Nice pictures but I haven't understood a single word of what's been written. 
Great work though, hat's off to you.
Great work though, hat's off to you.
This Autumn, I shall mostly be wearing ...
- Thread starter Magwych
- Start date
BlueBird
Registered user
Wheres the money shot!
Nice one Bruvva.
Im on 110k from my 05 and ive had it apart a few times because of my foolishness.
The design makes them easy and great to work on
Now all we need is a pic of nice looking woman in suitable attire on it.
Nice one Bruvva.
Im on 110k from my 05 and ive had it apart a few times because of my foolishness.
The design makes them easy and great to work on
Now all we need is a pic of nice looking woman in suitable attire on it.
MWH
Registered user
Thanks for sharing. Always interesting to see pics of things in their component states then the finished product.
Most parts were in reasonable condition, showing some signs of wear but nothing excessive. But, having gone through the pain of taking the frame off the engine once I just replaced all the internal wear parts.
Most parts in reasonable condition... bar the shock absorber on the gerbox input shaft. It looked OK when covered in a fine dark oil film; after cleaning up it initially still looked good, and a bit shinier. The I noticed the fractures on the outer body, and in the tabbed reatining washer:
The fractured washer relieves some of the tension on a really stiff spring inside the body, which provides the tension for a cam type shock aobserber on the shaft. I did have a lot of free lash in the gearbox, think this where it came from.
BMW have apparently redesigned this part, which can only be bought as a complete shaft assembly. I had one on order for a while, but was told that none were available, and I would have to wait for 6-8 weeks. That wait was not to actually get the part, that was how long BMW estimated it would be before they could give an idea of when one would be available.
I bought 3 second hand ones until I found one that was not fractured in a similar, or worse way. This was the worst, supplied by a well known online BMW parts dealer, who I hoped would have known better. The entire base of the outer body has fractured off and disappeared somewhere inside the gearbox letting the internals loose:
I sent that back for a full refund
The piston on the right was the worst of the pair, the scratches on the skirt are from being thrown into the scrap bucket. shiney new Wossner piston on the left. Different crown height and valve pocket size but same compression ratio.
Most parts in reasonable condition... bar the shock absorber on the gerbox input shaft. It looked OK when covered in a fine dark oil film; after cleaning up it initially still looked good, and a bit shinier. The I noticed the fractures on the outer body, and in the tabbed reatining washer:
The fractured washer relieves some of the tension on a really stiff spring inside the body, which provides the tension for a cam type shock aobserber on the shaft. I did have a lot of free lash in the gearbox, think this where it came from.
BMW have apparently redesigned this part, which can only be bought as a complete shaft assembly. I had one on order for a while, but was told that none were available, and I would have to wait for 6-8 weeks. That wait was not to actually get the part, that was how long BMW estimated it would be before they could give an idea of when one would be available.
I bought 3 second hand ones until I found one that was not fractured in a similar, or worse way. This was the worst, supplied by a well known online BMW parts dealer, who I hoped would have known better. The entire base of the outer body has fractured off and disappeared somewhere inside the gearbox letting the internals loose:
I sent that back for a full refund
The piston on the right was the worst of the pair, the scratches on the skirt are from being thrown into the scrap bucket. shiney new Wossner piston on the left. Different crown height and valve pocket size but same compression ratio.
elvisncheese
Registered user
I do admire those who can speak a foreign language.
Excellent job, btw.
Excellent job, btw.
Good job done there!
Hilux's seem to be the thing for us 1200GS owners, I know of at least 2 others in this part of the world besides me!
D.
Hilux's seem to be the thing for us 1200GS owners, I know of at least 2 others in this part of the world besides me!
D.
Ram
Registered user
Be interested to know the exact replacement shopping list to get your bike back to A1 condition. Would be useful for those of us who may do high mileages in the future, or face a total rebuild. Do you think it was economically viable, (Even doing the spanner work yourself) or would it have been cheaper to buy a decent low mileage 2013 plate?!!
It is not a short list, and does contain some chassis parts as well.
