XC Rebuild

[nicholsonj2252]

Be interesting to see what wear you have on the water pump, you got any photos? What millage is the engine on?

Mileage is only 6500 miles . There is no visible wear on the water pump and the seals all appear to be in place and intact . There was however slight misting/white foam in the oil in the oil tank filler neck and the outer surfaces of the LHS engine covers were completely stripped of paint and badly corroded , although this could well have been leakage from the rubber hoses ?

 

[mikecbrxx]

Hi. Looks like the cost of a water pump repair kit (impellor, shaft and seals), is not excessive when considered against the work in getting to it. May be worth replacing anyway. I know I am going to and I have no sign of any leaks.

 

[nicholsonj2252]

Hi. Looks like the cost of a water pump repair kit (impellor, shaft and seals), is not excessive when considered against the work in getting to it. May be worth replacing anyway. I know I am going to and I have no sign of any leaks.

Agree - by the time you have it stripped it's madness not to swap it out as you can guarantee if you didn't change it that as soon as you got the bike back together it would leak !

 

[nicholsonj2252]

PM sent

So thanks to Xchallenge I will have a set of replacement forks to use later in the month when he gets back from Portugal . Thanks Jamie

 

[Xchallenge]

Once your bike is fixed then you need to head down here for some of this...

 

[nicholsonj2252]

Very nice , I did a 6000 mile , ten country tour last July on my GSA and I'm planning on doing something this year on the XC


Sent from my iPhone using Tapatalk

 

[Losttheplot]

Once your bike is fixed then you need to head down here for some of this...

Looking good! do you have a set route you are following, or are you just making it up as you go along?

 

[nicholsonj2252]

Got all of the parts back from the powder coaters today , very pleased with them

Checked the valve clearances , all OK and then fitted new seals into the wheel hubs

Plan to strip and clean the brakes tomorrow then start doing some small bits of assembly work , then after that pretty much stopped until I get the new parts from BMW next week

 

[Xchallenge]

Looking good! do you have a set route you are following, or are you just making it up as you go along?

A little bit of both!

I do have multiple routes for Spain/Portugal

I followed one down from Santander to central Portugal which was about 90% off road

I'm now just making my own daily loops and leaving the luggage at the hotels

 

[nicholsonj2252]

Not much progress today as waiting on parts now , did manage to get new seals fitted into sprocket carrier , damaged thread in handlebar successfully re-cut (I can confirm it is M18 x 1.5) and front and rear brakes completely stripped and rebuilt . Back to work Monday so progress will slow due to weekend working only :-( , terrible when work gets in the way of a bike rebuild !

What I do need is a C Spanner for the Hyperpro rear shock , has anyone got one that they no longer need or even a link to where I could buy one ?

There are lots on eBay and the internet but none have the small double prong to fit the round holes in the adjuster collar of the Hyperpro shock , I have posted a wanted thread :

http://www.ukgser.com/forums/showthread.php/443084-C-Spanner-for-Hyperpro-Rear-Shock-Absorber

 

[Xchallenge]

Iv got one you can borrow

 

[nicholsonj2252]

Great - I've emailed Hyperpro to see if I can buy one off them but if not I'll borrow yours ;-)


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[nicholsonj2252]

Collected most of the parts from BMW today and got the new Clutch cover built up with its new needle bearings , shaft and seal . Also got the new LHS engine cover and got the new water pump impeller , seals and pinion assembled . A busy weekend ahead starting to reassemble the bike .....

 

[nicholsonj2252]

Good progress today . New clutch housing , clutch cover and water pump all fitted

Oil tank plumbed in and swinging arm and air shock fitted

Bike strapped down at rear to allow removal of front forks and triple trees

New steering head bearings fitted and front support frame re-fitted

Damage to front fork can be clearly seen , collecting replacement front end on Monday

 

[nicholsonj2252]

Wiring harness refitted and re-connected

Rear frame and petrol tank back on

Cooling system all back together and Touratech Radiator hard part fitted

Hepco & Becker pannier rails fitted

Remus header and exhaust all on

 

[nicholsonj2252]

Rear end plastics , seat lock and tail release all fitted

LED headlight bulb and LED indicators fitted

Footpegs , sidestand , foot brake lever and F650GS gear lever fitted

New tyres arrived so off to get fitted tomorrow

Coolant , oil and oil filter all done

 

[nicholsonj2252]

So just about there with the XC . tyres fitted , plus new wheel bearings and seals

Replacement set of forks fitted with fresh oil and new oil & dust seals

New chain and sprockets and replaced the chain roller bearings

Headlight , handlebars and switchgear , heated grips , Satnav , handguards and screen all back on

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Brakes refitted with new pads and system bled

Engine bars fitted

Bike plugged into GS-911 , no faults codes . all electrics work

Added a gallon of petrol and 3rd press of the button it fired up - no leaks and running lovely ;-)

Re-set all of the adaptions via the GS-911 then let it run up to temperature to re-learn the throttle valve position sensor zero and idle values

Fitted AF-XIED unit

Few small jobs to finish off tomorrow and thats it about done

 

[Chicken]

Looks well nice .... credit to you

 

[nicholsonj2252]

Finished ! Now time to ride it ;-)

 

[SIF]

WOW ! Do mine !