Biting the Bullet

Ozz

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In May 2014 I spent some of my retirement gratuity from 25yrs service in the Army on a new 14 plate R1200GS and returned to biking. Since that time the bike has been flawless (apart from a recall for switchgear and front master cylinder and a replaced exhaust for a stuck exhaust flap under warranty) and it’s done 36k miles across Europe and the UK.

However, about a year after the warranty expired I began to notice that the beginnings of corrosion mainly on the cast front wheel (between the spokes), the cylinder heads and under the gaiter between the shaft drive and the final drive

Now I will admit that the bike was my only way of getting around (until recently I did not have a car) and was used in all weathers and all seasons. But it was washed, cleaned and ACF’d but the corrosion was under the paint and protective layers - something that I know others faced, but I thought I’d escaped.

I had also always wanted a more individual Panzer. It’s a White TE but I’m not one for throwing a touratech catalogue at it - I have seen some shocking examples of just too much on some bikes, but each to their own. It does have a Puig touring screen, Altrider engine bars, radiator guards and rear luggage plate for the Kriega bags that I use, but that’s it.

So this winter I bit the bullet to sort the corrosion out and while that was going on to make the Panzer mine. So…

It’s been stripped bare - every nut and bolt - not by me (I’ll give a shout out to all involved at the end of the process)

The wheels have been blasted and powder coated gloss BMW M Deep Blue
Both front and rear frames have been blasted and powder coated gloss BMW M Red
The complete engine and transmission have had a similar process but to factory silver and the cylinder covers the deeper grey.

So now the rebuild will start. All seals, bearings and gaskets will be replaced with new and the shocks either rebuilt or replaced with Wilbers (if the budget allows). The final piece will be a wrap for the body work (from France) which picks out the BMW M Colour scheme. It won’t be to everyone’s taste, and the BMW M Colour scheme isn’t that original, but like I said...each to their own.

Hopefully it will be back on the road by the second bank holiday in May when I’, due to have a week in Scotland, if not sooner...I’ve missed it these last few months.

Being Stripped - <a href="https://imgur.com/C1VGsPQ"><img src="https://i.imgur.com/C1VGsPQ.jpg" title="source: imgur.com" /></a>

Back to Nothing - <a href="https://imgur.com/Abs1xKR"><img src="https://i.imgur.com/Abs1xKR.jpg" title="source: imgur.com" /></a>

Engine Corrosion - <a href="https://imgur.com/hqJYDHg"><img src="https://i.imgur.com/hqJYDHg.jpg" title="source: imgur.com" /></a>

Frame's new coat (it isn't orange when you actually see it) - <a href="https://imgur.com/QDiUVIY"><img src="https://i.imgur.com/QDiUVIY.jpg" title="source: imgur.com" /></a>

Wheely nice - <a href="https://imgur.com/ayRq1Qu"><img src="https://i.imgur.com/ayRq1Qu.jpg" title="source: imgur.com" /></a>

Engine cases - <a href="https://imgur.com/EsWr4q8"><img src="https://i.imgur.com/EsWr4q8.jpg" title="source: imgur.com" /></a>

Cylinder heads - <a href="https://imgur.com/4aGSBtQ"><img src="https://i.imgur.com/4aGSBtQ.jpg" title="source: imgur.com" /></a>
 
Oooo, that engine looks nice! and the rest (obviously the colour is your choise ;) )

so has the entire engine been powder coated?... assume its OK with the coating temps involved with all the O rings and seals??

cracking job.. keep the pictures coming of the re-build!! :)
 
Great to see someone doing a proper personal touch type of build!

However I can not help but think, that a 5 year old premium motorcycle with 36k on the clock, that has been properly looked after ,can be in a such a state.

I am not saying that other manufacturers produce better quality bikes. However where engine or frame paint is concerned, others tend to do it much better. But then again, other bmw bikes in the range, of same age, show no signs of poor paint.

Keep them pictures coming and keep up a good work.

EV


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Oooo, that engine looks nice! and the rest (obviously the colour is your choise ;) )

so has the entire engine been powder coated?... assume its OK with the coating temps involved with all the O rings and seals??

cracking job.. keep the pictures coming of the re-build!! :)

The whole bike was stripped - pistons out, gear box cassette, seals, O Rings - the lot. So it was just the cases (which were masked off where necessary), front cover, shaft drive / swim arm and final drive. There were 3 bearings left in the engine case which supported some of the gear shafts and the hope was that they would survive the process but it turns out they didn't (they melted - the replacements show why (they're made of plastic in places - bizarrely..)). So now its back in with new O Rings, seals, gaskets and bearings.
 
The whole bike was stripped - pistons out, gear box cassette, seals, O Rings - the lot. So it was just the cases (which were masked off where necessary), front cover, shaft drive / swim arm and final drive. There were 3 bearings left in the engine case which supported some of the gear shafts and the hope was that they would survive the process but it turns out they didn't (they melted - the replacements show why (they're made of plastic in places - bizarrely..)). So now its back in with new O Rings, seals, gaskets and bearings.

only way to do it right.. top job.. bit worrying there are bearings deep in the engine with plastc bits in... were these the shields that melted?... after a few years in red hot oil, im wondering if these bits are still good or if they become a bit brittle...
Anything else a bit 'cheap' inside?...
At least you'll know it inside out now... never had a LC in bits (yet :) )
 
Love these sorts of threads, Looks like it's going to be a right good job for the finish.
 
you've got me. Cant wait to see this built up.
 
I'm looking forward to seeing the end result :thumb
 
That's a proper strip down. It looks like a really good job has been done too. Will you be replacing the clutch, as you have easy access now it's it stripped down ?
 
So if you ever wondered what was in the bowels of your LC engine - amongst other things are a couple of these. They support the gearbox shafts within the crankcase and yes, the middle of the bearing is plastic. We think that the central plastic nozzle forms a jet to create oil pressure into the shafts of the gearbox.

<a href="https://imgur.com/waS3D6y"><img src="https://i.imgur.com/waS3D6y.jpg" title="source: imgur.com" /></a>

<a href="https://imgur.com/hBGKT7V"><img src="https://i.imgur.com/hBGKT7V.jpg" title="source: imgur.com" /></a>
 
Fantastic. I will keep my eye on this thread. Looking forward to seeing it finished. Keep us posted.
 
So if you ever wondered what was in the bowels of your LC engine - amongst other things are a couple of these. They support the gearbox shafts within the crankcase and yes, the middle of the bearing is plastic. We think that the central plastic nozzle forms a jet to create oil pressure into the shafts of the gearbox.

Mmm.. interesting...would rather see metal bits TBH... wonder what the life test was on those?... 10 years??

Just re-looking at your frame.. did a CB100RC up once... looks the exact same colour :)

So do you have all the kit to re-set the cams etc?... or is that still on the shoping list ...
 
Top thread and way beyond my skills!
 
Does look a quality job!.. even where its corroded is covered very nice :)

What are the big ends and mains like? all okay? are you replacing them as in theory they should only be fit once???? TBH I've re-used before but they say they could spin if you do.. not sure how that logic works though?

Yes, make sure you get the last bits of blasting stuff out.. I know people who haven't LOL
 


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