Engine and gearbox parts start "11" and "23" respectively:
[table="width: 600, class: grid, align: left"]
[tr][td]Description[/td][td]Part Number[/td][td] Qty[/td][/tr]
[tr][td]*gbox grooved ball bearing: 20x47x14 6204 2RS TM204 [/td][td]23 12 2 330 176 [/td][td]1[/td][/tr]
[tr][td]*gbox grooved ball bearing: 52X20X15 6304 2RS TM304[/td][td]23 12 7 709 852 [/td][td]1[/td][/tr]
[tr][td]*Gbox grooved ball bearing: 56X22X16 63/22 2RS/DDU TM3/22 [/td][td]23 12 7 709 798 [/td][td]3[/td][/tr]
[tr][td]*Gbox grooved ball bearing: 62X25X17 6305 2RSR TM305 [/td][td]23 12 7 709 809 [/td][td]1[/td][/tr]
[tr][td]*Shaft seal, drive shaft :*17X28X7 [/td][td]23 12 7 705 085 [/td][td]1[/td][/tr]
[tr][td]Bearing shell yellow [/td][td]11 21 8 521 860 [/td][td]2[/td][/tr]
[tr][td]Bearing shell, cover side, red [/td][td]11 24 7 700 603 [/td][td]2[/td][/tr]
[tr][td]Bearing shell, rod side, blue [/td][td]11 24 7 700 604 [/td][td]2[/td][/tr]
[tr][td]CHAIN TENSIONER [/td][td]11 31 7 677 666 [/td][td]1[/td][/tr]
[tr][td]Circlip for brake pedal [/td][td]07 11 9 905 594 [/td][td]1[/td][/tr]
[tr][td]Clamp for pannier rack [/td][td]46 54 7 698 984 [/td][td]1[/td][/tr]
[tr][td]comp shaft Grooved ball bearing [/td][td]11 27 7 675 034 [/td][td]1[/td][/tr]
[tr][td]compensating shaft seal Shaft seal 25X37X6,5 [/td][td]11 11 7 721 848 [/td][td]1[/td][/tr]
[tr][td]Connecting rod bolt [/td][td]11 24 7 684 644 [/td][td]4[/td][/tr]
[tr][td]Cyl. head gasket, 3 components [/td][td]11 12 7 672 598 [/td][td]2[/td][/tr]
[tr][td]Cylinder f chain tensioner, right [/td][td]11 31 7 709 276 [/td][td]1[/td][/tr]
[tr][td]Dowel : clutch housing [/td][td]11 11 1 340 009 [/td][td]2[/td][/tr]
[tr][td]Flange nut M10-10-ZNS3 [/td][td]07 11 9 904 670 [/td][td]1[/td][/tr]
[tr][td]Gasket [/td][td]11 31 7 674 453 [/td][td]1[/td][/tr]
[tr][td]Gbox grooved ball bearing: 20X47X14 [/td][td]23 12 2 330 176 [/td][td]1[/td][/tr]
[tr][td]gear selector shaft seal: 17X42X7,5 [/td][td]23 12 7 709 904 [/td][td]1[/td][/tr]
[tr][td]gear shift plastic bush [/td][td]35 41 7 674 080 [/td][td]2[/td][/tr]
[tr][td]Guide rail [/td][td]11 31 1 341 293 [/td][td]1[/td][/tr]
[tr][td]Guide-bearing shell yellow [/td][td]11 21 7 675 273 [/td][td]2[/td][/tr]
[tr][td]ISA screw M10X30 [/td][td]07 12 9 905 270 [/td][td]2[/td][/tr]
[tr][td]ISA screw M8X40 [/td][td]07 12 9 904 704 [/td][td]2[/td][/tr]
[tr][td]ISA screw M8X50 [/td][td]46 54 7 699 810 [/td][td]2[/td][/tr]
[tr][td]LEFT CHAIN TENSIONER [/td][td]11 31 1 341 295 [/td][td]1[/td][/tr]
[tr][td]oil pick up O-ring 20X2,5 [/td][td]11 41 1 342 499 [/td][td]1[/td][/tr]
[tr][td]oil pick up O-ring 22X2,50 [/td][td]11 41 1 341 597 [/td][td]1[/td][/tr]
[tr][td]Oil pump alu ISA screw M6X40 [/td][td]11 41 7 669 855 [/td][td]3[/td][/tr]
[tr][td]Oil pump alu ISA screw M6X45 [/td][td]11 41 7 669 856 [/td][td]3[/td][/tr]
[tr][td]oil sight glass [/td][td]11 11 8 523 906 [/td][td]1[/td][/tr]
[tr][td]O-ring* 10,5X1,5 [/td][td]11 11 1 342 242 [/td][td]4[/td][/tr]
