
Thats a pretty big (and expensive ) list.
I know you're being pretty thorough in your tear-down,but do you really need to change the telelever bearings?.
They dont exactly have a hard life and unless i was stripping the telelever for painting,i wouldn't bother.(unless of course they feel rough/rusty/notchy etc)
That clutch slave cylinder does look suspect so i would change that along with the gasket.
Does your clutch pushrod have the felt washer on it?.
You also mention the cam chain tensioners.Its only the LHS one that really needs changing to the later type.
Are you planning on Ohlins or Wilbers shocks?.
Did i see a thread on ADVrider about a group buy?.
What screen and seats do you have?.They dont look standard.
Looking at those paint schemes,the PD scheme with the BWM tri-colours looks best.
Cant say i'd like the word "basic" plastered on my tank.
 
Hi, everyone!

Decster -- I've thought about moving the filtre outside the tank, but, frankly, it's such an easy thing to swap -- even inside the tank -- that I'm just going to leave it in there. In addition, it seems like a number of people who've moved it outside have gone ahead and returned it inside after a while.

Colban -- Lots of good points. On the bearings -- I need to check them yet to see if they need swapping. And there again, I mis-spoke; I meant paralever (I always get front and rear terms flip-flopped; Maybe I should go into politics!

Clutch rod - yes, it has the felt washer on it. I presume I should replace that with a new one as well.

Cam chain tensioners -- you're right that the LH is the one that needs swapping. I may do both, simply on the advice of JimvonBaden.

shocks -- not sure if I'll go Wilbers or Ohlins, they both have pros and cons as far as I understand. I need to do quite a bit more research to make a choice, but I'm pretty sure that either one is a fine choice. I saw the group buy, too. I need to see if it's still good.

Screen and seats -- the screen is the Wunderlich Tourer-Screen for the 1150GS (part no. 8110064). The seats are, I believe are Russel day-long seats; the original owner had them put on. I have to admit, for a tractor-shaped seat, it's mighty comfortable. The dished shape makes it a bit difficult to shift my arse from side to side when I want to hang off a touch, but I can deal with that. I've done 600-700 mile days on that seat in complete comfort! :thumb2

I'm leaning towards the PD tri-colour scheme, too. Seems a bit more appropriate an homage and it just plain looks better.

You're certainly right about this being an expensive proposition. The way I see it, I ride the bike pretty much all year, so long as the roads are dry and it's not terribly bitter cold (read "below 0 degrees F). On top of that, my commute is 50 miles each way, so I'm racking up miles really fast. I'm an*l about routine maintenance on my auto, too. I just see this as an investment in safety and reliability. (My wallet may disagree, but it will just have to deal with it.) And as a last bit to consider, my girlfriend and I are going to start riding two-up next year and I want a safe bike for her, too.

I updated my ADV thread with a look at the rear main seal if anyone is interested.

Cheers, everyone! :beerjug: Thanks for all the help!

Bohdan
 
Okay, big updates over on ADV rider, but I'll post my colour-scheme post here for your dining and dancing pleasure. I'm open for suggestions and opinions.

Bohdan
------------
So here's the second post I promised. This is just part of an e-mail I sent to a local graphic designer for some thoughts. She's done MC decals before, including this one. It's one of my favourites. Her business is called "studio 299" and the bike is her husband's. The pic is from a 5 hour enduro he was racing in last fall.

I'm looking to do something of a replica of the Paris-Dakar bikes BMW raced in the mid-80's. You can get a basic idea of what I'm looking for from the attached photos.

There are some design issues, though, in terms of visual appearance, the most apparent one being that the bodylines of my bike -- the fuel tank in particular -- are different than the bikes I'm replicating. That being the case, I think something of an homage is more appropriate than a direct replica. So, to start the process going, I'm sending you some pics and ideas.

First, a pic of my bike to give you an idea of the body-lines. This is not my personal bike, but it is a much better picture than any I have of my own bike. My bike has a slightly different seat than this one, but otherwise is pretty much identical.
2004_7_r1150gsadvalum.jpg


Now for some ideas, with my thoughts further down...
rahier85.jpg


sm%201984%20Paris%20Dakar.JPG


sm%20paris-dakar86_2.jpg


The look I'm going for is the basic white with tri-colour. I'm a really big fan of the first two bikes -- the almost all-white ones. The third one isn't so much my favourite, but it provides a decent view of the tri-colour bands. Between all three, I think the first pic gives the best sense of what the colour-scheme would look like on my bike, too; the body-lines are fairly similar. I especially like the way the tri-colour would follow the flare/body-lines of my fuel tank fairly well. As far as visual balance goes, I think the sponsor logos provide good visual balance, breaking up the huge expanse of white that the tank otherwise presents. I'm not really sure I want to ride around with "penthouse" plastered on the bike, though. I've always liked the "elf" logo for its simplicity. (Only issue there is that it doesn't appear on the bike in the first pic.)

