2003 1150GS Adventure rebuild

dub 24

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Hey folks
Just thought I would document the rebuild I am doing in case any of ye are interested in following it. The bike is a 2003 with 60km on it. The bike ran well but suffered from corrosion from being stored outside under a cover.

Cheers
Dub 24
 

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Rebuild

So here is the various stages of the tear down. Every nut and bolt was a struggle to undo/remove.
 

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More photos of the corrosion
 

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Its amazing how two similar machines can rust so differently! I know there are many variables at play with this, but the differences still make me wonder about manufacturing consistency!
hubs look very similar to mine, but front wishbone on 1150 much worse, cylinder heads on mine worse, frame looks similar.

Just a note on the hubs, mine were not saveable as the spoke nipples pulled through where the rot had been at its worst. might be worth being prepared for.

Good luck with restoration and please keep posting as I love these type of threads!
 
More photos
 

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A few pictures of mother nature at work on German engineering
 

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It's getting smaller
 

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Pictures of Clutch
 

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Cheers Beak Freak I think your right about the wheels but to be honest I just removed them and parked them for the moment. I just wanted to get the bike down to the bare minimum. Our next job is to drill out the header studs which are literally welded in. we tried everything and now this the final solution hopefully.
 
Interesting post.
Amount of rust....proximity to the coast and salty air ?
 
So the list is as follows but is not finalised:jager
Front wheel - hubs, rims need repainting. Bearings replaced. Calipers rebuilt. Discs replaced.
Front supension, forks - seals replaced. Steering head bearing replaced. wishbone seals and bearing replaced. New clutch cable.New clutch slave cylinder, pushrod, felt pad thingy, gasket.
Various output input seals
HES , Alternator starter motor coil all need to be checked.
Fuel tank- fuel pump pipe work. filter. all new quick release fuel connectors. inside of tank checked.
Wiring loom protective cover is broken so replace same.
Ugrade headlight bulbs, bar risers,lowered footpegs.
Gearbox /Transmission - new clutch, replace bearings in final drive check boots re grease etc. new pivot pins.
Re drill re tap the following front frame where two crashbar studs snapped. 4 cylinder studs. rear grab rail plate.
Drill out all 4 footpeg mounting bolts yep tried heat 50/50 ATF /Acetone swearing hammering etc
For dipping / bead blasting/ spraying - subframe, telelever bracket , steering bridge, cylinder heads, rear grab rail and plate, probably wheels. handlebars, top of clutch and brake master reservoirs.
Seat recovered.
I'm sure there is more
 
Not by me but think your right previous owner may have had a propensity for the beach and sea water:D
 
Looks like rather than being kept under a cover it was carefuly stored under the Irish Sea or North Atlantic
 
Hey Johnny Boxer Neil W
Think you both might be on to something there but it's nothing a good sand, strip, rub, and paint won't resolve.
Cheers
Dub 24
 
Hey Johnny Boxer Neil W
Think you both might be on to something there but it's nothing a good sand, strip, rub, and paint won't resolve.
Cheers
Dub 24

Looking forward to seeing the 'Phoenix rise from the Ashes' and applaud your hard work and determination

More pics please
 
Looking forward to seeing the 'Phoenix rise from the Ashes' and applaud your hard work and determination

More pics please

Yes I agree a monumental amount of work to bring it back from the state it was in, but fair play for tackling it,and looking forward to seeing how it progresses
 
Now that’s what you call commitment. Well done I’m sure that will be something to be proud of when all up and running. Good luck :beerjug:
Look forward to follow your build
 
Looking forward to seeing it saved,well done.
I would enjoy the tear down but then I would be stuck!
 
Johnny Boxer, Doyle Peeping tom

Thanks for the encouragement and support, there's no doubt I''ll need it along the way. I will definitely keep you all abreast of the progress with plenty of pictures.

Cheers
dub 24
 


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