[tr][td]o-ring: 14x2 [/td][td]12 72 7 694 011 [/td][td]1[/td][/tr]
[tr][td]Oval-head screw, black M5X16 [/td][td]46 63 7 677 604 [/td][td]2[/td][/tr]
[tr][td]Paralever arm ISA screw M10X55-10.9-MK [/td][td]07 12 9 906 213 [/td][td]1[/td][/tr]
[tr][td]plastic rings DI=20.8 [/td][td]46 63 7 701 206 [/td][td]4[/td][/tr]
[tr][td]rear master cyclinder Oval head screw M6X20 [/td][td]35 21 7 685 343 [/td][td]2[/td][/tr]
[tr][td]RIGHT CHAIN TENSIONER [/td][td]11 31 1 341 296 [/td][td]1[/td][/tr]
[tr][td]rubber boot (gbox) [/td][td]33 17 7 685 599 [/td][td]1[/td][/tr]
[tr][td]Shaft seal : 10x18x6 [/td][td]23 12 2 332 884 [/td][td]1[/td][/tr]
[tr][td]Shaft seal : 20X32X8 [/td][td]23 12 7 705 086 [/td][td]1[/td][/tr]
[tr][td]Shaft seal : 25X40X8 [/td][td]23 12 7 705 087 [/td][td]1[/td][/tr]
[tr][td]Shaft seal: 36X50X7 [/td][td]11 11 8 528 387 [/td][td]1[/td][/tr]
[tr][td]Shaft seal: *65X83X8 [/td][td]11 11 8 528 386 [/td][td]1[/td][/tr]
[tr][td]Slide rail [/td][td]11 31 1 341 291 [/td][td]2[/td][/tr]
[tr][td]Snap ring oil sight glass [/td][td]07 11 9 904 991 [/td][td]1[/td][/tr]
[tr][td]Stop disc [/td][td]33 17 7 655 783 [/td][td]2[/td][/tr]
[tr][td]TIMING CHAIN [/td][td]11 31 7 694 426 [/td][td]1[/td][/tr]
[tr][td]TIMING CHAIN [/td][td]11 31 7 694 427 [/td][td]2[/td][/tr]
[tr][td]Washer ZNS3 [/td][td]07 11 9 904 198 [/td][td]2[/td][/tr]
[tr][td]ISA screw M8X55 [/td][td]07 12 9 905 217 [/td][td]1[/td][/tr]
[tr][td]ISA screw M12X50-8.8 ZNS3 [/td][td]07 12 9 906 088 [/td][td]2[/td][/tr]
[tr][td]ISA screw M10X40-8.8-MK [/td][td]07 12 9 904 632 [/td][td]4[/td][/tr]
[tr][td]Oval-head screw with anti-rotation lock M6X16 [/td][td]46 63 7 659 459 [/td][td]2[/td][/tr]
[tr][td]ISA screw M6X14 MK [/td][td]46 54 7 694 305 [/td][td]2[/td][/tr]
[tr][td]ISA screw M10X30 [/td][td]07 12 9 905 270 [/td][td]2[/td][/tr]
[/table]
Engine and gearbox parts start "11" and "23" respectively:
[table="width: 600, class: grid, align: left"]
[tr][td]Description[/td][td]Part Number[/td][td] Qty[/td][/tr]
[tr][td]*gbox grooved ball bearing: 20x47x14 6204 2RS TM204 [/td][td]23 12 2 330 176 [/td][td]1[/td][/tr]
[tr][td]*gbox grooved ball bearing: 52X20X15 6304 2RS TM304[/td][td]23 12 7 709 852 [/td][td]1[/td][/tr]
[tr][td]*Gbox grooved ball bearing: 56X22X16 63/22 2RS/DDU TM3/22 [/td][td]23 12 7 709 798 [/td][td]3[/td][/tr]
[tr][td]*Gbox grooved ball bearing: 62X25X17 6305 2RSR TM305 [/td][td]23 12 7 709 809 [/td][td]1[/td][/tr]
[tr][td]*Shaft seal, drive shaft :*17X28X7 [/td][td]23 12 7 705 085 [/td][td]1[/td][/tr]
[tr][td]Bearing shell yellow [/td][td]11 21 8 521 860 [/td][td]2[/td][/tr]
[tr][td]Bearing shell, cover side, red [/td][td]11 24 7 700 603 [/td][td]2[/td][/tr]
[tr][td]Bearing shell, rod side, blue [/td][td]11 24 7 700 604 [/td][td]2[/td][/tr]
[tr][td]CHAIN TENSIONER [/td][td]11 31 7 677 666 [/td][td]1[/td][/tr]
[tr][td]Circlip for brake pedal [/td][td]07 11 9 905 594 [/td][td]1[/td][/tr]
