XC ENGINE Rebuild

[mikecbrxx]

I was going to leave this thread till I was further into the job but it seems to gel nicely with the other Rebuild thread so will start putting up details now.

A few months ago I bought a spare XC engine, with claimed low mileage. I got it shipped to my sisters in Suffolk to await a time when I could pick it up and bring back to the Netherlands....and the Hyperpro workshop

Finally got it picked up in December. Over the Xmas vacation I made a start on stripping it down ready for powder coating. It was already in a part stripped state when I bought it with the cylinder off and, as it turned out, the stator missing. It appears that most other parts, including the starter and ECU are present so not a bad deal at £250. (I will post the rebuild parts cost later.... but that is looking to be at least twice the purchase price)

I am taking photos, and some video, of the work so far and I will start to post these up when I get organised. Its going to be a long project though so you will need to be patient. As an example, it took 2.5 days just to prepare the lower casing for powder coating even after removing all the mechanical components. The 2.5 days incuded the removal of all case bearings, along with making seals for all the ingress points so no sand gets inside when its sand blasted.

As a taster, here is the engine casing ready to go for powder coating. I will back fill the component removal when I have got all the photos with me.

I hope you will find it interesting. I'm an IT consultant and have no real mechanical knowledge.... so this is challenging for me. Luckily I have Bas @ Hyperpro/Alphen for guidance and am doing the work at his shop.

 

[Gaz]

Very interested in this.
I have a complete engine in parts after this escapade a few years ago


http://www.ukgser.com/forums/showthread.php/353075-Neutral-sensor-failure?p=3609395#post3609395

and I dream of putting it back together ( but more likely I'd eventually sell it).
Anyway, I'd love to see your rebuild pics.

 

[Micky]

Good one Mike ... best of luck with the project

Give Baz my regards, hope maybe to see him in the Spring

Micky
www.adventure.gs

 

[Xchallenge]

Looking forward to this one!

 

[Zorro]

Good luck with the rebuild. Being a mechanical numpty I look forward to learning some tricks from this thread.
I hope to bring my XC to Baz soon for a suspension upgrade so may see you there. Cheers

 

[mikecbrxx]

Thanks for the encouragement. As I said, this will take a while!

For general inormation, this is the provisional parts list that I think I will need. Taken from realoem so prices not correct. Nothing actually ordered yet. The reason for some of it is looks, like the new set of bolts, and some is precautionary, like new water pump. I want to get the powder coat done before laying out this sort of money, just in case anything goes wrong.

 

[Losttheplot]

Thanks for the encouragement. As I said, this will take a while!

For general inormation, this is the provisional parts list that I think I will need. Taken from realoem so prices not correct. Nothing actually ordered yet. The reason for some of it is looks, like the new set of bolts, and some is precautionary, like new water pump. I want to get the powder coat done before laying out this sort of money, just in case anything goes wrong.

Is the clutch cover the later item with the steel sleeve?

 

[mikecbrxx]

Is the clutch cover the later item with the steel sleeve?

Ahhh, thanks for the reminder. I'd better check that before it goes to the powder coater or it would be a waste.

 

[mikecbrxx]

I just got notified that the engine (bottom) is back from powder coating. Image below. If you look carefully, you can see where the case was badly oxidised. I'll take some more photos when I get my hands on it next Saturday. I only get 1 day a week to do this work which is why it will take a while.

 

[King Rat]

Looking good. I am also making note as you go along.

 

[Tractors are go]

Thank you for finding the time to document the rebuild, good luck.

 

[mikecbrxx]

A few more pics of the engine after powder coating.

Cleaning the gasket surfaces. Much more work that I imagined and getting through loads of scotchbrite!

Becomes...

We have decided to do the cylinder & head as well, so will take even longer, which is frustrating, and sheared bolts on the cylinder are always fun.

I am trying to finalise the parts order but it appears, there are many conflicting part numbers, depending on engine year. Does anyone know of a website that I can enter the engine number and get the bike details (year/model) that an engine was fitted to ? The number appears to be D8507218651EA, or thats what it looks like to me. see below.

 

[mikecbrxx]

Bad news

While inspecting the head and preparing to powdercoat the cylinder & head, we found that all the valves required replacement (rusty) and that the valve guides showed some play. In addition, while we knew the piston rings needed replacing, it now look like the ring seats are also corroded. We now think that this engine must have had water in it at some time or been left (apart) for some time in a very damp environment. So, I have had to take the view that it is no longer economically viable to continue the work, even as a learning experience, as the costs are now well over £1000. As such, I'll leave the thread open for a couple days incase anyone wants to ask anything then close it after the weekend.

 

[Zorro]

Oh no...how annoying for you! Sorry to hear this.

 

[magno]

Hi Mike

Sounds bad but a new piston and rings isn´t that much from BMW I think. Just leaves valves and guides to sort? Which I know you have some experience of.

 

[solidstate100]

As you have come this far it would be a waste to stop now - Piston and rings and valves and guides are consumables essentially, (being the main wearing parts) and you needent ness get them from BMW nor even ness have to have new ones (as far as the piston goes anyway) so you could be in danger of spoiling the ship for a h'appath of tar, so to speak....

 

[mikecbrxx]

Thanks for the encouragement...

The rebuild parts I'd already ordered from BMW (and managed to cancel) totalled over 600. Thats gaskets, case/main bearings, needle bearings, new sensors, seals, water pump repair kit , complete bolt set. The valves (x4) on top of that added more than another couple of hundered, the valve guides on these are not easy to do and are not a part you can order from BMW, they have to be specially machined and fitted. Then there is the new piston on top of that plus anything else we have not yet identified. Once you actually get down to pricing even small parts, it adds up very quickly!

If I actually needed an engine, it would still be a viable project, but I don't. I wanted a spare and to learn during the rebuild. I bought the engine for 250 and have spent 50 on the powdercoat so far. I am not going to get rid of anything, it will be stored for the future, but I think its too much money to continue right now.

 

[Deleted account 190117001]

Buy a second hand F 650 engine and take the parts out of that.
Valves.
Crank and con rod.
oil pumps / water pump.
Balancer shaft.

The piston is different but pretty much everything else is identical.

Andres

 

[mikecbrxx]

Thanks for everyone's comments, closing the thread now.