My thought -- and I'm open for suggestions here, too -- is to paint the bike white, probably leaving the front fender extension black like it is now. I think it might make sense to move the BMW logo to another place on the tank (Right now, they're actual badges set into the tank. I'm considering removing them and filling the recess with body-filler.) That way, the tri-colour can be done as a decal that can get cleared over. Likewise, the "moved" BMW logo could get done as a decal, too. In addition, I think a small tri-colour band would look good on the tail rack; it would break up the plain white there (since I won't have a number plate), and it would echo the tri-colour on the tank.

As I said before, I like the idea of the sponsor logos on there, but I'm not sure about appropriateness. The "elf" logo could go on permanently. I'd also like to include the "Paris - Dakar '84" tag as seen in the next pic (this is the same bike as the wheelie-ing bike in the first "idea" pic). This also gives a great view of the sponsor decals.

84dash.jpg


Some other thoughts -- since "penthouse" isn't exactly appropriate, I'm open to ideas for something else there to maintain the look and visual balance. For example, a decal with "die miniKuh" (the miniature cow), as that's my nickname for the bike. Or something whimsical/funny there, either including "die miniKuh" or something entirely different. Maybe "die miniKuh" with some goofy-looking or stylised cow? That being said, I think it could be fun to have a cling-decal made with the "penthouse" logo on it so that I can go for the accurate look when I want to.
 
Curious why you were so intent to change everything:nenau

IMO, some parts are better than others and just because it's new, dosn't mean it's better. New clutch sounds lovely though. I'd love to have a new clutch.
 
Hi, Flatknuckles!

Good question on your part. Since I'm the third owner of the bike, have no idea how she was treated prior to my ownership, since it seems some blokes have to replace various bits due to wear at 40-50k miles, since I'm at 38k miles, since I put on more than 18k miles a year, since I've been noticing various performance-related issues, since some things were definitely amiss, and since I've got a good opportunity now, I decided to tear into things and replace what needs replacing. I'm not swapping out any parts just for the sake of swapping, though. As I go in, if it needs replacement, I do. If not, I don't. As an example, my checks of the engine haven't revealed any issues (leak-down is good, there are no leaks, etc.), I'm not tearing into it. Clutch, splines, and bearings, on the other hand, gave indications of being shot, so I've gone in, looked, and replaced what needs it.

Bohdan
 
Hey Bodhan,

Have been reading this on ADV before you posted up here...great stuff:thumb2

As for the paint job, i would not be putting any advertisers names on the bike, whats wrong with 'gonzomup' or 'Bodhan', your bike afterall:nenau

D
 
An Overdue Update

Hello, everyone!

I posted a large update about my progress on ADV, but I'll post it here as well for your convenience and entertainment.

Bohdan
---------------
So this is a while overdue, but I want to update this thread with some info and pics.

First, remember the damaged ADV tank I bought? Well, Stephen has been doing a lot of work on it for me. Up to this point, all the work has been spent on just getting the previous paint and body filler off. Yes, I said body filler. It seems the damage was a bit more extensive than we could see initially. But rather than me going on about it, I'll just insert part of Stephen's most recent e-mail about the tank.

First, update one...
I got the GS Adv tank mostly down to the metal today... at least on the top and sides... issues under the evercoat. I had to grind away a lot of filler, and I still don;t have it all off. Have to do it more by hand detail... chip it out of the dents, etc. I'll then pull those dents out so we don't have to use so much damn filler!

OK... so... Big swells and dents both. THAT why they had so much coat built up.. they did not bother to knock down the 'walnuts' in the tank.. just built up and built up and built up the body filler.

There were like, 3 paint coats and 3 primer coats on that sucker... LOTS to remove. Man... it took some AGGRESSIVE tactics to get all that off. I couldn't believe it. The lot outside my shop looks like a 40lb dust bomb went off!
...and the update from the next day...
OK... your tank got lots and lots and lots of love today. 6 hours worth, in fact.