[tr][td]Clamp for pannier rack [/td][td]46 54 7 698 984 [/td][td]1[/td][/tr]
[tr][td]comp shaft Grooved ball bearing [/td][td]11 27 7 675 034 [/td][td]1[/td][/tr]
[tr][td]compensating shaft seal Shaft seal 25X37X6,5 [/td][td]11 11 7 721 848 [/td][td]1[/td][/tr]
[tr][td]Connecting rod bolt [/td][td]11 24 7 684 644 [/td][td]4[/td][/tr]
[tr][td]Cyl. head gasket, 3 components [/td][td]11 12 7 672 598 [/td][td]2[/td][/tr]
[tr][td]Cylinder f chain tensioner, right [/td][td]11 31 7 709 276 [/td][td]1[/td][/tr]
[tr][td]Dowel : clutch housing [/td][td]11 11 1 340 009 [/td][td]2[/td][/tr]
[tr][td]Flange nut M10-10-ZNS3 [/td][td]07 11 9 904 670 [/td][td]1[/td][/tr]
[tr][td]Gasket [/td][td]11 31 7 674 453 [/td][td]1[/td][/tr]
[tr][td]Gbox grooved ball bearing: 20X47X14 [/td][td]23 12 2 330 176 [/td][td]1[/td][/tr]
[tr][td]gear selector shaft seal: 17X42X7,5 [/td][td]23 12 7 709 904 [/td][td]1[/td][/tr]
[tr][td]gear shift plastic bush [/td][td]35 41 7 674 080 [/td][td]2[/td][/tr]
[tr][td]Guide rail [/td][td]11 31 1 341 293 [/td][td]1[/td][/tr]
[tr][td]Guide-bearing shell yellow [/td][td]11 21 7 675 273 [/td][td]2[/td][/tr]
[tr][td]ISA screw M10X30 [/td][td]07 12 9 905 270 [/td][td]2[/td][/tr]
[tr][td]ISA screw M8X40 [/td][td]07 12 9 904 704 [/td][td]2[/td][/tr]
[tr][td]ISA screw M8X50 [/td][td]46 54 7 699 810 [/td][td]2[/td][/tr]
[tr][td]LEFT CHAIN TENSIONER [/td][td]11 31 1 341 295 [/td][td]1[/td][/tr]
[tr][td]oil pick up O-ring 20X2,5 [/td][td]11 41 1 342 499 [/td][td]1[/td][/tr]
[tr][td]oil pick up O-ring 22X2,50 [/td][td]11 41 1 341 597 [/td][td]1[/td][/tr]
[tr][td]Oil pump alu ISA screw M6X40 [/td][td]11 41 7 669 855 [/td][td]3[/td][/tr]
[tr][td]Oil pump alu ISA screw M6X45 [/td][td]11 41 7 669 856 [/td][td]3[/td][/tr]
[tr][td]oil sight glass [/td][td]11 11 8 523 906 [/td][td]1[/td][/tr]
[tr][td]O-ring* 10,5X1,5 [/td][td]11 11 1 342 242 [/td][td]4[/td][/tr]
[tr][td]o-ring: 14x2 [/td][td]12 72 7 694 011 [/td][td]1[/td][/tr]
[tr][td]Oval-head screw, black M5X16 [/td][td]46 63 7 677 604 [/td][td]2[/td][/tr]
[tr][td]Paralever arm ISA screw M10X55-10.9-MK [/td][td]07 12 9 906 213 [/td][td]1[/td][/tr]
[tr][td]plastic rings DI=20.8 [/td][td]46 63 7 701 206 [/td][td]4[/td][/tr]
[tr][td]rear master cyclinder Oval head screw M6X20 [/td][td]35 21 7 685 343 [/td][td]2[/td][/tr]
[tr][td]RIGHT CHAIN TENSIONER [/td][td]11 31 1 341 296 [/td][td]1[/td][/tr]
[tr][td]rubber boot (gbox) [/td][td]33 17 7 685 599 [/td][td]1[/td][/tr]
[tr][td]Shaft seal : 10x18x6 [/td][td]23 12 2 332 884 [/td][td]1[/td][/tr]
[tr][td]Shaft seal : 20X32X8 [/td][td]23 12 7 705 086 [/td][td]1[/td][/tr]
[tr][td]Shaft seal : 25X40X8 [/td][td]23 12 7 705 087 [/td][td]1[/td][/tr]
[tr][td]Shaft seal: 36X50X7 [/td][td]11 11 8 528 387 [/td][td]1[/td][/tr]
[tr][td]Shaft seal: *65X83X8 [/td][td]11 11 8 528 386 [/td][td]1[/td][/tr]
[tr][td]Slide rail [/td][td]11 31 1 341 291 [/td][td]2[/td][/tr]
[tr][td]Snap ring oil sight glass [/td][td]07 11 9 904 991 [/td][td]1[/td][/tr]
[tr][td]Stop disc [/td][td]33 17 7 655 783 [/td][td]2[/td][/tr]
[tr][td]TIMING CHAIN [/td][td]11 31 7 694 426 [/td][td]1[/td][/tr]
[tr][td]TIMING CHAIN [/td][td]11 31 7 694 427 [/td][td]2[/td][/tr]
[tr][td]Washer ZNS3 [/td][td]07 11 9 904 198 [/td][td]2[/td][/tr]
[tr][td]ISA screw M8X55 [/td][td]07 12 9 905 217 [/td][td]1[/td][/tr]
[tr][td]ISA screw M12X50-8.8 ZNS3 [/td][td]07 12 9 906 088 [/td][td]2[/td][/tr]
[tr][td]ISA screw M10X40-8.8-MK [/td][td]07 12 9 904 632 [/td][td]4[/td][/tr]
[tr][td]Oval-head screw with anti-rotation lock M6X16 [/td][td]46 63 7 659 459 [/td][td]2[/td][/tr]
[tr][td]ISA screw M6X14 MK [/td][td]46 54 7 694 305 [/td][td]2[/td][/tr]
[tr][td]ISA screw M10X30 [/td][td]07 12 9 905 270 [/td][td]2[/td][/tr]
[/table]
Looks great love the paint scheme very different and smart
david a hall
Registered user
Great job.
Wow. What a transformation. That's a fantastic job. Health to enjoy many more miles. Well done that man
Brilliant- top job!.. and thanks for sharing with the class!
Down side of the light colour on the frame is that it shows the road filth really quickly. After just over 1,000 miles the frame is a mess of road filth and London traffic soot, which seems to be impervious to any of the cleaners I have got.
I was after a more "organic" look anyway ..
I was after a more "organic" look anyway ..
Great thread. What's the mileage now and how's the bike looking
IrishGaucho
Registered user
Wow, that's an amazing job!!!!
I could probably take it apart but then I'll end up with 2 brake pedals no throttle, 3 wheels and lots of "spare bolts" for sure.
I could probably take it apart but then I'll end up with 2 brake pedals no throttle, 3 wheels and lots of "spare bolts" for sure.
That's real commitment to a bike, full mid life refurb. Interesting point re the front wishbone bearings, are these supposed to be sealed for life? I've got some suspension and drive line maintenance to do (trunnion bearings, drive shaft splines, swing arm bearings) and maybe I should add these to the list, though my bike has only done a paltry 20k
Great job. And one which is probably about due on my 116k mile 1150.
Bendy toy
Registered user
It will be interesting to know how much Magwych spent.
I had my steelwork powder coated (boring gloss black) with a conductive zinc undercoat. I also had the steering top yoke, rear swing arm and FD casing done in gloss silver grey. Mikeyboy rebuilt the FD trunion bearings and back end UJ. With new steering and swing arm bearings, total cost was around £1000.
My steelwork wasn't as bad as Magwych but probably a close second. The other bits were bling to match the recoated grotty FD case.
The coaters (Wing and Son) had the alloy parts in the (cold) Biostrip tank for days. The OEM paint is uber hard. Too hard IMO because when corrosion gets under, it runs riot. The frame parts were bare metal in a couple of hours.
How's the bike enjoying the French roads ?? Have you hit 200 K yet 