Knocked down all the crowning spots and leveled and reshaped both 'side panels of the tank. BIG project, but it came around. We now have to only use a skim of filler.. nothing like before.

I went ahead and put my first coat of filler onas well... on both sides of the tank.

I reshaped both top sections of the tank where it contours to the sides.

Found a crack in a weld that was where someone's nuts would hit and dent the tank (you know... the back part where there was filler). I re-welded then brazed that fully, filled it in with body solder as well.. and it should be good to go. Will still require a bit of plastic filler, as I can not 'pull" on that weld and braze now... and was afraid to do so even before the repair. Regardless, I got it out about 1/4" before... and only noticed the crack when I had a light inside the tank.
So that work is going along fairly well, I think. As far as the work I've been doing, well, the drivetrain is all re-installed (I figure no need for a pic, since you all know what that looks like), and I'm currently working on electrics. No exciting pics there, either.

But, to keep all you boys and girls happy, let me post a whole slew of pics showing various bits and pieces that are going on or already on the bike. Sort of a bit of a tease to whet your whistle about what the final thing will look like...Ready kids? Here we go...

[cue fashion-show catwalk music]
Let's take a look at what fashionable GS riders in the Upper Midwest will be sporting this spring, shall we?

As we start at the top of the bike, we'll find these first...
sm%20bars.JPG


...on which the ends will have these...
sm%20grips.JPG


...all of which will be mounted in these...
sm%20rox.JPG


Now while it's wonderful that our rider's hands will be enjoying the comforts of the new set-up, let's not forget the rider's butt. We wouldn't want anything to be jostled around too much, would we? No, we wouldn't. So let's take a peek under the front fender. Oh my, what's this?
sm%20fr%20shock.JPG


Hmm...I'm not sure I believe my eyes. Let me rub them and take a look under the rear fender.
sm%20rear%20shock.JPG


Well, that pretty gold colour looks familiar. What's that you say? You can't place where you've seen it before? Maybe this will help.
sm%20preload.JPG


Ah, yes, now I remember...Geez, with such a cushy ride how do we suppose our rider will feel about his control over the bike? Maybe these will help...
sm%20SS%20fr%20brake.JPG

On the front, some SS brake lines in a beautiful blue colour, reminiscent of the BMW blue.


On the rear, we find something similar. After all, we want to make sure things match.
sm%20SS%20brake.JPG


And as we take a peek at something poking out from underneath the airbox, we see this...
sm%20SS%20clutch.JPG

a beautiful custom-made, SS clutch line.

Now having all those SS lines wouldn't do our rider much good with old wheels now, would they? So let's add a pair of these...
sm%20wheel.JPG

A set of wheels, freshly laced with SS spokes courtesy of Woody's Wheel Works, and a new set of ABM brake discs. My, aren't they sexy?

With such beautiful mod's to the bike, we wouldn't want anything to happen now, would we? So to make sure that nobody tries to get too close a look while travelling, our rider will have the luxury of a noise-maker.
sm%20stebel.JPG


And last, but certainly not least, we should be proud of our new bike because of the extra weight she lost. Now, with her ass-end a bit smaller and lighter, she'll look -- and sound -- oh, so very sexy!
sm%20stubby.JPG

[end fashion show catwalk music]

So there you have it, my friends, most of the new toys going on the bike. Not sure what I'll update with next. Maybe some pics of the new lightbar and lights as I get them wired up.

Or maybe I should just keep all of you in suspense and wait till its all done [cue maniacal laugh]

Bohdan
 
Hi Bohdan,now you're just teasing us.:D
All that GS porn--nice.:thumb
Have you decided on a colour scheme yet?.
 
I just noticed your sig' line, Colban! :yelrotflm I'm going to have to put that on a t-shirt or bumper sticker!

ianboydsnr -- That may be true, but my wallet would argue that it's a lot more than half!

Oh yes, colour scheme. I'm going with the entire bike (tank, rear "rack," beak, and beak extender) in Alpine White. The tank will have the tricolour following the line of the tank. For text in place of "penthouse," I'm going to probably go with "miniaturkuh." Also, the three vendors/craftspeople who have had the biggest role in it will have small logos on my bike, similar to the ones on the PD bike -- in other words, small, but there for people to see if they're curious.

Thanks again for all the kind words!

Bohdan
 


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